Johnson Controls PCA2513 User manual

PCA2513 Advanced Application
Programmable Controller Installation
Instructions
Application
The PCA2513 Controller run pre-engineered and user-programmed applications and provides
the inputs and outputs required to monitor and control a wide variety of HVAC and other facility
equipment.
PCA controllers operate on an RS-485 BACnet® MS/TP Bus as BACnet Application Specific
Controllers (B-AACs) and integrate into Johnson Controls and third-party BACnet systems.
Communications protocols
The PCA2513 controller can communicate using BACnet MS/TP or N2. By default, the PCA2513
controller communicates using the standard BACnet MS/TP protocol based on the ANSI/ASHRAE
135-2012. The BACnet protocol is a standard for ANSI, ASHRAE, and the International Standards
Organization (ISO) for building controls.
North American Emissions Compliance
United States
This equipment has been tested and found to comply with the limits for a Class A digital device
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when this equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instruction manual, may cause harmful interference to
radio communications. Operation of this equipment in a residential area may cause harmful
interference, in which case the users will be required to correct the interference at their own
expense.
Canada
This Class (A) digital apparatus meets all the requirements of the Canadian Interference-Causing
Equipment Regulations.
Cet appareil numérique de la Classe (A) respecte toutes les exigences du Règlement sur le
matériel brouilleur du Canada.
Installation
Observe the following guidelines when installing a PCA controller:
• To minimize vibration and shock damage, transport the controller in the original container.
• Verify that all parts shipped with the controller.
• Do not drop the controller or subject it to physical shock.test
Parts included
• One PCA controller with removable terminal blocks (Power, SA bus, and FC bus are removable)
Part No. 24-10143-1167 Rev B
2019-03-22 CH-PCA2513-0
*24101431167B*

• One installation instructions sheet
Materials and special tools needed
• Three fasteners appropriate for the mounting surface (M4 screws or #8 screws)
• One 20 cm (8 in.) or longer piece of 35 mm DIN rail and appropriate hardware for DIN rail mount
(only)
• Small straight-blade screwdriver for securing wires in the terminal blocks
Mounting
Observe the following guidelines when mounting a PCA controller:
• Ensure the mounting surface can support the controller, DIN rail, and any user-supplied
enclosure.
• Mount the controller horizontally on 35 mm DIN rail whenever possible.
• Mount the controller in the proper mounting position (Figure 1).
• Mount the controller on a hard, even surface whenever possible in wall-mount applications.
• Use shims or washers to mount the controller securely and evenly on the mounting surface.
• Mount the controller in an area free of corrosive vapors and observe the Ambient Conditions
requirements in Technical specifications.
• Provide for sufficient space around the controller for cable and wire connections for easy cover
removal and good ventilation through the controller (50 mm [2 in.] minimum on the top, bottom,
and front of the controller).
• Do not mount the controller on surfaces prone to vibration, such as duct work.
• Do not mount the controller in areas where electromagnetic emissions from other devices or
wiring can interfere with controller communication.
Observe these additional guidelines when mounting a PCA controller in a panel or enclosure:
• Mount the controller so that the enclosure walls do not obstruct cover removal or ventilation
through the controller.
• Mount the controller so that the power transformer and other devices do not radiate excessive
heat to the controller.
• Do not install the controller in an airtight enclosure.
PCA2513 Advanced Application Programmable Controller Installation Instructions2

