Johnson Controls PCV1617 User manual

PCV1617 and PCV1632 VAV Box Controllers

Installation instructions

Applications

The PCV1617 and PCV1632 are programmable digital controllers designed for VAV box applications

that communicate through the BACnet® MS/TP protocol. The controllers feature an integral digital

pressure sensor, a damper actuator, and a 32-bit microprocessor. The controllers' small package

size facilitates quick field installation and efficient use of space without compromising high-tech

control performance. The PCV controllers connect easily to either the networked or to the non-

communicating sensor for zone air temperature sensing.

Communications Protocol

The PC family controllers and network sensors communicate using the standard BACnet protocol,

based on the ANSI/ASHRAE 135-2008. The BACnet protocol is a standard for ANSI, ASHRAE, and the

International Standards Organization (ISO) for building controls.

PCV field controllers are BTL-listed as BACnet Application Specific Controllers (B-ASCs).

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 these guidelines when installing the PCV1617 and PCV1632 controllers:

• Transport the PCV controller in the original container to minimize vibration and shock damage to

the PCV controller.

• Do not drop the PCV controller or subject it to physical shock.

Part No. 24-10143-1299 Rev B

2019-03-22 (barcode for factory use only)

CH-PCV1617, CH-PCV1632

*2410143299B*

Parts included

• One PCV1617 or PCV1632 controller with removable FC terminal block

• One installation instructions sheet

• One self-drilling No. 10 x 25 mm (1 in.) screw

Materials and special tools needed

• Several 6 mm (1/4 in.) female spade terminals for input and output wiring and crimping tool or

spade mounted terminal blocks

• Small, straight-blade screwdriver for securing wires in the terminal blocks

• 8 mm (5/16 in.) wrench or 10 mm (3/8 in.) 12-point socket to tighten the square coupler bolt

• Several shims or washers to mount the PCV

• Power screwdriver, 100 mm (4 in.) extension socket, punch, drill, and 3.5 mm (9/64 in.) drill bits to

mount the PCV

• Pliers to open and close the damper

• Required length of 3.97 mm (5/32 in.) ID pneumatic tubing and barbed fittings

Mounting

Observe these guidelines when mounting a PCV:

Important: When the air supply to the VAV box is below 10°C (50°F), make sure that any

condensation on the VAV box, particularly on the damper shaft, does not enter the PCV

electronics. Mount the PCV vertically above the damper shaft to allow any shaft condensation

to fall away from the PCV. Additional measures may be required in some installations.

• Ensure the mounting surface can support the PCV and any user-supplied enclosure.

• Mount the PCV on a hard, even surface whenever possible.

• Use shims or washers to mount the PCV securely and evenly on the mounting surface.

• Mount the PCV in an area free of corrosive vapors that matches the ambient conditions specified

in the Technical specifications section.

• Provide sufficient space around the PCV for cable and wire connections and adequate ventilation

through the controller (at least 50 mm [2 in.] on the top, bottom, sides, and front of the

controllers).

• Do not mount the PCV in areas where electromagnetic emissions from other devices or wiring

can interfere with controller communication.

• When using the PCV1617 or PCV1632 to replace an existing controller, plug the unused open hole

from the original controller mounting, if possible.

• Avoid mounting the PCV on surfaces with excessive vibration.

On panel or enclosure mount applications, observe these additional guidelines:

• Do not install the PCV in an airtight enclosure.

• Mount the PCV so that the enclosure walls do not obstruct cover removal or ventilation through

the controller.

• Mount the PCV so that the power transformer and other devices do not radiate excessive heat to

the controller.

PCV1617 and PCV1632 VAV Box Controllers Installation instructions2

To mount a PCV1617 or PCV1632 controller:

1. Set all the switches on the PCV controller to their known settings.

2. Place the PCV controller in the proper mounting position on the damper shaft so that the

wiring connections are easily accessible. Make sure the PCV controller base is parallel to the

VAV box (perpendicular to the damper shaft). If needed, use a spacer to offset tipping of the

PCV controller caused by the shaft bushings.

Note: Use the alignment marks to center the captive spacer to ensure sufficient PCV

movement in either direction.

3. Secure the self-drilling No. 10 screw through the captive spacer with a power screwdriver and

100 mm (4 in.) extension socket. Otherwise, use a punch to mark the position of the shoulder

washer, and then drill a hole into the VAV box using a 3.5 mm (9/64 in.) drill bit. Insert the

mounting screw and tighten against the spacer.

Important: Do not overtighten the screw, or the threads may strip. If you are mounting

the controller to a VAV box, make sure the screws do not interfere with damper blade

movement.

4. Locate the damper position using the typical marking on the end of the damper shaft (Figure

1).

