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