Figure 1: Mounting positions
DIN rail mount applications
Mounting the PCA horizontally on 35 mm DIN rail is the preferred mounting method.
To mount a controller on 35 mm DIN rail, complete the following steps:
1. Securely mount a 20 cm (8 in.) or longer section of 35 mm DIN rail horizontal and centered
in the appropriate location so that the controller mounts in the horizontal position shown in
Figure 1.
2. Pull the two bottom mounting clips outward from the controller to the extended position
(Figure 2).
3. Hang the controller on the DIN rail by the hooks at the top of the (DIN rail) channel on the back
of the controller, and position the controller snugly against the DIN rail.
4. Push the bottom mounting clips inward (up) to secure the controller on the DIN rail.
To remove the controller from the DIN rail, pull the bottom mounting clips out to the extended
position and carefully lift the controller off the DIN rail.
Wall mount applications
To mount a PCA directly on a wall or other flat vertical surface, complete the following steps:
1. Pull the two bottom mounting clips outward and ensure they are locked in the extended
position as shown in Figure 2.
2. Mark the mounting hole locations on the wall using the dimensions in Figure 2 and one of the
mount positions shown in Figure 1. Or hold the controller up to the wall or surface in a proper
mount position and mark the hole locations through the mounting clips.
3. Drill holes in the wall or surface at the marked locations, and insert appropriate wall anchors in
the holes (if necessary).
4. Hold the controller in place, and insert the screws through the mounting clips and into the
holes (or anchors). Carefully tighten all of the screws.
Important: Do not overtighten the mounting screws. Overtightening the screws may
damage the mounting clips.
3PCA2513 Advanced Application Programmable Controller Installation Instructions

Mounting features and dimensions
See Figure 2 for mounting dimensions in millimeters and inches. Inches are listed in parenthesis.
Figure 2 also illustrates the DIN rail channel and the mounting clips in an extended position.
Figure 2: Back of PCA2513 Controller
PCA2513 Advanced Application Programmable Controller Installation Instructions4

PCA2513 physical features
Figure 3: PCA2513 physical features
Table 1: Physical features
Callout Physical features: description and references
1Device Address Dip Switch Block (see Setting the device address)
2Configurable Output (CO) Terminal Block (see Table 3)
324 VAC, Class 2 Supply Power Terminal Block (see Supply power terminal block)
4Field Controller (FC) Bus Terminal Block (see FC bus terminal Bblock)
5Sensor Actuator (SA) Bus Terminal Block (see SA bus terminal block)
6Sensor Actuator (SA) Bus (RJ-12 6-pin Modular Jack) (see Sensor port)
7Binary Input (BI) Terminal Block (see Table 3)
8Universal Inputs (UI) Terminal Block (see Table 3)
9LED Status Indicators (see Table 8)
10 Binary Output (BO) Terminal Block (see Table 3)
11 Analog Outputs (AO) Terminal Block (see Table 3)
12 Cover lift tabs
5PCA2513 Advanced Application Programmable Controller Installation Instructions

Wiring
CAUTION
Risk of Electric Shock
Disconnect the power supply before making electrical connections to avoid electric shock.
CAUTION
Risque de décharge électrique
Débrancher l'alimentation avant de réaliser tout raccordement électrique afin d'éviter tout risque de
décharge électrique.
CAUTION
Risk of Property Damage
Do not apply power to the system before checking all wiring connections. Short circuited or improperly
connected wires may result in permanent damage to the equipment.
CAUTION
Mise En Garde: Risque de dégâts matériels
Ne pas mettre le système sous tension avant d'avoir vérifié tous les raccords de câblage. Des fils
formant un court-circuit ou connectés de façon incorrecte risquent d'endommager irrémédiablement
l'équipement.
Important: Do not exceed the controller electrical ratings. Exceeding controller electrical
ratings can result in permanent damage to the controller and void any warranty.
Important: Use copper conductors only. Make all wiring in accordance with local, national,
and regional regulations.
Important: Electrostatic discharge can damage controller components. Use proper
electrostatic discharge precautions during installation, setup, and servicing to avoid damaging
the controller.
For detailed information on configuring and wiring an MS/TP Bus, FC bus, and SA bus, refer to
the following documents depending on your system (FX or BCPro): FX-PC Series Controllers MS/TP
Communications Bus Technical Bulletin (LIT-12011670 or MS/TP Communications Bus for BCPro™ System
Technical Bulletin (LIT-12011908).
Terminal blocks and bus ports
See Figure 3 for a terminal block and bus port locations on the controller. Observe the following
guidelines for terminal blocks and bus ports when you wire a controller.
PCA2513 Advanced Application Programmable Controller Installation Instructions6