Figure 1: Typical damper end shaft icons

5. Note the direction, clockwise (CW) or counterclockwise (CCW), required to close the damper.

Grasp the damper shaft firmly with pliers, and either manually close the damper for 90° boxes

or manually open the damper for 45° or 60° boxes.

6. Push down and hold the Manual Override button and turn the PCV controller coupler until it

contacts the mechanical end-stop at either the full-closed (90° boxes) or full-open (45° and 60°

boxes) position.

7. If the damper for a 90° box closes CCW, rotate the coupler to the CCW mechanical limit. If the

damper for a 90° box closes CW, rotate the coupler to the CW mechanical limit. The open end-

stop is automatically set for 90° boxes.

For 45° and 60° boxes, hard stops must be provided at both full-closed and full-open damper

positions. By installing the PCV controller at the full-open position, the PCV controller provides

the open stop for 45° and 60° boxes. The closed damper seal provides the full-closed stop.

8. Tighten the square coupler bolt to the shaft using an 8 mm (5/16 in.) wrench or 10 mm (3/8 in.)

12-point socket. Tighten to 11 N·m , ±.5 N-m (100 lb·in, ±5 lb·in).

9. Loop the pneumatic tubing (supplied by field personnel) to include a trap for condensation.

Attach the needed length of tubing (supplied and installed by field personnel) to the dual port

fitting on the PCV controller and the other ends of the tubing to the pressure transducer in the

VAV box application.

Note: The PCV uses a digital non-flow pressure sensor with bidirectional flow operation,

which allows the high- and low-pressure DP tube connections to be made to either

3PCV1617 and PCV1632 VAV Box Controllers Installation instructions

barbed fitting on the PCV controller. There is no need to make a specific high- or low-side

connection when attaching the tubing to the barbed fittings on the PCV.

10. Push the Manual Override button, and turn the actuator coupling manually to ensure that the

actuator can rotate from full-closed to full-open positions without binding.

11. Complete the mounting by rotating the damper to the full-open position.

CAUTION

Risk of Property Damage:

Rotate the damper to the full-open position before starting the air handler. Failure to rotate the damper

to the full-open position may result in damage to the VAV box or ductwork when the air handler is

started.

CAUTION

Risque de dommages matériels:

Faire pivoter le registre pour le placer en position d'ouverture complète avant de démarrer l'unité de

traitement d'air. Le non-respect de cette directive risque d'endommager le caisson de l'unité à volume

d'air variable (VAV) ou le réseau de conduites au démarrage de l'unité de traitement d'air.

PCV1617 and PCV1632 VAV Box Controllers Installation instructions4

Wiring diagram

Figure 2: PCV1617/PCV1632 Controller wiring terminations and physical features

Table 1: PCV1617/PCV1632 features callout numbers and descriptions

Callout Physical features: description and references

1 24 VAC, Class 2 Supply Power Spade Terminals (see Supply power terminal

block)

2 Device Address DIP Switch Block (see Setting the device address)

3 Binary Outputs, 24 VAC Triacs (see Table 2)

4 Configurable Outputs: Voltage Analog Output (0–10 VDC) and Binary

Output (24 VAC Triac) (PCV1632 only) (see Table 2)

5 Dual Port Fitting (see Figure 2)

6 Manual Override Button (see Mounting)

7 Controller Coupler (see Mounting)

8 Coupler Bolt (see Mounting)

5PCV1617 and PCV1632 VAV Box Controllers Installation instructions

Table 1: PCV1617/PCV1632 features callout numbers and descriptions

Callout Physical features: description and references

9 Universal Input: Voltage Analog Input (0–10 VDC)

Resistive Analog Inputs (0–600k ohm) (see Table 2):

0–2k Potentiometer

RTD: 1k Nickel, 1k Platinum, or A99B SI

NTC: 10K Type L (10K JCI Type II is equivalent to Type L) or 2.252K Type II

Dry Contact Binary Input

10 FC Bus Pluggable Screw Terminal Block (see FC bus terminal block)

11 EOL (End-of-Line) Switch (see Setting the EOL switch)

12 SA Bus Spade Terminals (see SA bus terminal blocks)

13 TSTAT Modular Port: RJ-45 8-Pin Modular Jack (see Modular port)

14 Captive Spacer and Screw (see Figure 2)

15 LED Status Indicators (see Table 8)

Wiring

Warning

Risk of Electric Shock:

Disconnect or isolate all power supplies before making electrical connections. More than one

disconnection or isolation may be required to completely de-energize equipment. Contact with

components carrying hazardous voltage can cause electric shock and may result in severe personal

injury or death.

Important: Do not connect supply power to the controller before finishing wiring and

checking all wiring connections. Short circuits or improperly connected wires can result in

damage to the controller and void any warranty.

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.

PCV terminals and bus ports

See Figure 2 for input and output terminal and bus port locations on the PCV1617 and PCV1632

controllers. Observe the following guidelines when wiring a PCV controller.

