Johnson Controls FX-PCG1621 Series User manual

FX-PCG16 General Purpose Programmable Controller

Installation Instructions

FX-PCG1611-x, FX-PCG1621-x Part No. 24-10143-152, Rev. G

Issued April 2016

Refer to the QuickLIT website for the most up-to-date version of this document.

Application

The FX-PCG16 controller is part of the Facility Explorer

Controller FX-PCG family. The FX-PCG16 controller runs

pre-engineered and user-programmed applications and

provides the inputs and outputs required to monitor and

control a wide variety of HVAC equipment.

The FX-PCG controllers operate on an RS-485 BACnet®

Master-Slave/Token-Passing (MS/TP) Bus as BACnet

Application Specific Controllers (B-ASC) and integrate

into Johnson Controls®and third-party BACnet systems.

With Release 10.1, you can use the FX-PCT software

to switch the FX-PCG to use the N2 protocol.

The FX-PCG16 controller is available with or without an

integral LCD and push button user interface.

Switchable Communications

Protocols

By default, the FX-PC family controllers and network

sensors communicate using the standard BACnet

protocol, based on the ANSI/ASHRAE 135-2004.

The BACnet protocol is a standard for ANSI, ASHRAE,

and the International Standards Organization (ISO) for

building controls.

FX-PCG, FX-PCX, and FX-PCV controllers are BTL-

tested and listed as BACnet Application Specific

Controllers (B-ASCs). FX-PCA field controllers are

BTL-listed as BACnet Advanced Application Controllers

(B-AACs). The NS Series Sensors are BTL-listed as

BACnet Smart Sensors (B-SSs).

Release 10.1 of FX-PCT and later can be used to switch

the Field Bus communications protocol in FX-PC

Controllers to be either the standard BACnet

Master-Slave/Token-Passing (MS/TP) or the N2 protocol.

BACnet MS/TP is the default communications protocol

for all new controllers. Switchable communications

protocols provide a cost-effective upgrade and

modernization path for customers with existing N2

controllers. The Modernization Guide for Legacy N2

Controllers (LIT-12012045) and the controller-specific

documentation provide installation and commissioning

support and include tips for efficient and safe

replacement. Refer to the N2 Compatibility Options

chapter of the Controller Tool Help (LIT-12011147) for

information about mapping N2 Objects in controllers with

switchable communications protocols.

The N2-capable FX-PC controllers can be used as

functional replacements for legacy N2 controllers. The

N2-capable FX-PC controllers:

• have the I/O quantities and characteristics of the

FX-PC family controllers

• must be programmed with FX-PCT, which has

programming capabilities that are similar (but not

identical) to HVACPro, GX9100, GPL, and other

legacy tools

• support SA Bus devices

•support FX-WRZ wireless sensors from the controller

using the FX-WRZ7860 receiver when configured for

BACnet MS/TP communication

The N2-capable FX-PC controllers:

• do not support Zone Bus (for example, TMZ sensors

and M100 actuators)

• do not support pass through in the commissioning

mode

•do not support remote downloading or commissioning

using BACnet routing

• do not support wireless connection to the N2 bus

1FX-PCG16 General Purpose Programmable Controller Installation Instructions

North American Emissions

Compliance

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.

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.

Installation

Observe these guidelines when installing an FX-PCG:

• Transport the controller in the original container to

minimize vibration and shock damage.

• Verify that all parts shipped with the controller.

• Do not drop the controller or subject it to physical

shock.

Parts Included

• one FX-PCG16 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 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 these guidelines when mounting an FX-PCG:

• 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 Table 10.

• 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

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.

Figure 1: FX-PCG Mounting Positions

2FX-PCG16 General Purpose Programmable Controller Installation Instructions

DIN Rail Mount Applications

Mounting the controller horizontal on 35 mm DIN rail is

the preferred mounting method.

To mount an FX-PCG on 35 mm DIN rail:

1. Securely mount a 20 cm (8 in.) or longer section of

35 mm DIN rail horizontal and centered in the desired

space 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 (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 an FX-PCG directly on a wall or other flat

vertical surface:

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 three 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 locations

marked in Figure 2, and insert appropriate wall

anchors in all of the mounting 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.

Figure 2: Back of Controller Showing Extended

Mounting Clips, DIN Rail Channel, and Mounting

Dimensions, mm (in.)

3FX-PCG16 General Purpose Programmable Controller Installation Instructions

Figure 3: FX-PCG16 Physical Features

Table 1: FX-PCG Physical Features Callouts and Descriptions

Physical Feature: Description and ReferencesCallout

Binary Output (BO) Source Power Selection Jumpers (See Binary Output (BO) Source Power Selection Jumpers)

Device Address DIP Switch Block (See Figure 9)

Mounting Clip3

Configurable Output (CO) Terminal Blocks (See Table 3)

24 VAC, Class 2 Supply Power Terminal Block (See Supply Power Terminal Block)

Cover Lift Tab (One of Two) (See Figure 3)

Display Navigation Buttons (See Setting Up an Integral or Local Display)

Note: Not available on all FX-PCG models.

LCD Display Area (See Setting Up an Integral or Local Display)

Note: Not available on all FX-PCG models.