Input and Output terminal blocks
The fixed input terminal blocks are mounted on the bottom of the controller and the output
terminal blocks are mounted on the top of the controller. See Figure 3 for more information about
I/O terminal functions, requirements, and ratings.
FC bus terminal Bblock
The FC Bus terminal block is a blue, removable, 4-terminal plug that fits into a board-mounted jack.
Wire the removable FC bus terminal block plugs on the controller, and other controllers in a daisy-
chain configuration using 3-wire twisted, shielded cable as shown below. See Table 6 for more
information.
Figure 4: FC bus terminal block wiring
Note: The FC bus Shield (SHLD) terminal is isolated and can be used to connect (daisy chain)
the shields for FC bus wiring.
SA bus terminal block
The SA Bus terminal block is a brown, removable, 4-terminal plug that fits into a board-mounted
jack.
Wire the removable SA Bus terminal block plugs on the controller and other SA Bus devices in a
daisy-chain configuration using 4-wire twisted, shielded cable as shown in the following figure. See
Table 6 for more information.
7PCA2513 Advanced Application Programmable Controller Installation Instructions

Figure 5: SA bus terminal block wiring
Note: The SA PWR terminal supplies 15 VDC. The SA PWR terminal can be used to connect
(daisy chain) the 15 VDC power leads on the SA bus.
Sensor port
The Sensor (SA Bus) port on the bottom of the controller (Figure 3) is an RJ-12, 6-position modular
jack that provides a connection for the Mobile Access Portal (MAP) Gateway, the Bluetooth®
Commissioning Converter (BTCVT), the VAV Balancing Tool, specified network sensors, or other SA
Bus devices with RJ-12 plugs.
The Sensor port is connected internally to the SA bus terminal block. See Table 6 for more
information. The Sensor Port pin assignment is shown in Figure 6.
Note:
The MAP Gateway serves as a replacement for the BTCVT, which is no longer available for pur-
chase, but continues to be supported.
Figure 6: Pin number assignments for sensor and SA bus ports on Controllers
PCA2513 Advanced Application Programmable Controller Installation Instructions8

Supply power terminal block
The 24 VAC supply power terminal block is a gray, removable, 3-terminal plug that fits into a board-
mounted jack on the top right of the controller.
Wire the 24 VAC supply power wires from the transformer to the HOT and COM terminals on the
terminal plug as shown below. Do not use the middle terminal on the supply power terminal block.
See Table 6 for more information about the Supply Terminal Block.
Figure 7: 24 VAC supply power terminal block wiring
Note: The supply power wire colors may be different on transformers from other
manufacturers. Refer to the transformer manufacturer’s instructions and the project
installation drawings for wiring details.
Important: Connect 24 VAC supply power to the controller and all other network devices so
that transformer phasing is uniform across the network devices. Powering network devices
with uniform 24 VAC supply power phasing reduces noise, interference, and ground loop
problems. The PCA does not require an earth ground connection.
9PCA2513 Advanced Application Programmable Controller Installation Instructions

Termination diagrams
A set of Johnson Controls termination diagrams provides details for wiring inputs and outputs to
the controllers. See the figures in this section for the applicable termination diagrams.
Table 2: Termination details
Type of field
device
Type of
Input/
Output
Termination diagrams
Temperature
Sensor
UI
Voltage
Input -
External
Source
UI
Voltage
Input -
Internal
Source
UI
Voltage
Input (Self-
Powered)
UI
PCA2513 Advanced Application Programmable Controller Installation Instructions10

Table 2: Termination details
Type of field
device
Type of
Input/
Output
Termination diagrams
Feedback
from
EPP-1000
UI
Dry Contact
(Binary
Input)
UI or BI
0–10 VDC
Output to
Actuator
(External
Source)
AO
0–10 VDC
Output to
Actuator
(Internal
Source)
AO
Voltage
(Analog
Output)
AO
11PCA2513 Advanced Application Programmable Controller Installation Instructions

