Johnson Controls FX-PCV18 Series User manual

FX-PCV1826/1832 Programmable VAV Box
Controller Installation Instructions
Applications
FX-PCV1826 controllers are well-suited for commercial zoning applications and can be used
for pressure dependent VAV box applications where no differential pressure tranduser (DPT) is
required.
Note: At Controller Configuration Tool (CCT) 13.0 or later, using Release Mode 10.1, the PCV18
Series controllers can be configured as either N2 devices or as standard BACnet® MS/TP
devices. This ability provides a potential cost-effective protocol upgrade path for existing
customers and should be considered when you install the controller.
Important: When you receive an FX-PCV18 Series controller from the factory or upgrade the
firmware or main code, the controller defaults to using the MS/TP communications protocol.
The Load Summary screen of CCT shows the connection as Wired Field Bus, indicating that
the MS/TP protocol is in use. If you have an N2 application, the Load Summary screen indicates
that you need to switch the communications protocol to N2.
These FX-PCV controllers feature an integral digital pressure sensor (FX-PCV1832 model only), a
damper actuator, and a 32-bit microprocessor. The controller's small package size facilitates quick
field installation and efficient use of space for field replacements, while still enabling precision
control performance.
Note: Connecting an FX-PCX to the FX-PCV via the SA Bus connection is not supported.
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-PCV18 Series controller:
Part No. 24-10143-381 Rev H
2019-03-22 (barcode for factory use only)
FX-PCV1826-1, FX-PCV1832-1
*2410143381H*

• 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-PCV18 Series controller with removable N2/FC bus terminal block
• One installation instructions sheet
• Two 6.35 mm x 6.35 mm (1/4 in. x 1/4 in. ) brass fittings
• One self-drilling No. 10 x 25 mm (1 in.) screw
• Two 12-in. (30.48 cm.) pieces of flexible tubing
• One controller/sensor Y cable adapter
• One 8-pin to 6-pin single-socket cable adapter
Note: Remove the cap plug from the TSTAT port of the controller and save for future use. The
cap plug is used on existing sensor ports that are no longer used.
Materials and special tools needed
Note: You may not require all the materials listed for your controller installation.
• Several 6 mm (1/4 in.) female spade terminals for input and output wiring and crimping tool or
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
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 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.
FX-PCV1826/1832 Programmable VAV Box Controller Installation Instructions2

• Provide sufficient space around the FX-PCV for cable and wire connections and adequate
ventilation through the controller (50 mm [2 in.] minimum 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.
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-PCV18 Series controller, complete the following steps:
1. Place the FX-PCV18 Series controller in the proper mounting position on the damper shaft so
that the wiring connections are easily accessible.
Note: The line from the captive spacer and screw through the center of the damper shaft
must be either horizontal or vertical, and the wall plate must be wall-mounted to comply
with UL requirements. See the following figure for possible mounting positions.
Figure 1: Possible FX-PCV18 series controller mounting positions
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: Using the alignment marks to center the captive spacer ensures sufficient FX-PCV18
controller movement in either direction.
2. Secure the self-drilling No. 10 screw through the shoulder washer (Figure 3) 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.
3FX-PCV1826/1832 Programmable VAV Box Controller Installation Instructions

3. Locate the damper position using the typical marking on the end of the damper shaft. See the
following figure.
Figure 2: Typical damper end shaft icons
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 3) 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. 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).
8. Loop the pneumatic tubing to include a trap for condensation. If needed, use the included
brass fittings and attach the included pieces of tubing to the tubing of the FX-PCV controller.
Attach the tubing from the FX-PCV controller 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
3). The FX-PCV1826 does not come with the tubing pieces.
Note: The FX-PCV uses a digital non-flow pressure sensor with bidirectional flow
operation, which allows the high- and low-pressure DP tube connections to be made 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.
9. Push the manual release button, and turn the actuator coupling manually to ensure that the
actuator can rotate from full-closed to full-open positions without binding.
10. Complete the mounting by rotating the damper to the full-open position.
FX-PCV1826/1832 Programmable VAV Box Controller 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.
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.
Wiring diagram
Figure 3: FX-PCV Series Controller wiring terminations and physical features
5FX-PCV1826/1832 Programmable VAV Box Controller Installation Instructions

Table 1: FX-PCV18 Series Controller feature callout numbers and descriptions
Callout Physical features: description and references
1 24 VAC, Class 2 Supply Power Spade Terminals (see Supply power spade terminals)
2 Device Address DIP Switch Block (see Setting the device address)
3 Binary Outputs, 24 VAC Triacs (see Table 4)
4 Configurable Outputs: Voltage Analog Output (0–10 VDC) and Binary Output (24 VAC
Triac) (see Table 4)
5 Dual Port Fitting (see Figure 3)
Not included in the FX-PCV1826 model.
6 Manual Override Switch (see Mounting)
7 Controller Coupler (see Mounting)
8 Coupler Bolt (see Mounting)
9 Universal Input: Voltage Analog Input (0–10 VDC)
Resistive Analog Inputs (0–600k ohm) (see Table 4):
0–2k Potentiometer
RTD: 1k Nickel, 1k Platinum, or A99B SI
NTC: 10K Type L (10K JCI Type II is equivalent to Type L) or 2.252K Type II
Dry Contact Binary Input
10 N2/FC Bus Pluggable Screw Terminal Block (see N2/FC bus terminal block)
11 EOL (End-of-Line) Switch (see Setting the EOL switch)
12 SA Bus Spade Terminals (see SA bus spade lugs)
13 TSTAT Modular Port: RJ-45 8-Pin Modular Jack (see Modular port)
14 Captive Spacer and Screw (see Figure 3)
15 LED Status Indicators (see Table 7)
Wiring
Warning
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
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.
FX-PCV1826/1832 Programmable VAV Box Controller Installation Instructions6

