Facility Explorer FX16 Service manual

Technical Bulletin FX16 Master Controller
Issue Date May 14, 2007
©2007 Johnson Controls, Inc. www.johnsoncontrols.com
Code No. LIT-12011108
FX16 Master Controller
Introduction to FX16 Master Controller................................................4
FX16 Master Controller Key Concepts...............................................................5
FX16 Master Controller.....................................................................................................5
Installation...............................................................................................6
North American Emissions Compliance..............................................................................7
Installation Procedures .......................................................................................8
Mounting the FX16 Controller.............................................................................................8
Connection Details..............................................................................................................9
Connection Details for FX Slave Controllers - Distributed Application and Gateway
Objects - on Local Link Extension Bus .............................................................................13
Connection Details for I/O Expansion (XT91/XP91 Modules) on Local Extension Bus....15
Connection Details for the RS-485 N2 Open Card...........................................................16
LONWORKS Communication Card.....................................................................................20
RS-232C Communications Card.......................................................................................22
Connecting a Computer with the Null Modem Cable........................................................31
User Interfaces .................................................................................................................34
Integral MUI ......................................................................................................................37
FX Programming Key........................................................................................................40
Inputs and Outputs............................................................................... 43
Introduction.......................................................................................................................43
Inputs and Outputs Concepts...........................................................................44
Analog Inputs....................................................................................................................44
Digital Inputs.....................................................................................................................44
Analog Outputs.................................................................................................................44
Digital Outputs ..................................................................................................................44
Detailed Inputs and Outputs Procedures.........................................................45

FX16 Master Controller Technical Bulletin
2
FX16D and FX16X (Not Rev. A) Master Controller 24 VAC Power Connection...............45
FX16X Rev. A Master Controller 24 VAC Power Connection...........................................46
Analog Inputs....................................................................................................................47
Digital Inputs.....................................................................................................................53
Analog Outputs.................................................................................................................57
Digital Outputs ..................................................................................................................60
Extension Modules ...........................................................................................................63
Troubleshooting.................................................................................................65
Reading 9999 or Invalid from the Analog Inputs...............................................................65
Cannot Properly Read Current Sensors...........................................................................65
Operation...............................................................................................66
Introduction........................................................................................................66
Operation Concepts...........................................................................................66
Local Link Extension Bus..................................................................................................66
Distributed Application......................................................................................................67
Gateway Function.............................................................................................................67
Web Server.......................................................................................................................67
Communication Services..................................................................................................67
Supervisory Option ...........................................................................................................68
Alarm and Event Management .........................................................................................68
Data Trend Logging..........................................................................................................68
Time Scheduling...............................................................................................................68
User Interface ...................................................................................................................69
Application Configuration and Commissioning .................................................................69
Security.............................................................................................................................70
Application Upload/Download...........................................................................................70
Detailed Operation Procedures ........................................................................71
Local Link Extension Bus..................................................................................................71
Distributed Application......................................................................................................74
Gateway Function (LP-FX16X Rev. A Only).....................................................................77
Web Server.......................................................................................................................78
Communication Services..................................................................................................90
Supervisory Option ...........................................................................................................91

FX16 Master Controller Technical Bulletin 3
Event Management...........................................................................................................93
Data Trend Logging..........................................................................................................95
Time Scheduling...............................................................................................................96
User Interfaces .................................................................................................................98
Application Configuration and Commissioning ...............................................................100
FX Builder.......................................................................................................................101
FX CommPro N2/LON....................................................................................................105
Security...........................................................................................................................107
Application Upload/Download.........................................................................................108
Troubleshooting...............................................................................................114
GSM Modem Not Able to Send SMS #1.........................................................................114
GSM Modem Not Able to Send SMS #2.........................................................................114
Null Modem Connection Problems .................................................................................115
Multiple Null Modem Connections Error .........................................................................116
Specifications and Technical Data....................................................117
Ordering Codes................................................................................................117
Technical Specifications.................................................................................120
I/O Technical Details.......................................................................................................120
FX16 Master Controller...................................................................................................122
N2 Open Card.................................................................................................................123
LON Connection .............................................................................................................123
GSM Connection ............................................................................................................124
Programming Key...........................................................................................................125

FX16 Master Controller Technical Bulletin
4
Introduction to FX16 Master
Controller
Figure 1: FX16 Master Controller with Display
The FX16 Master Controller is a high performance field controller in
the Facility Explorer system. The FX16 Master Controller is
specifically designed for commercial Heating, Ventilating, Air
Conditioning, and Refrigeration (HVACR) applications, such as chillers
and rooftops, indoor packaged air conditioning units, air handling units,
and close control units.
The controller has 27 physical inputs and outputs and supports a wide
range of temperature sensors and actuating devices. Additional physical
inputs and outputs may be achieved by adding the XT/XP expansion
modules on the local Extension bus.
The FX16 Master Controller can manage a distributed control
application with up to 16 FX slave controllers (FX05 Advanced, FX06,
FX07, FX14 or FX15 controllers). You can display and modify
parameters in the distributed control application from the optional
integral or remote mounted user interface.
The FX16 also features communication services to transmit event
notification messages via Short Messaging Service (SMS) or e-mail.
With its embedded Web server, you can browse and make adjustments
to parameters of the application from remote locations.