Table 2: Termination details
Type of field
device
Type of
Input/
Output
Termination diagrams
24 VAC Triac
Output
(Switch Low,
External
Source)
Incremental
Control to
Actuator
(Switch Low,
Externally
Sourced)
(Triac
Jumpers
Where
Applicable)
BO
24 VAC
Binary
Output
(Switch Low,
Externally
Sourced)
(Triac
Jumpers
Where
Applicable)
BO
24 VAC
Binary
Output
(Switch High,
Externally
Sourced)
(Triac
Jumpers
Where
Applicable)
BO
PCA2513 Advanced Application Programmable Controller Installation Instructions12

Table 2: Termination details
Type of field
device
Type of
Input/
Output
Termination diagrams
Incremental
Control to
Actuator
(Switch High,
Externally
Sourced)
(Triac
Jumpers
Where
Applicable)
BO
Network
Stat with
Phone
Jack (Fixed
Address =
199)
SA Bus
Note: The bottom jack (J2) on the TE-700 and TE-6x00 Series
Sensors is not usable as a zone bus or an SAB connection.
Network
Stat with
Terminals
Addressable
SA Bus
13PCA2513 Advanced Application Programmable Controller Installation Instructions

Table 2: Termination details
Type of field
device
Type of
Input/
Output
Termination diagrams
Network
Stat with
Terminals
(Fixed
Address =
199)
SA Bus
Terminal wiring guidelines, functions, ratings, and
requirements
Input and Output wiring guidelines
Table 3 provides information and guidelines about the functions, ratings, and requirements for the
controller input and output terminals. This table also references guidelines for determining proper
wire sizes and cable lengths.
In addition to the wiring guidelines in the table, observe the following guidelines when you wire
controller inputs and outputs:
• Run all low-voltage wiring and cables separate from high-voltage wiring.
• All input and output cables, regardless of wire size or number of wires, should consist of
stranded, insulated, and twisted copper wires.
• Shielded cable is not required for input or output cables.
• Shielded cable is recommended for input and output cables that are exposed to high
electromagnetic or radio frequency noise.
• Inputs/outputs with cables less than 30 m (100 ft) typically do not require an offset in the
software setup. Cable runs over 30 m (100 ft) may require an offset in the input/output software
setup.
PCA2513 Advanced Application Programmable Controller Installation Instructions14

Input and Output wiring guidelines table
Table 3: I/O Terminal Blocks, Functions, Ratings, Requirements, and Cables
Terminal
block label
Terminal label Function, ratings, requirements Determine wire size
and maximum cable
length
+15 V 15 VDC Power Source for active (3-
wire) input devices connected to the
Universal INn terminals.
Provides 100 mA total current
Same as (Universal) INn
Note: Use 3-wire
cable for devices
that source power
from the +15 V
terminal.
See Guideline A in Table
5.
Analog Input - Voltage Mode (0–10
VDC)
10 VDC maximum input voltage
Internal 75k ohms pull-down
See Guideline B in Table
5.
Analog Input - Resistive Mode (0–
600k ohms)
Internal 12 V 15k ohms pull up
Qualified Sensors: 0–2k ohms
potentiometer, RTD (1k Nickel
[Johnson Controls sensor], 1k
Platinum, and A99B Silicon
Temperature Sensor) Negative
Temperature Coefficient (NTC) Sensor
(10k Type L, 10k JCI Type II, 2.252k
Type II)
See Guideline A in Table
5.
INn
Binary Input - Dry Contact
Maintained Mode
1 second minimum pulse width
Internal 12 V 15k ohms pull up
See Guideline A in Table
5.
UNIVERSAL
(Inputs)
ICOMnUniversal Input Common for all
Universal Input terminals
Note: All Universal ICOMn
terminals share a common,
which is isolated from all other
commons, except the SA bus
common.
Same as (Universal) INn
BINARY
(Inputs)
INnBinary Input - Dry Contact
Maintained Mode
0.01 second minimum pulse width
Internal 18 V 3k ohms pull up
See Guideline A in Table
5.
15PCA2513 Advanced Application Programmable Controller Installation Instructions

