Johnson Controls PCA3613 User manual

PCA3613 Advanced Application
Programmable Controller Installation
Instructions
Application
The PCA3613 controller runs pre-engineered and user-programmed applications and provide
the inputs and outputs required to monitor and control a wide variety of HVAC and other facility
equipment.
PCA36 controllers operate on an RS-485 BACnet® MS/TP Bus and integrate into Johnson Controls®
and third-party BACnet systems.
PCA36 controllers include an integral real-time clock, which enables the controllers to monitor and
control schedules, calendars, and trends, and operate for extended periods of time as stand-alone
controllers when offline from the system network.
Communications protocols
By default, the controllers communicate 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 PCA3613:
• 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.
Part No. 24-10143-1175 Rev C
2019-03-22 (barcode for factory use only)
CH-PCA3613
*24101431175C*

Parts included
• One PCA3613 controller with removable terminal blocks
• One installation instructions sheet
Materials and special tools needed
• Three fasteners appropriate for the mounting surface (M4 screws or #8 screws)
• One 23 cm (9.125 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 PCA3613:
• 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 correct mounting position (Figure 1).
• Whenever possible in wall-mount applications, mount the controller on a hard, even surface.
• 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 sufficient space around the controller for cable and wire connections, 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 ductwork.
• 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 PCA3613 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.
PCA3613 Advanced Application Programmable Controller Installation Instructions2

Figure 1: Controller mounting positions
DIN rail mount applications
Mounting the PCA3613 controller 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 23 cm (9.125 in.) or longer section of 35 mm DIN rail, horizontally and
centered in the desired space, so that the controller mounts in the 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 (Figure 2), 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 PCA3613 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.
3PCA3613 Advanced Application Programmable Controller Installation Instructions

Figure 2: Back of Controller showing extended mounting
clips, DIN rail channel, and mounting dimensions, mm (in.)
PCA3613 Advanced Application Programmable Controller Installation Instructions4

PCA3613 physical features
Figure 3: PCA3613 physical features
Table 1: Physical features
Callout Physical feature: description and references
1Analog Output (AO) Terminal Block: Can be defined as Voltage Analog Output (0–10
VDC) or Current Analog Output (4–20 mA) (see Table 3)
2Device Address DIP Switch Block (see Setting the Device Addresses)
3Mounting clip
4Binary Outputs (BO) Terminal Block: 24 VAC Triac (see Table 3)
524 VAC, Class 2/SELV Supply Power Terminal Block (see Supply power terminal block)
6Cover Lift Tab (One of Two)
7FC Bus Terminal Block (see FC bus terminal block )
8SA Bus Terminal Block (see SA bus terminal block)
9Sensor Port: (SA Bus) RJ-12 6-Pin Modular Jack (see Sensor port )
10 Binary Input (BI) Terminal Block: Dry Contact Maintained or Pulse Counter/Accumulator
Mode (see Terminal wiring guidelines, functions, ratings, and requirements)
11 Universal Inputs (UI) Terminal Block: Can be defined as Voltage Analog Input (0–10
VDC), Current Analog Input (4–20 mA), Resistive Analog Inputs (0–600k ohms), or Dry
Contact Binary Input (see Input and Output wiring guidelines)
5PCA3613 Advanced Application Programmable Controller Installation Instructions

Table 1: Physical features
Callout Physical feature: description and references
12 End-of-Line (EOL) Switch (see Setting the End-of-Line (EOL) switch)
13 LED Status Indicators (see Table 8)
14 FC Bus Port (RJ-12 6-pin Modular Jack)
Wiring
CAUTION
Risk of Electric Shock:
Disconnect the power supply before making electrical connections to avoid electric shock
CAUTION
Mise En Garde: 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.
PCA3613 Advanced Application Programmable Controller Installation Instructions6

