Johnson Controls FX-PCG1621 Series, FX-PCG16 Series, FX-PCG1611 Series, FX-PCG16 Installation Instructions Manual
FX-PCG16 General Purpose Programmable Controller
Installation Instructions
FX-PCG1611-x, FX-PCG1621-x
Refer to the QuickLIT website for the most up-to-date version of this document.
Part No. 24-10143-152, Rev. G
Issued April 2016
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.
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
FX-PCG, FX-PCX, and FX-PCV controllers are BTLtested 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.
1FX-PCG16 General Purpose Programmable Controller Installation Instructions
North American Emissions Compliance
Mounting
Observe these guidelines when mounting an FX-PCG:
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.
• 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.
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
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:
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.)
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.
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
1
2
4
5
6
7
8
9
Binary Output (BO) Source Power Selection Jumpers (See Binary Output (BO) Source Power Selection Jumpers)
Device Address DIP Switch Block (See Figure 9)
Mounting Clip3
Configurable Output (CO) Terminal Blocks (See Table 3)
24 VAC, Class 2 Supply Power Terminal Block (See Supply Power Terminal Block)
Cover Lift Tab (One of Two) (See Figure 3)
Display Navigation Buttons (See Setting Up an Integral or Local Display)
Note: Not available on all FX-PCG models.
LCD Display Area (See Setting Up an Integral or Local Display)
Note: Not available on all FX-PCG models.
FC Bus Terminal Block (See FC Bus Terminal Block)
4FX-PCG16 General Purpose Programmable Controller Installation Instructions
Table 1: FX-PCG Physical Features Callouts and Descriptions
Physical Feature: Description and ReferencesCallout
10
11
12
13
14
15
16
Sensor Actuator (SA) Bus Terminal Block (See SA Bus Terminal Block)
Sensor Port (Sensor Actuator [SA] Bus, RJ-12 6-pin Modular Jack) (See Figure 6)
Binary Inputs (BIs) Terminal Block (See Table 3)
Universal Inputs (UIs) Terminal Blocks (See Table 3)
LED Status Indicators (See Table 8)
Field Controller (FC) Bus Port (RJ-12 6-pin Modular Jack) (See Figure 6)
Binary Output (BO) Terminal Block (See Table 3)
Terminal Wiring Guidelines,
Functions, Ratings, and
Important: Electrostatic discharge can damage
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.
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.
controller components. Use proper
electrostatic discharge precautions during
installation, setup, and servicing to avoid
damaging the controller.
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.
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.
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
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
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
Type of Field Device
Input/Output
UITemperature Sensor
UIVoltage Input - External
Source
UIVoltage Input - Internal
Source
Termination DiagramsType of
(Self-Powered)
Source (Isolated)
Source (2 wire)
UIVoltage Input
UICurrent Input - External
UICurrent Input - Internal
8FX-PCG16 General Purpose Programmable Controller Installation Instructions
Table 2: Termination Details
Type of Field Device
Input/Output
UICurrent Input - Internal
Source (3 wire)
UICurrent Input - External
Source (in Loop)
UIFeedback from EPP-1000
Termination DiagramsType of
Actuator (External Source)
Actuator (Internal Source)
UI or BIDry Contact (Binary Input)
CO0–20 VDC Output to
CO0–10 VDC Output to
9FX-PCG16 General Purpose Programmable Controller Installation Instructions
Table 2: Termination Details
Type of Field Device
Input/Output
CO24 VAC Triac Output
(Switch Low, External
Source)
COIncremental Control to
Actuator (Switch Low,
Externally Sourced)
CO
Termination DiagramsType of
Actuator (Switch High,
Externally Sourced)
(Switch Low, Externally
Sourced)
(Switch High, Externally
Sourced)
COIncremental Control to
BO24 VAC Binary Output
BO24 VAC Binary Output
10FX-PCG16 General Purpose Programmable Controller Installation Instructions
Table 2: Termination Details
Type of Field Device
Input/Output
BOIncremental Control to
Actuator (Switch Low,
Externally Sourced)
BO
Termination DiagramsType of
Jack (Fixed Address = 199)
SA BusNetwork Stat with Phone
11FX-PCG16 General Purpose Programmable Controller Installation Instructions
Table 2: Termination Details
Type of Field Device
Input/Output
SA BusNetwork Stat with
Terminals Addressable
SA BusNetwork Stat with
Terminals (Fixed Address
= 199)
Termination DiagramsType of
12FX-PCG16 General Purpose Programmable Controller Installation Instructions
Input and Output Wiring Guidelines
Table 3 provides information and guidelines about the
functions, ratings, and requirements for the controller
input and output terminals; and references guidelines for
determining proper wire sizes and cable lengths.