PCV1617 and PCV1632 VAV Box Controllers Installation instructions6

Input and Output terminals

The input spade terminals are located on the side of the PCV near the FC Bus terminal block. The

output spade terminals are located on the opposite side of the controller near the power supply

spade terminals. See Table 2 for more information.

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 PCV and other PC controllers in a daisy-

chain configuration using 3-wire twisted, shielded cable as shown in Figure 3. See Table 5 for more

information.

Figure 3: FC bus terminal block wiring

Note: The Shield terminal (SHLD) on the FC Bus terminal block is isolated and can be used to

connect the cable shields on the bus (Figure 3).

SA bus terminal blocks

Wire the SA Bus terminal blocks on the PCV and other SA Bus devices, such as a communicating NS-

family room sensor, in a daisy-chain configuration using 4-wire twisted, shielded cable as shown in

the following diagram. . See Table 5 for more information.

7PCV1617 and PCV1632 VAV Box Controllers Installation instructions

Figure 4: SA bus terminal block wiring

Modular port

The modular (TSTAT) port on the face of the PCV (Figure 2) is an RJ-45, 8-position modular jack used

to easily connect one TE-730 series analog (non-communicating) sensor to the PCV. The modular

TSTAT port provides 15 VDC, SA Bus communications, and analog signals for zone temperature,

zone setpoint, and temporary zone occupancy override.

Note: On the TE-730 Series sensors, you can activate the occupancy override functionality by

using a pushbutton to momentarily short the zone temperature AI.

The TSTAT pin assignment is shown in Figure 5.

Note: Do not use the modular SA Bus port and the terminal block SA Bus simultaneously. Only

use one of these connections at a time.

Figure 5: Pin number assignments for the

modular port on PCV1617 and PCV1632 Controllers

Supply power terminal block

The 24 VAC supply power terminal block is a gray, removable, 2-terminal plug that fits into a board-

mounted jack on the upper left of the PCV controller.

PCV1617 and PCV1632 VAV Box Controllers Installation instructions8

Wire the 24 VAC supply power wires from the transformer to the HOT and COM terminals on the

spade terminals as shown in Figure 6. See Table 5 for more information.

Figure 6: 24 VAC supply power spade terminal wiring

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 PCV 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 PCV does not require an earth ground connection. However, when grounding

the secondary of the 24 VAC transformer is required, only one connection to ground should be

made near the transformer. See the following figure.

Figure 7: Transformer grounding

CAUTION

Risk of Property Damage:

Do not apply power to the system before checking all wiring connections. Improper wiring of this

terminal may cause a short circuit across the 24 VAC power supply on -1 PCV models. A short circuit

may result in a tripped circuit breaker or blown fuse. If using a transformer with a built-in fuse, the

transformer may need to be replaced.

9PCV1617 and PCV1632 VAV Box Controllers Installation instructions

CAUTION

Risque de dommages matériels:

Ne mettez pas l’appareil sous tension avant d’avoir vérifié toutes les connexions du câblage. Le câblage

inadéquat de cette borne peut causer un court-circuit sur l’alimentation électrique de 24 V c.a. des

PCV 16xx-1 modèles. Un court-circuit peut causer le déclenchement du disjoncteur ou le grillage d’un

fusible. Si vous utilisez un transformateur avec un fusible intégré, vous pourriez devoir remplacer le

transformateur.

To wire the PCV1617 or PCV1632 controller:

1. Terminate wiring according to the appropriate figure in Termination diagrams.

2. Wire network sensors and other devices to the PCV's SA Bus.

3. Wire the FC Bus in a daisy chain.

4. Ensure that the PCV’s device address DIP switches are set to the appropriate device address.

See Setting the device address. Also, activate the end-of-line (EOL) switch if necessary.

5. Connect the PCV controller to 24 VAC, Class 2 power.

PCV terminal functions, ratings, requirements, and wiring

guidelines

Input and Output wiring guidelines

Table 2 provides information about the functions, ratings, and requirements for the PCV input and

output terminals, and Table 3 provides guidelines for wire sizes and cable lengths.

In addition to the wiring guidelines in Table 2, observe these guidelines when wiring PCV 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 twisted,

insulated, and stranded copper wires.

• Shielded cable is recommended for input and output cables that are exposed to high

electromagnetic or radio frequency noise.

• Cable runs of less than 30 m (100 ft) typically do not require an offset in the input/output

software setup. Cable runs over 30 m (100 ft) may require an offset in the input/output software

setup.

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.

FC and SA bus and supply power wiring guidelines

Table 5 provides information about terminal block functions, ratings, and requirements.

Table 5 also provides wire size, cable type, and cable length guidelines for wiring the PCV

communication buses and supply power.

PCV1617 and PCV1632 VAV Box Controllers Installation instructions10

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