Johnson Controls FX-PCV1615 User manual

FX-PCV1615/1626/1628/1630 Programmable

VAV Box Controllers Installation

Instructions

Applications

The FX-PCV1615/1626/1628/1630 programmable digital controllers are designed for controlling

Variable Air Volume (VAV) boxes. These FX-PCV Variable Air Volume Modular Assembly (VMA)

controllers feature combinations of an integral digital pressure sensor (DPT), a damper actuator,

and a 32-bit microprocessor. The FX-PCV1626 has an actuator but does not contain a DPT. The FX-

PCV1628 model has a DPT but does not contain an actuator. The controllers' small package size

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

performance. These FX-PCV controllers connect easily to the wired and wireless network sensors for

zone and discharge air temperature sensing.

Communications protocol

The FX-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.

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

The Controller Configuration Tool (CCT) can be used to switch the Field Bus communications

protocol in supported FX-PC Controllers to be either the standard BACnet MS/TP or the N2 protocol.

All new controllers use either BACnet MS/TP as the default communications protocol, or BACnet/

IP. Switchable communications protocols in the MS/TP models 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 CCT, 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 passthrough in the commissioning mode

• do not support remote downloading or commissioning using BACnet routing

• do not support wireless connection to the N2 bus

Part No. 24-10143-357 Rev. H

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

FX-PCV1615, FX-PCV1626, FX-PCV1628, FX-PCV1630

*2410143357H*

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 an FX-PCV1615/1626/1628/1630 controller:

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

to the FX-PCV controller.

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

Parts included

• One FX-PCV1615/1626/1628/1630 controller with removable SA bus and power terminal blocks.

• One installation instructions sheet.

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

• The FX-PCV1628 model includes a 1.25 inch extended length screw.

Materials and special tools needed

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

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 FX-PCV.

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

mount the FX-PCV.

• Pliers to open and close the damper.

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

FX-PCV1615/1626/1628/1630 Programmable VAV Box Controllers Installation Instructions2

Mounting

Observe these guidelines when mounting an FX-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 FX-

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

condensation to fall away from the FX-PCV. Additional measures may be required in some

installations.

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

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

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

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

specified in the Technical specifications section.

• Provide sufficient space around the FX-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 FX-PCV in areas where electromagnetic emissions from other devices or wiring

can interfere with controller communication.

• Avoid mounting the FX-PCV on surfaces with excessive vibration.

• When using the FX-PCV1615/1626/1628/1630 to replace an FX-PCV1610 or FX-PCV1620 controller,

plug the unused open hole in the duct work from the original FX-PCV mounting if possible. Plug

the hole using the sheet metal screw from the original installation (preferred option).

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

• Do not install the FX-PCV in an airtight enclosure.

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

through the controller.

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

to the controller.

To mount the FX-PCV1615/1626/1628/1630 controllers:

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

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

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

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

FX-PCV controller caused by the shaft bushings.

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

movement in either direction.

3. Secure the self-drilling No.10 screw through the captive spacer (Figure 2) with a power

screwdriver and 100mm (4in.) 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 3.5mm (9/64in.) drill bit.

Insert the mounting screw and tighten against the spacer. For the FX-PCV1628 models, use

the additional 1.25 inch screw to mount to one of the two holes provided near the actuator

opening (Figure 2) to mount the controller.

Important: Do not overtighten the screw, or the threads may strip. If mounting to the VAV

box, make sure the screws do not interfere with damper blade movement.

3FX-PCV1615/1626/1628/1630 Programmable VAV Box Controllers Installation Instructions

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

shown in the figure below.

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 (Figure 2) and turn the FX-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.

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

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

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

the full-closed stop.

9. All models are compact in size and are easily installed on VAV boxes. The FX-

PCV1615/1626/1630 models have either a round shaft up to 13 mm in diameter or a 10 mm

square shaft. 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 10.5 to 11.5 N·m (95 to 105 lb·in).

10. Skip this step if you are installing the FX-PCV1626 model. 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 FX-PCV controller and

the other ends of the tubing to the pressure transducer in the VAV box application (Figure 2).

Note: The FX-PCV uses a digital non-flow pressure sensor (all models except the FX-

PCV1626) with bidirectional flow operation, which allows you to connect the high- and low-

pressure DP tubes to either barbed fitting on the FX-PCV controller. You do not need to

make a specific high- or low-side connection when you attach the tubing to the barbed

fittings on the FX-PCV.

11. 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.

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

FX-PCV1615/1626/1628/1630 Programmable VAV Box Controllers Installation Instructions4

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 dégâts 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.