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 N2 Bus, refer to the N2 Communications Bus
Technical Bulletin (LIT-636018).
FX-PCV terminals and bus ports
See Figure 3 for input and output terminal and bus port locations on the FX-PCV18 Series
controllers. Observe the following guidelines when wiring an FX-PCV18 controller.
Input and Output terminals
The input spade terminals are located on the side of the FX-PCV near the N2/FC Bus terminal block.
The output spade terminals are located on the opposite side of the controller near the power
supply spade terminals. See Table 4 for more information.
N2/FC bus terminal block
The N2/FC Bus terminal block is a blue, removable, 4-terminal plug that fits into a board-mounted
jack.
Wire the removable N2/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 4. See Table 5 and
Table 6 for more information.
Figure 4: N2/FC bus terminal block wiring
Note: The Shield terminal (SHLD) on the N2/FC Bus terminal block is isolated and can be used
to connect the cable shields on the bus (Figure 4).
7FX-PCV1826/1832 Programmable VAV Box Controller Installation Instructions

SA bus spade lugs
Wire the SA Bus spade lugs on the FX-PCV and other SA Bus devices in a daisy-chain configuration
using 4-wire twisted, shielded cable as shown in Figure 5. See Table 6 for more information.
Figure 5: SA bus spade lug wiring
Note: Connecting an FX-PCX to the FX-PCV by using the SA Bus connection is not supported.
Modular port
The modular (TSTAT) port on the face of the FX-PCV (Figure 3) is an RJ-45, 8-position modular jack
used to connect your new or existing sensor to the FX-PCV using one of the two included adapters.
Refer to the Sensor Replacement section in the N2 FX-PCV Application Note (LIT-12011838).
Figure 6: Pin number assignments for the modular port on FX-PCV18 Controllers
Supply power spade terminals
Wire the 24 VAC supply power wires from the transformer to the HOT and COM terminals on the
spade terminal as shown in Figure 7. See Table 6 for more information.
FX-PCV1826/1832 Programmable VAV Box Controller Installation Instructions8

Figure 7: 24 VAC supply power spade terminal wiring
Important:
• The supply power terminal block on the FX18-PCV is a two-position spade lug (Figure 7).
Exercise caution while rewiring the power plug when replacing an existing controller. Stray
wire strands may make contact and cause a short circuit across the 24 VAC power supply.
• To maintain proper phasing when replacing the existing PCV14xx controller with the FX-
PCV18 controller, connect the power wire from 24 VAC: 1 terminal on the existing controller
to the HOT power terminal on the FX-PCV18. Also connect the power wire from the 24 VAC: 2
terminal on the existing controller to the COM power terminal on the FX-PCV18 controller.
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.
CAUTION
Risk of Personal Injury and Property Damage
Improper wiring of this terminal may cause a short circuit across the 24 VAC power supply on -1
models.
To wire the FX-PCV18 Series controller, complete the following steps:
1. Terminate wiring per engineering drawings.
2. Wire network sensors and other devices to the FX-PCV's SA Bus.
3. Wire the N2/FC Bus in a daisy chain (see Table 6).
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.
Refer to the N2 FX-PCV Application Note (LIT-12011838) for more information about replacing an
existing controller with an FX-PCV18 controller.
9FX-PCV1826/1832 Programmable VAV Box Controller Installation Instructions

FX-PCV terminal functions, ratings, requirements, and wiring
guidelines
Input and Output wiring guidelines
Table 4 provides information about the functions, ratings, and requirements for the FX-PCV input
and output terminals, and Table 5 provides guidelines for wire sizes and cable lengths.
In addition to the wiring guidelines in Table 4, 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 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. Cable runs over 30 m (100 ft) may require an offset in the input/output software
setup.
Maximum cable length versus load current
Use Figure 12 to estimate the maximum cable length relative to the wire size and the load current
(in mA) when wiring inputs and outputs.
N2/FC and SA bus and supply power wiring guidelines
Table 6 provides information about terminal block functions, ratings, and requirements.
Table 6 also provides wire size, cable type, and cable length guidelines for wiring the FX-PCV
communication buses and supply power.
In addition to the guidelines in Table 6, observe these guidelines when wiring the SA and N2/FC
Buses and supply power:
• Run all low-voltage wiring and cables separate from high-voltage wiring.
• All N2/FC and SA Bus cables, regardless of wire size, should be twisted, insulated, stranded
copper wire.
• Shielded cable is strongly recommended for all N2/FC and SA Bus cables.
• Refer to the N2 Communications Bus Technical Bulletin (LIT-636018) for detailed information
regarding wire size and cable length requirements for the N2/FC and SA buses.
Termination diagrams
A set of Johnson Controls® termination diagrams provides details for wiring inputs and outputs
to the FX-PCV18 Series controllers. See the figures in this section for the applicable termination
diagrams.
FX-PCV1826/1832 Programmable VAV Box Controller Installation Instructions10