FX16 Master Controller Technical Bulletin 5
The FX16 Master Controller is fully configurable or programmable,
using the FX Tools Pro software package, for a wide range of
commercial HVACR applications.
The FX16 Master Controller is also available with a serial
communication card for the integration into an N2 Open or
LONWORKS® Building Automation network system.
Optional accessories make the FX16 Master Controller the ideal
solution for the building controls market. These include:
•N2 Open, plug-in communication card
•LON, plug-in communication card
•RS-232C, plug-in serial communication card
•Global System for Mobile Communications (GSM) modem
•Medium User Interface (MUI): integral, remote panel or wall-
mountable
FX16 Master Controller Key Concepts
FX16 Master Controller
The main features of the FX16 Master Controller include:
•fully programmable using FX Tools software package
•RS-485, N2 Open, or LON FTT10 plug-in communication card for
supervisory system
•as an alternative, an RS-232C port for a modem (or null modem)
connection
•DIN rail mounting
•removable screw connectors for servicing operations
•embedded Web server
•e-mail and SMS communications services manager
•Input/Output (I/O) expansion modules (up to 64 points)
•Distributed Application with up to 16 FX slave controllers
•optional Medium User Interface: integral, or remote panel or wall-
mounted
•multiple language support
•trend logging (up to 4 MB flash memory)
•easy commissioning via FX CommPro commissioning tool
•Programming Key for easy application uploading and downloading

FX16 Master Controller Technical Bulletin
6
Installation
This chapter takes you through the process of installing an FX16 Master
Controller.
!
WARNING: Risk of Electric Shock. Disconnect power supply before
making electrical connections. Contact with components carrying hazardous
voltage can cause electric shock and may result in severe personal injury or
death.
IMPORTANT: Use this FX16 controller only as an operating control. Where
failure or malfunction of the FX16 could lead to personal injury or damage to
the controlled equipment or other property, additional precautions must be
designed into the control system. Incorporate and maintain other devices such
as supervisory or alarm systems or safety or limit controls that are intended to
warn of, or protect against, failure or malfunction of the FX16 controller.
IMPORTANT: In North America, the controller is intended for installation with
Class 2 inputs and outputs only where no special electrical safety mounting
precautions are generally necessary. These controllers are UL- recognized as
Temperature Indicating and Regulating Equipment in accordance with UL 873
and UL Listed as Open Energy Management Equipment per UL 916.
IMPORTANT: Before specifying the FX16 for plenum applications, verify
acceptance of exposed plastic materials in plenum areas with the local
building authority. Building codes for plenum requirements vary by location.
Some local building authorities accept compliance to UL 1995, Heating and
Cooling Equipment, whereas others use different acceptance criteria.
IMPORTANT: Cables and wiring at Safety Extra-Low Voltage (SELV) and
Class 2 wiring (North America) must be separated from power line voltage
wiring. A minimum separation distance of 30 cm (12 in.) is recommended. Do
not run extra low voltage cables parallel to power line voltage cables for long
distances greater than 3 m (10 ft). Do not run extra low voltage wiring close to
transformers or high frequency generating equipment.

FX16 Master Controller Technical Bulletin 7
179 (7.05)
44 (1.73)
75 (2.95)
215 (8.46)
122 (4.8) 142 (5.59)
35 (1.38)
66 (2.6)
49 (1.93)
BB
Figure 2: Mounting Dimensions for FX16 (Shown with Integral User Display and
Screw Connectors), mm (in.)
Two different types of terminal connectors are available: spring clamp
or screw connectors. The screw connectors are included, whereas you
must order the spring clamp connectors separately. For details, see
Ordering Codes.
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 is
likely to cause harmful interference, in which case the user is required
to correct the interference at his/her 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.

FX16 Master Controller Technical Bulletin
8
Installation Procedures
Follow these instructions to properly install and connect the FX16.
!
WARNING: Risk of Electric Shock. Disconnect power supply before
making electrical connections. Contact with components carrying hazardous
voltage can cause electric shock and may result in severe personal injury or
death.
Mounting the FX16 Controller
To mount the FX16 controller:
1. Snap the controller onto the 35 mm (1.38 in.) rail for DIN rail
mounting.
To release the controller, insert a screwdriver in Slot B and lift the
retaining clip. Since the retaining clip is spring-loaded, you can also
remove the controller without a screwdriver by carefully pushing the
controller up against the clip and then tilting the top forward to
release the top lugs from the DIN rail.
2. Make wiring terminations with detachable connectors.
The detachable connectors accept 1 x 1.5 mm2 (0.002 in.2)/14 AWG
cable. Two types of connector are available: screw connectors
shipped with the controller and cage clamp connectors ordered
separately.
Terminations to the Supervisor Link, Local Link Bus, and Remote
Display are made via the connectors provided with the controller.
3. Verify that the wiring has been correctly installed and that voltage
levels are appropriate for the various input signals according to the
application.
4. Set the jumpers and address switches of the controller. For more
information, see Jumper Details.
IMPORTANT: The Complementary Metal Oxide Semiconductor (CMOS)
circuits in the controller are sensitive to static electricity. Take suitable
precautions.

