Johnson Controls FX-PCV Series User manual

FX-PCV Programmable Variable Air
Volume Box Controllers Installation
Instructions
Applications
The FX-PCV1610/1620 controllers are part of the Facility Explorer® Series Programmable Controller
(FX-PC) family. FX-PCV controllers feature an integral 4 Nm damper actuator and Differential
Pressure Transducer. FX-PCV controllers run pre-engineered and user-programmed applications
required to monitor and operate a wide variety of VAV boxes.
The FX-PCV controllers operate on an RS-485 BACnet® MS/TP Bus as BACnet Application Specific
Controllers (B-ASCs) and integrate into the web-based Facility Explorer system.
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-PCV controller:
• Transport the controller in the original container to minimize vibration and shock damage to the
FX-PCV Box controller.
• Do not drop the controller or subject it to physical shock.
Parts included
• One FX-PCV controller with removable bus and power terminal blocks
• One installation instructions sheet
Materials and special tools needed
• One screw or other type of fastener appropriate for the mounting surface
Part No. 24-10143-179 Rev. C
2019-03-22 (barcode for factory use only)
FX-PCV1610-0, FX-PCV1620-0
*2410143179C*

• Several 6 mm (1/4 in.) female spade terminals for input and output wiring
• Small straight-blade screwdriver for securing wires in the terminal blocks
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 the mounting surface can support the controller and any user-supplied enclosure.
• Mount the controller on a hard, even surface whenever possible.
• 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 in
the Technical specifications section.
• Provide sufficient space around the controller for cable and wire connections and good
ventilation through the controller. Leave a minimum of 50 mm (2 in.) around the top, bottom,
sides, and front of the controller.
• Do not mount the controller on surfaces prone to vibration, such as duct work, or in areas
where electromagnetic emissions from other devices or wiring can interfere with controller
communication.
On panel or enclosure mount applications, observe these additional guidelines:
• Do not install the controller in an airtight 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.
To mount the FX-PCV controller:
1. Place the controller in the proper mounting position on the damper shaft so that the wiring
connections are easily accessible. Make sure the 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.
2. Secure the self-drilling No. 10 screw through the FX-PCV controller mounting slot 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 washer.
Important: Do not overtighten the screws, or the threads may strip. If mounting to the
VAV box, make sure the screws do not interfere with damper blade movement.
3. Locate the damper position using the typical marking on the end of the damper shaft.
FX-PCV Programmable Variable Air Volume Box Controllers Installation Instructions2

Figure 1: Typical damper end shaft Iocns
4. 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).
5. 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 fully closed (90° boxes) or fully
open (45° and 60° boxes) position.
6. 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 fully closed and fully open damper positions. By installing the FX-PCV controller at the
fully open position, the FX-PCV controller provides the open stop for 45° and 60° boxes. The
closed damper seal provides the fully closed stop.
7. All models are compact in size and are easily installed on VariableAir Volume (VAV) boxes with 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 11
to 15 N·m (100 to 130 lb·in).
8. Loop the pneumatic tubing to include a trap for condensation. Attach the tubing from the FX-
PCV controller to the VAV box pickup. The HIGH (red) tubing is connected to the inlet or high-
pressure side and the clear tubing to the low side (Figure 2).
9. Push the manual release button, and turn the actuator coupling manually to ensure that the
actuator can rotate from fully closed to fully open positions without binding.
10. Complete the mounting by rotating the damper to the fully 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
Mise En Garde: 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.
3FX-PCV Programmable Variable Air Volume Box Controllers Installation Instructions

Wiring diagram
Figure 2: FX-PCV Controller physical features and wiring terminations
Table 1: FX-PCV Controller physical features
Number Feature
1 Pneumatic tubing
2 Controller coupler
3 Coupler bolt
4 Manual override switch
5 Binary Outputs (24 VAC Triacs)
6 Configurable outputs can be defined as:
• Voltage Analog Output (0-10 VDC)
• Binary Output (24 VAC Triac)
7 24 VAC, Class 2 Supply Power Terminal Block
8 Anti-rotation slot
9 LED Status Indicators
10 FC Terminal Block
11 Sensor Port (SA Bus) RJ-12 6-Pin Modular Jack
12 SA Terminal Block
13 Sensor Port (SA Bus) RJ-12 6-Pin Modular Jack
FX-PCV Programmable Variable Air Volume Box Controllers Installation Instructions4

Table 1: FX-PCV Controller physical features
Number Feature
14 Device Address DIP Switch Block
15 Universal Input can be defined as:
Voltage Analog Input (0-10 VDC)
• Resistive Analog Inputs (0-600k ohm)
• 0-2K Potentiometer
• RTD: 1k Nickle 1k Platinum or A99B SI
• NTC: 10k Type L 10k JCI Type II, or 2.252k Type II
Dry Contact Binary Input
Wiring
CAUTION
Risk of Electric Shock
Disconnect the power supply before making electrical connections to avoid electric shock.
CAUTION
Mise En Garde: Risque de décharge électrique
Débrancher l'alimentation avant de réaliser tout raccordement électrique afin d'éviter tout risque de
décharge électrique.
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 Figure 2 for input and output terminal and bus port locations on the FX-PCV controller. Observe
the following guidelines when wiring an FX-PCV controller.
5FX-PCV Programmable Variable Air Volume Box Controllers Installation Instructions