In addition to the wiring guidelines in Table 3, observe
these guidelines when wiring controller inputs and
• 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.
• Inputs/outputs with cables less than 30 m (100 ft)
typically do not require an offset in the software setup.
Cable runs over 30 m (100 ft) may require an offset
in the input/output software setup.
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 stranded, insulated,
and twisted copper wires.
Table 3: FX-PCG Terminal Blocks, Functions, Ratings, Requirements, and Cables
Terminal Block
Label
(Inputs)
Label
+15 VUNIVERSAL
INn
ICOMn
Function, Ratings, RequirementsTerminal
15 VDC Power Source for active (3-wire) input devices
connected to the Universal INn terminals.
Provides 100 mA total current
Analog Input - Voltage Mode (0–10 VDC)
10 VDC maximum input voltage
Internal 75k ohm Pull-down
Analog Input - Current Mode (4–20 mA)
Internal 100 ohm load impedance
Note: Current loop jumpers are fail-safe to maintain a
closed 4 to 20 mA current loop, even when the power to
the controller is interrupted or off. See Universal Input
Current Loop Jumpers.
Analog Input - Resistive Mode (0–600k ohm)
Internal 12 V. 15k ohm pull up
Qualified Sensors: 0-2k ohm 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, 2.252k Type
II)
Binary Input - Dry Contact Maintained Mode
1 second minimum pulse width
Internal 12 V. 15k ohm pull up
Universal Input Common for all Universal Input terminals
Note: All Universal ICOMn terminals share a common,
which is isolated from all other commons.
Determine Wire Size and
Maximum Cable Length
Same as (Universal) INn
Note: Use 3-wire cable for
devices that source power from
the +15V terminal.
See Guideline A in Table 4.
See Guideline B in Table 4.
See Guideline A in Table 4.
See Guideline A in Table 4.
Same as (Universal) INn
13FX-PCG16 General Purpose Programmable Controller Installation Instructions
Table 3: FX-PCG Terminal Blocks, Functions, Ratings, Requirements, and Cables
Terminal Block
Label
BINARY
(Inputs)
BINARY
(Output)
Power Selection
Jumper positioned to
External (EXT) power.
BINARY
(Output)
Power Selection
Jumper positioned to
Internal (INT) power.
Label
INn
ICOMn
OUTn
OCOMn
OUTn
OCOMn
Function, Ratings, RequirementsTerminal
Binary Input - Dry Contact Maintained Mode
0.01 second minimum pulse width
Internal 18 V. 3k ohm pull up
Binary Input - Pulse Counter/Accumulator Mode
0.01 second minimum pulse width
(50 Hz at 50% duty cycle)
Internal 18 V. 3k ohm pull up
Binary Input Common for all Binary Input (IN) terminals
Note: All Binary ICOMn terminals share a common, which
is isolated from all other commons, except the Configurable
Output (CO) common (OCOMn) when the CO is defined
as an Analog Output.
Binary Output - 24 VAC Triac (External Power Source)
Connects OUTn to OCOMn when activated.
External Power Source Requirements:
30 VAC maximum output voltage
0.5 A maximum output current
1.3 A at 25% duty cycle
40 mA minimum load current
Binary Output Common (for OUTn terminal)
Note: Each Binary Output Common terminal (OCOMn) is
isolated from all other commons, including other Binary
Output Common terminals.
Binary Output - 24 VAC Triac (Internal Power Source)
Model FX-PCG1611-0: Sources internal 24 VAC power
(24~ COM).