For detailed information about configuring and wiring an MS/TP bus, FC bus and SA bus, refer to
the following documents depending on your system (FX or BCPro): MS/TP Communications Bus for
the BCPro™ System Technical Bulletin (LIT-12011908) or FX-PC Series Controllers MS/TP Communications
Bus Technical Bulletin (LIT-12011670).
Terminal blocks and bus ports
See PCA3613 physical features for terminal block and bus port locations on the PCA3613 controller.
Observe the following guidelines when wiring a PCA3613 controller.
Input and Output terminal blocks
The fixed input terminal blocks are located on the bottom of the controller, and the output terminal
blocks are located on the top of the controller. See Table 3 for more information about I/O terminal
functions, requirements, and ratings.
FC bus terminal block
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 in Figure 4. For more information
about the FC Bus terminal function, requirements, and ratings, see Table 5.
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 Figure 5. For more
information about the SA Bus terminal function, requirements, and ratings, see Table 5.
7PCA3613 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.
FC bus port
The FC bus port on the front of the controller is an RJ-12, 6-position modular jack that provides a
connection for the Mobile Access Portal (MAP) Gateway, the FX-BTCVT Bluetooth® Commissioning
Converter, or the FX-ZFR/ZFR Pro Wireless Field Bus Router.
The FC bus port is connected internally to the FC bus terminal block. For more information about
the FC Bus port functions, requirements, and ratings, see Table 5. The FC bus 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
purchase, but continues to be supported.
Figure 6: Pin number assignments for sensor, SA bus, and FC bus ports on Controllers
PCA3613 Advanced Application Programmable Controller Installation Instructions8

Sensor port
The Sensor (SA Bus) port on the bottom of the controller is an RJ-12, 6-position modular jack that
provides a connection for MAP Gateway, the Bluetooth® Commissioning Converter (BTCVT), the VAV
Balancing Tool, specified network sensors, or other SA Bus devices with RJ-12 plugs.
A DIS1710 Local Controller Display also can be connected to the SA Bus port.
The Sensor port is connected internally to the SA bus terminal block. For more information about
the Sensor port functions, requirements and ratings, see Table 5. 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 purchase, but continues to be supported.
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 in Figure 7. Do not use the middle terminal on the supply power terminal
block. See Table 5 for more information about the Supply Power 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 controller does not require an earth ground connection.
9PCA3613 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
PCA3613 Advanced Application Programmable Controller Installation Instructions10

Table 2: Termination details
Type of field
device
Type of
Input/
Output
Termination diagrams
Current
Input -
External
Source
(Isolated)
UI
Current
Input -
Internal
Source (2-
wire)
UI
Current
Input -
Internal
Source (3
wire)
UI
Current
Input -
External
Source (in
Loop)
UI
Feedback
from
EPP-1000
UI
11PCA3613 Advanced Application Programmable Controller Installation Instructions

Table 2: Termination details
Type of field
device
Type of
Input/
Output
Termination diagrams
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
Current
Output
AO
24 VAC Triac
Output
(Switch Low,
External
Source)
AO
PCA3613 Advanced Application Programmable Controller Installation Instructions12

Table 2: Termination details
Type of field
device
Type of
Input/
Output
Termination diagrams
Analog
Output
(Current)
AO
4–20 mA
Output to
Actuator
AO
4–20 mA
Output to
Actuator
AO
Incremental
Control to
Actuator
(Switch Low,
Externally
Sourced)
BO
13PCA3613 Advanced Application Programmable Controller Installation Instructions

Table 2: Termination details
Type of field
device
Type of
Input/
Output
Termination diagrams
24 VAC
Binary
Output
(Switch Low,
Externally
Sourced)
BO
24 VAC
Binary
Output
(Switch High,
Externally
Sourced)
BO
Incremental
Control to
Actuator
(Switch High,
Externally
Sourced)
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.
PCA3613 Advanced Application Programmable Controller Installation Instructions14

Table 2: Termination details
Type of field
device
Type of
Input/
Output
Termination diagrams
Network
Stat with
Terminals
Addressable
SA Bus
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. The table also references guidelines for determining proper
wire sizes and cable lengths.
In addition to the wiring guidelines in Table 3, observe these 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.
15PCA3613 Advanced Application Programmable Controller Installation Instructions