Wiring diagram

Figure 2: PCV1615/1626/1628/1630 Controller wiring terminations and physical features

5FX-PCV1615/1626/1628/1630 Programmable VAV Box Controllers Installation Instructions

Table 1: FX-PCV1615/1626/1628/1630 Programmable VAV Box feature callout numbers and

descriptions

Callout Physical features: description and references

1 24 VAC, Class 2 Supply Power Terminal Block (see Supply power terminal block)

2 Device Address DIP Switch Block

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

4 Configurable Outputs: Voltage Analog Output (0–10 VDC) and Binary Output (24 VAC

Triac) FX-PCV1630, 1626, and 1628 only) (see Table 3)

5 Dual Port Fitting

6 Manual Override Button (see Mounting)

7 Coupler Bolt (see Mounting)

8 Controller Coupler (see Mounting)

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

Resistive Analog Inputs (0–600k ohm) (see Table 3):

0–2k Potentiometer

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

NTC: 10K Type L (10K Johnson Controls® Type II is equivalent to Type L) or 2.252K

Type II

Dry Contact Binary Input

10 FC Bus Terminal Block. May also be used for N2 connections.

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

12 SA Bus Terminal Block

13 Modular Port (FC Bus) RJ-12 6-Pin Modular Jack (see Modular ports)

14 Modular Port (SA Bus) RJ-12 6-Pin Modular Jack (see Modular ports)

15 Captive Spacer and Screw

16 LED Status Indicators (see Table 8)

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.

FX-PCV1615/1626/1628/1630 Programmable VAV Box Controllers Installation Instructions6

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.

For detailed information on configuring and wiring an MS/TP Bus, FC Bus, or SA Bus, refer to the FX-

PC Series Controllers MS/TP Communications Bus Technical Bulletin (LIT-12011670).

FX-PCV terminals and bus ports

See Input and Output terminals for input and output terminal and bus port locations on the FX-

PCV1615/1626/1628/1630 controllers. Observe the following guidelines when wiring an FX-PCV

controller.

Input and Output terminals

The input spade terminals are located on the side of the FX-PCV near the terminal block. The output

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

block. See Table 3 for more information.

FC bus terminal block (Or N2 protocol as required)

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 FX-PCV and other 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).

7FX-PCV1615/1626/1628/1630 Programmable VAV Box Controllers Installation Instructions

SA bus terminal block

The SA Bus terminal block is a brown, removable, 4-terminal plug with +15 VDC that fits into a

board-mounted jack. Wire the removable SA Bus terminal block plugs on the FX-PCV and other SA

Bus devices in a daisy-chain configuration using 4-wire twisted, shielded cable as shown in Figure 4.

See Table 5 for more information.

Figure 4: SA bus terminal block wiring

Modular ports

The modular and FC Bus ports on the face of the FX-PCV (Figure 2) are RJ-12 (6-position) modular

jacks as shown in Figure 5.

Figure 5: Pin number assignments for sensor (SA bus and

FC bus) ports on FX-PCV1615/1626/1628/1630 Controllers

The modular SA Bus port provides a connection for the Bluetooth Commissioning Converter (FX-

BTCVT), FX-ATV7003 VAV Balancing Tool, FX-DIS1710 Local Controller Display, FX-WRZ78xx Series

One-to-One Wireless Transmitter, and NS Series sensors. The modular FC Bus port provides a

connection for the Bluetooth Commissioning Converter and the FX-ZFR Wireless Router.

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.

FX-PCV1615/1626/1628/1630 Programmable VAV Box Controllers Installation Instructions8

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 FX-PCV 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 6. See Table 5 for more information.

Figure 6: 24 VAC supply power terminal block wiring

Important: Exercise caution while rewiring the power plug when replacing an FX-PCV1610

or FX-PCV1620 controller withan FX-PCV1615/1626/1628/1630 controller. The supply power

terminal on a new FX-PCV is a two-position terminal block (Figure 6). An FX-PCV1610 or FX-

PCV1620 controller uses a three-position terminal block, and the center position is not used.

Stray wire strands may make contact and cause a short circuit across the 24 VAC power supply.

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 FX-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 FX-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 for further details.

Figure 7: Transformer grounding

9FX-PCV1615/1626/1628/1630 Programmable VAV Box Controllers Installation Instructions

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 FX-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.

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 FX-

PCV16xx-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 FX-PCV1615/1626/1628/1630 controller:

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

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

3. Ensure that the FX-PCV’s device address DIP switches are set to the appropriate device address.

(See Setting the device address.) Also, activate the EOL switch if necessary.

4. Connect the FX-PCV controller to 24 VAC, Class 2 power.

Note: If you are using the FX-PCV1615/1626/1628/1630 controller with the Wireless Field

Bus System, refer to the WNC1800/FX-ZFR182x Pro Series Wireless Field Bus System Bulletin

(LIT-12012378) or the FX-ZFR1800 Series Wireless Field Bus System Bulletin (LIT-12011660).

FX-PCV terminal functions, ratings, requirements, and wiring

guidelines

Input and Output wiring guidelines

Table 3 provides information about the functions, ratings, and requirements for the FX-PCV input

and output terminals, and Table 4 provides guidelines for wire sizes and cable lengths.

In addition to the wiring guidelines in Table 3, observe these guidelines when wiring FX-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 not required for input or output cables but 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.

FX-PCV1615/1626/1628/1630 Programmable VAV Box Controllers Installation Instructions10

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