Input and Output terminals
The input spade terminals are located on the side of the FX-PCV near the device address switch. The
output spade terminals are located on the opposite side of the controller near the power supply
terminal block. 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 FX-PCV and other field controllers in a daisy-
chain configuration using 3-wire twisted, shielded cable as shown in Figure 3. See Table 5 for more
information.
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).
Figure 3: FC bus terminal block 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 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
FX-PCV Programmable Variable Air Volume Box Controllers Installation Instructions6

Sensor port
The Sensor (SA Bus) port on the left side of the FX-PCV (Figure 2) is an RJ-12, 6-position modular jack
that provides a connection for the VAV Balancing Tool, specified network sensors, or other SA Bus
devices with RJ-12 plugs.
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 5.
Figure 5: Pin number assignments for sensor, SA bus, and FC bus ports on FX-PCVs
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 bottom right of the FX-PCV.
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. The middle terminal on the supply power terminal block is not
used. See Table 5 for more information.
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.
Figure 6: 24 VAC supply power terminal block wiring
7FX-PCV Programmable Variable Air Volume Box Controllers Installation Instructions

To wire the FX-PCV controller:
1. Terminate wiring per engineering drawings.
2. Wire network sensors and other devices to the FX-PCV'sSA Bus.
3. Wire the FC Bus in a daisy chain.
4. Ensure that the FX-PCV’s device address DIP switches are set to the appropriate device address.
(See Setting the device address.)
5. Connect the FX-PCV controller to 24 VAC, Class 2 power.
FX-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 FX-PCV input
and output terminals; and references guidelines for determining proper wire sizes and cable
lengths.
In addition to the wiring guidelines in Table 2, 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.
• Shielded cable is recommended for input and output cables that are exposed to high
electromagnetic or radio frequency noise.
• Cable runs that are less than 30 m (100 ft) typically do not require an offset in the input/output
software setup. Cable runs that are over 30 m (100 ft) may require an offset in the input/output
software setup.
Input and Output wiring guidelines tables
Table 2: I/O terminal blocks, functions, ratings, requirements, and cables
Terminal block
label
Terminal
labels
Function, ratings, and
requirements
To determine wire size
and maximum cable
length
UNIVERSAL
(Inputs)
+15 V 15 VDC Power Source for active (3-
wire) input devices connected to the
Universal INn terminals.
Provides 100 mA total current.
Same as (Universal)
INn.
Note: Use 3-wire
cable for devices
that source power
from the +15 V
terminal.
FX-PCV Programmable Variable Air Volume Box Controllers Installation Instructions8

Table 2: I/O terminal blocks, functions, ratings, requirements, and cables
Terminal block
label
Terminal
labels
Function, ratings, and
requirements
To determine wire size
and maximum cable
length
Analog Input - Voltage Mode (0–10
VDC)
10 VDC maximum input voltage
Internal 75k ohm Pulldown
See Guideline A in Table
3.
INn
Analog Input - Resistive Mode (0–
600k ohm)
Internal 12 V, 15k ohm pull up
Qualified Sensors: 0–2k
potentiometer,
RTD (1k Nickel [Johnson Controls
sensor],
1k Platinum, and A99B Silicon
Temperature Sensor)
Negative Temperature Coefficient
(NTC) Sensor
10K Type L (10K JCI Type II is
equivalent to Type L) or 2.252K Type II
See Guideline A in Table
3.
ICOMnUniversal Input Common for all
Universal IN terminals
Note: All Universal ICOMn
terminals share a common,
which is isolated from all other
commons.
Same as (Universal)
INn.
BINARY
(Outputs)
OUTnBinary Output - 24 VAC Triac
(Internal Power)
Sources internal 24 VAC power (24~
HOT)
See Guideline C in Table
3.
9FX-PCV Programmable Variable Air Volume Box Controllers Installation Instructions

Table 2: I/O terminal blocks, functions, ratings, requirements, and cables
Terminal block
label
Terminal
labels
Function, ratings, and
requirements
To determine wire size
and maximum cable
length
OCOMnBinary Output - 24 VAC Triac
(Internal Power)
Connects OCOMn to 24~ COM when
activated.
Internal Power Source:
30 VAC maximum voltage to load
0.5 A maximum output current
1.3 A at 25% duty cycle
Maximum 6 cycles/hour with M9220-
BGx-3
40 mA minimum load current
Analog Output - Voltage Mode (0–10
VDC)
10 VDC maximum output voltage
10 mA maximum output current
External 1k to 50K ohm load required
See Guideline A in Table
3.
CONFIGURABLE
(Outputs)
OUTn
Binary Output 24 VAC Triac
Connects OUT to OCOM when
activated.
External Power Source:
30 VAC maximum voltage to load
0.5 A maximum output current
1.3 A at 25% duty cycle
Maximum 6 cycles/hour with M9220-
BGx-3
40 mA minimum load current
See Guideline C in Table
3.
FX-PCV Programmable Variable Air Volume Box Controllers Installation Instructions10