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)
1
Device Address DIP Switch Block (See Figure 9)
2
Mounting Clip3
Configurable Output (CO) Terminal Blocks (See Table 3)
4
24 VAC, Class 2 Supply Power Terminal Block (See Supply Power Terminal Block)
5
Cover Lift Tab (One of Two) (See Figure 3)
6
Display Navigation Buttons (See Setting Up an Integral or Local Display)
Note: Not available on all FX-PCG models.
7
LCD Display Area (See Setting Up an Integral or Local Display)
Note: Not available on all FX-PCG models.
8
FC Bus Terminal Block (See FC Bus Terminal Block)
9
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)
10
Sensor Port (Sensor Actuator [SA] Bus, RJ-12 6-pin Modular Jack) (See Figure 6)
11
Binary Inputs (BIs) Terminal Block (See Table 3)
12
Universal Inputs (UIs) Terminal Blocks (See Table 3)
13
LED Status Indicators (See Table 8)
14
Field Controller (FC) Bus Port (RJ-12 6-pin Modular Jack) (See Figure 6)
15
Binary Output (BO) Terminal Block (See Table 3)
16
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)
CO
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