Table 3: I/O Terminal Blocks, Functions, Ratings, Requirements, and Cables
Terminal
block label
Terminal label Function, ratings, requirements Determine wire size
and maximum cable
length
Binary Input - Pulse Counter/
Accumulator Mode
0.01 second minimum pulse width
(50 Hz at 50% duty cycle)
Internal 18 V 3k ohms pull up
ICOMnBinary Input Common for all Binary
Input (IN) terminals
Note: All Binary ICOMn terminals
share a common, which is
isolated from all other commons,
except the Configurable Output
(CO) common (OCOMn) when
the CO is defined as an Analog
Output.
OUTnAnalog Output - Voltage Mode (0–10
VDC)
10 VDC maximum output voltage
10 mA maximum output current
Required an external load of 1,000
ohms or more.
Note: The Analog Output (AO)
operates in the Voltage Mode
when connected to devices with
impedances greater than 1,000
ohms. Devices that drop below
1,000 ohms may not operate
as intended for Voltage Mode
applications.
ANALOG
(Outputs)
OCOMnAnalog Output Signal Common for
all Analog OUT terminals.
Note: All Analog Output
Common terminals (OCOMn)
share a common, which is
isolated from all other commons.
See Guideline C in Table
5.
BINARY
(Output)
OUTnBinary Output - 24 VAC Triac
(Internal Power Source)
Sources internal 24 VAC power (24~
HOT).
See Guideline C in Table
5.
PCA2513 Advanced Application Programmable Controller Installation Instructions16

Table 3: I/O Terminal Blocks, Functions, Ratings, Requirements, and Cables
Terminal
block label
Terminal label Function, ratings, requirements Determine wire size
and maximum cable
length
OCOMnBinary Output - 24 VAC Triac
(Internal Power Source)
Connects OCOMn to 24~ when
activated.
Internal Power Source:
30 VAC maximum output voltage
0.5 A maximum output current
1.3 A at 25% duty cycle
40 mA minimum load current
Analog Output - Voltage Mode (0–10
VDC)
10 VDC maximum output voltage
10 mA maximum output current
Required an external load of 1,000
ohms or more.
See Guideline A in Table
5.
OUTn
Binary Output - 24 VAC Triac
(External Power Source only)
Connects OUTn to OCOMn when
activated.
External Power Source Requirements:
30 VAC maximum output voltage
0.5 A maximum output current
1.3 A at 25% duty cycle
40 mA minimum load current
See Guideline C in Table
5.
Analog Output Signal Common All
Configurable Outputs (COs) defined
as Analog Outputs (AOs) share a
common, which is isolated from all
other commons except the Binary
Input common.
CONFIGURABL
E
(Outputs)
OCOMn
Binary Output Signal Common All
Configurable Outputs (COs) defined
as Binary Outputs are isolated from all
other commons, including other CO
commons.
Same as (Configurable)
OUTn.
17PCA2513 Advanced Application Programmable Controller Installation Instructions

PCA2513 point type counts
The following table shows the different point types and counts available in the PCA2513 Series
controllers.
Table 4: PCA2513 point type counts
Point types Signals accepted PCA2513
Universal Input (UI) Analog Input, Voltage Mode, 0–
10 VDC
Analog Input, Current Mode, 4–
20 mA
Analog Input, Resistive Mode,
0–2k ohm, RTD (1k NI [Johnson
Controls], 1k PT, A99B SI), NTC
(10k Type L, 2.252k Type 2)
Binary Input, Dry Contact
Maintained Mode
4 (Does not support Current
Mode)
Binary Input (BI) Dry Contact Maintained Mode
Pulse Counter/Accumulator
Mode (High Speed), 100 Hz
6
Analog Output (AO) Analog Output, Voltage Mode,
0–10 VDC
Analog Output, Current Mode,
4–20 mA
2 (Voltage Only)
Binary Output (BO) 24 VAC Triac 2 (Ext Power only)
Configurable Output (CO) Analog Output, Voltage Mode,
0–10 VDC
Binary Output Mode, 24 VAC
Triac
2
Cable and wire length guidelines
Table 5 defines cable length guidelines for the various wire sizes that may be used for wiring low-
voltage (30V) input and outputs.
Note: The required wire sizes and lengths for high voltage (>30 V) Relay Outputs are
determined by the load connected to the relay, and local, national, or regional electrical codes.
Table 5: Cable length guidelines for recommended wire sizes for low-voltage (<30 V) Inputs
and Outputs
Guideline Wire size/Gauge and
type
Maximum cable
length and type
Assumptions
1.0 mm (18 AWG)
stranded copper
457 m (1,500 ft)
twisted wire
A
0.8 mm (20 AWG)
stranded copper
297 m (975 ft) twisted
wire
100 mV maximum voltage drop
Depending on cable and the
connected input or output
PCA2513 Advanced Application Programmable Controller Installation Instructions18