• 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.
I/O Terminal blocks, ratings, and requirements
Table 3: 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 +15V
terminal.
Analog Input - Voltage Mode (0–10
VDC)
10 VDC maximum input voltage
Internal 75k ohms pull-down
See Guideline A in
Table 4.
Analog Input - Current Mode (4–20 mA)
Internal 100 ohms load impedance. See
Setting the Input Jumpers.
Note: A current loop fail-safe jumper
must be in the Enable position to
maintain a closed 4 to 20 mA current
loop. See UI current loop jumpers.
See Guideline B in
Table 4.
Analog Input - Resistive Mode (60–600k
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
See Guideline A in
Table 4.
UNIVERSAL
(Inputs)
INn
Binary Input - Dry Contact Maintained
Mode
1 second minimum pulse width
Internal 12 V. 15k ohms pull-up
See Guideline A in
Table 4.
PCA3613 Advanced Application Programmable Controller Installation Instructions16

Table 3: Terminal blocks, functions, ratings, requirements, and cables
Terminal block
label
Terminal
label
Function, ratings, requirements Determine wire size
and maximum cable
length
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. One common
screw terminal point is provided
for every two input screw terminal
points.
Same as (Universal)
INn
Binary Input - Dry Contact Maintained
Mode
0.01 second minimum pulse width
Internal 18 V. 3k ohms pull-up
INn
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
BINARY
(Inputs)
ICOMnBinary Input Common for all Binary
Input (IN) terminals
Note: All Binary ICOMn terminals
share a common, which is isolated
from all other commons.
See Guideline A in
Table 4.
ANALOG
(Outputs)
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
ohm may not operate as intended
for Voltage Mode applications.
See Guideline C in
Table 4.
17PCA3613 Advanced Application Programmable Controller Installation Instructions

Table 3: Terminal blocks, functions, ratings, requirements, and cables
Terminal block
label
Terminal
label
Function, ratings, requirements Determine wire size
and maximum cable
length
Analog Output - Current Mode (4–20
mA)
Requires an external load between 0 and
300 ohms.
Note: The Analog Output (AO)
operates in the Current Mode
when connected to devices with
impedances less than 300 ohms.
Devices that exceed below 300 ohms
may not operate as intended for
Current Mode applications.
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. One common screw
terminal point is provided for every
two output screw terminal points.
OUTnBinary Output - 24 VAC Triac Class 2, 24
V, 500 mA (External Power Source)
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
BINARY
(Output)
OCOMnBinary Output Common (for OUTn
terminal)
Note: Each Binary Output Common
terminal (OCOMn) is isolated from
all other commons, including other
Binary Output Common terminals.
See Guideline C in
Table 4.
Cable and wire length guidelines
The following table defines cable length guidelines for the various wire sizes that may be used for
wiring low-voltage (<30 V) 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.
PCA3613 Advanced Application Programmable Controller Installation Instructions18

Table 4: 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
0.8 mm (20 AWG) stranded
copper
297 m (975 ft) twisted
wire
0.6 mm (22 AWG) stranded
copper
183 m (600 ft) twisted
wire
A
0.5 mm (24 AWG) stranded
copper
107 m (350 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.
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
0.5 mm (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 wiring inputs and outputs.
Note: Figure 8 applies to low-voltage (<30 V) inputs and outputs only.
19PCA3613 Advanced Application Programmable Controller Installation Instructions

Figure 8: Maximum wire length for low-voltage
(<30 V) Inputs and Outputs by current and wire size
Communications bus and supply power wiring guidelines
Table 5 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 5, observe these 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): MS/TP
Communications Bus for the BCPro™ System Technical Bulletin (LIT-12011908) or FX-PC Series
Controllers MS/TP Communications Bus Technical Bulletin (LIT-12011670) for detailed information
regarding wire size and cable length requirements for SA and FC buses.
Communications bus and supply power terminal block
Note: The SA Bus and FC Bus wiring recommendations in this table are for MS/TP bus
communications at 38.4k baud. For more information, refer to the following documents
depending on your system (FX or BCPro): MS/TP Communications Bus for the BCPro System
Technical Bulletin (LIT-12011908) or FX-PC Series Controllers MS/TP Communications Bus Technical
Bulletin (LIT-12011670).
PCA3613 Advanced Application Programmable Controller Installation Instructions20