Model FX-PCG1611-1: Sources internal 24 VAC power
(24~ HOT).
Binary Output - 24 VAC Triac (Internal Power Source)
Model FX-PCG1611-0: Connects OCOMn to 24~ HOT
when activated.
Model FX-PCG1611-1: Connects OCOMn to 24~ COM
when activated.
Internal Power Source:
30 VAC maximum output voltage
0.5 A maximum output current
1.3 A at 25% duty cycle
40 mA minimum load current
Determine Wire Size and
Maximum Cable Length
See Guideline A in Table 4.
See Guideline C in Table 4.
See Guideline C in Table 4.
14FX-PCG16 General Purpose Programmable Controller Installation Instructions
Table 3: FX-PCG Terminal Blocks, Functions, Ratings, Requirements, and Cables
Terminal Block
Label
CONFIGURABLE
(Outputs)
Label
OUTn
OCOMn
Function, Ratings, RequirementsTerminal
Analog Output - Voltage Mode (0–10 VDC)
10 VDC maximum output voltage
10 mA maximum output current
Required an external load of 1,000 ohm or more.
Binary Output - 24 VAC Triac (External Power Source
only)
Connects OUTn to OCOMn when activated.
External Power Source Requirements:
30 VAC maximum output voltage
0.5 A maximum output current
1.3 A at 25% duty cycle
40 mA minimum load current
Analog Output Signal Common All Configurable Outputs
(COs) defined as Analog Outputs (AOs) share a common,
which is isolated from all other commons except the Binary
Input common.
Binary Output Signal Common All Configurable Outputs
(COs) defined as Binary Outputs are isolated from all other
commons, including other CO commons.
Determine Wire Size and
Maximum Cable Length
See Guideline A in Table 4.
See Guideline C in Table 4.
Same as (Configurable) OUTn.
Cable and Wire Length Guidelines
Table 4 defines cable length guidelines for the various
wire sizes that may be used for wiring low-voltage (<30V)
input and outputs.
Table 4: Cable Length Guidelines for Recommended Wire Sizes for Low-Voltage (<30V) Inputs and Outputs
Wire Size/Gauge and TypeGuideline
Length and Type
A
B
C
1.5 mm2(18 AWG) stranded copper
1.5 mm2(18 AWG) stranded copper
See Figure 8 to select wire size/gauge.
Use stranded copper wire
457 m (1,500 ft) twisted
wire
297 m (975 ft) twisted wire0.8 mm (20 AWG) stranded copper
183 m (600 ft) twisted wire0.6 mm (22 AWG) stranded copper
107 m (350 ft) twisted wireN/A (24 AWG) stranded copper
229 m (750 ft) twisted wire
137 m (450 ft) twisted wire0.8 mm (20 AWG) stranded copper
91 m (300 ft) twisted wire0.6 mm (22 AWG) stranded copper
61 m (200 ft) twisted wireN/A (24 AWG) stranded copper
See Figure 8 to determine
cable length. Use twisted
wire cable.
AssumptionsMaximum Cable
100 mV maximum voltage drop
Depending on cable and the connected input
or output device, you may have to define an
offset in the setup software for the input or
output point.
100 mV maximum voltage drop
Depending on cable and the connected input
or output device, you may have to define an
offset in the setup software for the input or
output point.
N/A
15FX-PCG16 General Purpose Programmable Controller Installation Instructions
Maximum Cable Length versus Load Current
Figure 8: Maximum Wire Length for Low-Voltage (<30V) Inputs and Outputs by Current and Wire Size
Use Figure 8 to estimate the maximum cable length
relative to the wire size and the load current (in mA) when
wiring inputs and outputs.
Note: Figure 8 applies to low-voltage (<30V) inputs and
outputs only.
SA/FC Bus and Supply Power Wiring Guidelines
Table 5 provides information about the functions, ratings,
and requirements for the communication bus and supply
power terminals; and guidelines for wire sizes, cable
types, and cable lengths when wiring the controller's
communication buses and supply power.