Table 5: Cable length guidelines for recommended wire sizes for low-voltage (<30 V) Inputs
and Outputs
Guideline Wire size/Gauge and
type
Maximum cable
length and type
Assumptions
0.6 mm (22 AWG)
stranded copper
183 m (600 ft) twisted
wire
N/A (24 AWG)
stranded copper
107 m (350 ft) twisted
wire
device, you may have to define
an offset in the setup software
for the input or output point.
1.0 mm (18 AWG)
stranded copper
229 m (750 ft) twisted
wire
0.8 mm (20 AWG)
stranded copper
137 m (450 ft) twisted
wire
0.6 mm (22 AWG)
stranded copper
91 m (300 ft) twisted
wire
B
N/A (24 AWG)
stranded copper
61 m (200 ft) twisted
wire
100 mV maximum voltage drop
Depending on cable and the
connected input or output
device, you may have to define
an offset in the setup software
for the input or output point.
CSee Figure 8 to select
wire size/gauge. Use
stranded copper wire
See Figure 8 to
determine cable
length. Use twisted
wire cable.
N/A
Maximum cable length versus load current
Use Figure 8 to estimate the maximum cable length relative to the wire size and the load current (in
mA) when you wire inputs and outputs.
Note: Figure 8 applies to low-voltage (<30 V) inputs and outputs only.
Figure 8: Maximum wire length for low-voltage
(<30 V) Inputs and Outputs by current and wire size
19PCA2513 Advanced Application Programmable Controller Installation Instructions

Communications bus and supply power wiring guidelines
Table 6 provides information about the functions, ratings, and requirements for the communication
bus and supply power terminals. The table also provides guidelines for wire sizes, cable types, and
cable lengths for when you wire the controller's communication buses and supply power.
In addition to the guidelines in Table 6, observe the following guidelines when you wire an SA or FC
bus and the 24 VAC supply power:
• Run all low-voltage wiring and cables separate from high-voltage wiring.
• All SA and FC bus cables, regardless of wire size, should be twisted, insulated, stranded copper
wire.
• Shielded cable is strongly recommended for all SA and FC bus cables.
• Refer to the following documents depending on your system (FX or BCPro): FX-PC Series
Controllers MS/TP Communications Bus Technical Bulletin (LIT-12011670 or MS/TP Communications
Bus for BCPro™ System Technical Bulletin (LIT-12011908) for detailed information regarding wire
size and cable length requirements for the SA and FC buses.
Communications bus and supply power terminal blocks,
ratings, and requirements
Note: The SA Bus and FC bus wiring recommendations in this table are for MS/TP bus
communications at 38.4k baud.
Table 6: Communications Bus and Supply Power Terminal Blocks, Functions, Ratings,
Requirements, and Cables
Terminal
block/Port
label
Terminal
labels
Function, electrical ratings/Requirements Recommended cable
type
+
-
FC Bus Communications
COM Signal Reference (Common) for Bus
communications
FC BUS
SHLD Isolated terminal (optional shield drain
connection)
0.6 mm (22 AWG)
stranded, 3-wire
twisted, shielded cable
recommended
+
-
SA Bus Communications
COM SA Bus Signal Reference and 15 VDC
Common
SA BUS
SA PWR 15 VDC Supply Power for Devices on the SA
Bus
(Maximum total current draw for SA Bus is
240 mA.)
0.6 mm (22 AWG)
stranded, 4-wire (2
twisted-pairs), shielded
cable recommended.
Note: The + and - wire
are one twisted pair,
and the COM and SA
PWR are the second
twisted pair of wires.
PCA2513 Advanced Application Programmable Controller Installation Instructions20