FX16 Master Controller Technical Bulletin 9
Connection Details
Wiring Diagram
-20T50
1
41 51 91787255
62 75
921 26 31 2
42 52 92797356 63 76
10 22 27 323
43 53 93807457 777154 61
11 23 28 334
44
12 24 29 345
45
13 25 30 356
46
147
47
158
48
AGND
DO1 Com
DO4 no DO5 no
DO4/5Com
Earth
AO1
AO3 AO2 AO4
DO6/7/8Com
DO2 Com DO3 Com
DO1 no
V~ Com
DO8 no
DO7 no
DO6 no
V~ Hot
FAIL no
FAIL Com
FAIL nc
AO Com AO Com
AO Com AO Com
DO2 no DO3 no AGND
DI1 DI2 DI Com DI7 DI5 DI8 DI3 DI6 DI V~ Hot
AGND AGND AGND AGND
AI1 AI4
DI Com DI4 DI Com DI Com DICom DI V~ Com
AI2 AI5 AI3 AI6
Com LL+ LL- LL- LL+ +16 V Com
EXT V EXT V
AVPS/EXT V
Digital Inputs Analog Inputs
Extension Bus
To Supervisor
To Remote Display
Max
8(3)250V~
Digital Outputs
Analog Outputs
TB1 TB2
TB9
TB8
TB7
TB6
TB5
J2
J1
TB4
TB3
24 V~ 24 V~
JP1
1
2 3
AO V~ Com
AO V~ Hot
24 V~
!
FX16-006_112003
JP2
To Modem
(Optional )
*
(Optional )
*
( )
*
Connectors JP1 and JP2 are in alternative
1:
2:
3:
N2 LON
Com
RT-
RT+
Not Used
NET B
NETA
Figure 3: Connection Details for the FX16 Master Controller
LP-FX16D0x-000C, LP-FX16X0x-000C, and LP-FX16X5x-000C (with 9 Relays)
In the FX16X Rev. A controllers, 24 VAC power is isolated at 500 V
from the internal processor circuits. This isolation enables the use of the
24 VAC power supply to the controller for the Analog Outputs (AOs)
and Digital (binary) Inputs (DIs), maintaining the isolation from the
internal processor circuits. Therefore, in the FX16X Rev. A controllers,
the external wiring of a 24 VAC power supply to the analog outputs
(terminals 79 and 80) and to the digital inputs (terminals 34 and 35) is
not required as the 24 VAC power supply is used internally for the
analog outputs and digital inputs. The terminals 34, 35, 79 and 80 still
exist on the FX16X Rev. A controllers to provide backward
compatibility when replacing a controller. In the FX16X Rev. A
controllers, terminals 35 and 80 are not connected to any internal
circuit. You can use terminals 34 and 79 as extra Com connections,
which are electrically connected to the 24 VAC Power Com.

FX16 Master Controller Technical Bulletin
10
Isolation Diagram
1
41 51 91787255 62 75
921 26 31 2
42 52 92797356 63 76
10 22 27 32 3
43 53 93807457 777154 61
11 23 28 33 4
44
12 24 29 34 5
45
13 25 30 35 6
46
147
47
158
48
Digital Inputs
A
nalog Input
s
Extension
Bus To Remote Display
Digital Outputs Analog Outputs Power Supply
TB1
TB9
()
*
TB8TB7TB6TB5TB4TB3
J2
J1
To
Supervisor To
Modem
TB2
()
*
()
**
()
***
()
**
()
**
()
**
CPU
FX16-005_10 2003
Figure 4: FX16 Isolation Diagram
Figure 4 displays the isolation diagram for the FX16 controller. Use the
following list as a reference to understand the diagram:
•(*) Opto-isolated from the Central Processing Unit (CPU) circuits
(max. 500 V):
LP-FX16D and LP-FX16X (not Rev. A), when separate power
supply is used
LP-FX16X (Rev. A), with same power supply as controller
•(**) Not isolated from CPU (Analog Inputs, Local Link Extension
Bus, and Modem connections)
•(***) DC/DC converter with dielectric strength up to 500 V
•(****) Isolation of power supply from CPU is hardware model
dependent:
−Models LP-FX16D and LP-FX16X (not Rev. A) are not
isolated.
−Model LP-FX16X (Rev. A) is isolated (maximum 500 V).
FX16D and FX16 Controllers (Not Rev. A)
Consider the following information when you work with the
connections details for FX16D and FX16X controllers (not Rev. A):
•Analog Inputs (AIs) are not isolated from the processor circuits
(CPU) or the 24 VAC power supply.
(****)