FC Bus Terminal Block (See FC Bus Terminal Block)

4FX-PCG16 General Purpose Programmable Controller Installation Instructions

Table 1: FX-PCG Physical Features Callouts and Descriptions

Physical Feature: Description and ReferencesCallout

Sensor Actuator (SA) Bus Terminal Block (See SA Bus Terminal Block)

Sensor Port (Sensor Actuator [SA] Bus, RJ-12 6-pin Modular Jack) (See Figure 6)

Binary Inputs (BIs) Terminal Block (See Table 3)

Universal Inputs (UIs) Terminal Blocks (See Table 3)

LED Status Indicators (See Table 8)

Field Controller (FC) Bus Port (RJ-12 6-pin Modular Jack) (See Figure 6)

Binary Output (BO) Terminal Block (See Table 3)

Terminal Wiring Guidelines,

Functions, Ratings, and

Requirements

Wiring

Observe the following guidelines when wiring a controller:

Risk of Electric Shock: Disconnect the power supply

before making electrical connections to avoid electric

shock.

Mise En Garde: Risque de décharge électrique:

Débrancher l'alimentation avant de réaliser tout

raccordement électrique afin d'éviter tout risque de

décharge électrique.

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.

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 FX-PC

Series Controllers MS/TP Communications Bus Technical

Bulletin (LIT-12011670) or to the MS/TP Communications

Bus for BCM System Technical Bulletin (LIT-12011908).

For detailed information on wiring an N2 bus, refer to the

N2 Communications Bus Technical Bulletin (LIT-636018).

FX-PCG Terminal Blocks and Bus Ports

See Figure 3 for terminal block and bus port locations on

the FX-PCG controller. Observe the following guidelines

when wiring a controller.

Input and Output Terminal Blocks

All of 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 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. See Table 5 for more information.

5FX-PCG16 General Purpose Programmable Controller Installation Instructions

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. See Table 5 for more information.

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 FX-BTCVT Bluetooth®Commissioning Converter,

ZFR-USBHA-0 ZigBee®wireless dongle, or FX-ZFR1811

Wireless Field Bus Router.

The FC bus port is connected internally to the FC bus

terminal block. See Table 5 for more information. The FC

bus Port pin assignment is shown in Figure 6.

Note: When an FX-PCG is configured for N2 network

communication, the FC bus port is not used.

Figure 6: Pin Number Assignments for Sensor, SA

Bus, and FC Bus Ports on Controllers

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 Bluetooth Commissioning

Converter, the VAV box Balancing Tool, specified network

sensors, or other SA Bus devices with RJ-12 plugs.

When the FX-PCG is configured for N2 communication,

the SA Bus port must be used to download and

commission the controller.

An FX-DIS1710 Local Controller Display also can be

connected to the SA Bus port (but only on FX-PCG

models without integral display and push buttons).

The Sensor port is connected internally to the SA bus

terminal block. See Table 5 for more information. The

Sensor Port pin assignment is shown in Figure 6.

6FX-PCG16 General Purpose Programmable Controller Installation Instructions

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. The middle terminal on the supply

power terminal block is not used. See Table 5 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 controller does

not require an earth ground connection.

Wireless Network Applications

When configured for BACnet MS/TP communication, the

controller can also be installed in a wireless application

using an FX-ZFR1811 Series Wireless Field Bus Router.

To configure a controller for use with the FX-ZFR1811

Series Wireless Field Bus system:

1. Wire the input/output terminals and SA bus.

Note: In wireless network applications, do not

connect any wires to the FC Bus terminal

block. (Connect the SA/FC terminal block on

an FX-PCX to an SA bus only.)

2. Connect the FX-ZFR1811 Wireless Field Bus Router

to the FC bus port (RJ-12 modular jack) on the front

of the controller.

3. Ensure that the controller's device address DIP

switches are set to the correct device address. See

Setting the Device Addresses.

4. Set DIP switch 128 to ON, which enables wireless

operation on the controller.

For more information on installing a controller in a

wireless configuration, refer to the FX-ZFR1811

Wireless Field Bus Router Installation Instructions

(Part No. 24-10325-29).

7FX-PCG16 General Purpose Programmable Controller Installation Instructions

Termination Diagrams

A set of 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

Termination DiagramsType of

Input/Output

Type of Field Device

UITemperature Sensor

UIVoltage Input - External

Source

UIVoltage Input - Internal

Source

UIVoltage Input

(Self-Powered)

UICurrent Input - External

Source (Isolated)

UICurrent Input - Internal

Source (2 wire)

8FX-PCG16 General Purpose Programmable Controller Installation Instructions

Table 2: Termination Details

Termination DiagramsType of

Input/Output

Type of Field Device

UICurrent Input - Internal

Source (3 wire)

UICurrent Input - External

Source (in Loop)

UIFeedback from EPP-1000

UI or BIDry Contact (Binary Input)

CO0–20 VDC Output to

Actuator (External Source)

CO0–10 VDC Output to

Actuator (Internal Source)

9FX-PCG16 General Purpose Programmable Controller Installation Instructions

Table 2: Termination Details

Termination DiagramsType of

Input/Output

Type of Field Device

CO24 VAC Triac Output

(Switch Low, External

Source)

COIncremental Control to

Actuator (Switch Low,

Externally Sourced)

COIncremental Control to

Actuator (Switch High,

Externally Sourced)

BO24 VAC Binary Output

(Switch Low, Externally

Sourced)

BO24 VAC Binary Output

(Switch High, Externally

Sourced)

10FX-PCG16 General Purpose Programmable Controller Installation Instructions

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