In addition to the guidelines in Table 5, observe these
guidelines when wiring an SA or FC bus and the 24 VAC
supply power:
• Run all low-voltage wiring and cables separate from
high-voltage wiring.
• All SA and FC bus cables, regardless of wire size,
should be twisted, insulated, stranded copper wire.
• Shielded cable is strongly recommended for all SA
and FC bus cables.
•
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 about wire
size and cable length requirements for the SA and
FC buses.
16FX-PCG16 General Purpose Programmable Controller Installation Instructions
Table 5: Communications Bus and Supply Power Terminal Blocks, Functions, Ratings, Requirements, and
Cables
Terminal
Block/Port
Labels
Recommended Cable TypeFunction, Electrical Ratings/RequirementsTerminal
Label
FC BUS
FC BUS
(Port)
SA BUS
Sensor
1
FC Bus Communications+
-
Signal Reference (Common) for Bus communicationsCOM
Isolated terminal (optional shield drain connection)SHLD
or
1
RJ-12 6-Position Modular Connector provides:
FC Bus Communications
FC Bus Signal Reference and 15 VDC Common
15 VDC, 180 mA, Power for Bluetooth Commissioning
Converter or ZFR1811 Wireless Router
1
SA Bus Communications+
-
SA Bus Signal Reference and 15 VDC CommonCOM
SA PWR
15 VDC Supply Power for Devices on the SA Bus
(Maximum total current draw for SA Bus is 240 mA.)
1
Sensor
RJ-12 6-Position Modular Connector provides:
SA Bus Communications
SA Bus Signal Reference and 15 VDC Common
15 VDC Power for devices on the SA bus and Wireless
Commissioning Converter
HOT24~
24 VAC Power Supply - Hot
Supplies 20–30 VAC (Nominal 24 VAC)
COM
24 VAC Power Supply Common (Isolated from all other
Common terminals on controller)
35 VA
0.6 mm (22 AWG) stranded, 3-wire
twisted, shielded cable
recommended
Bluetooth Commissioning Converter
retractable cable or 24 AWG 3-pair
CAT 3 Cable <30.5 m (100 ft)
0.6 mm (22 AWG) stranded, 4-wire
(2 twisted-pairs), shielded cable
recommended.
Note: The + and - wire are one
twisted pair, and the COM and SA
PWR are the second twisted pair of
wires.
24 AWG 3-pair CAT3 cable <30.5
m (100 ft)
0.8 mm to 1.5 mm
2
(18 AWG) 2-wire
1 The SA Bus and FC Bus wiring recommendations in this table are for MS/TP bus communications at 38.4k baud. For more
information, 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 more information about N2 bus
communications, refer to the N2 Communications Bus Technical Bulletin (LIT-636018).
17FX-PCG16 General Purpose Programmable Controller Installation Instructions
Setup and Adjustments
Setting the Device Addresses
FX-PCG controllers are master devices on MS/TP (SA
or FC) buses. Before operating FX-PCG controllers on
a bus, you must set a valid and unique device address
for each controller on the bus. You set a controller's
device address by setting the positions of the switches
on the DIP switch block at the top of the controller (Figure
3). Consult the appropriate Communication Technical
Bulletin to find valid addresses for these controllers.
Figure 9: Device Address DIP Switch Block Set to
Address 21
Note: FX-PCG ship with switch 128 ON and the
remaining address switches off rendering the
controllers wired slave devices, which do not
operate on MS/TP buses, but will not interfere
with bus operation. Set a valid and unique device
address on the controller before applying power
to the controller on the bus.
1. Set all of the switches on the address DIP switch
block (128 through 1) to off.
2. Set one or more of the seven address switches (64
though 1) to ON, so that the sum of the switch
numbers set to ON equals the intended device
address. See Table 6 for valid device addresses.
Set the highest number switch that is less than or
equal to the intended device address to ON. Then
continue setting lower numbered switches until the
total equals the intended address. For example, if the
intended device address is 21, set switch 16 to ON
first, then set switch 4 ON, followed by switch 1
(16+4+1= 21). See Figure 9.
3. Set switch 128 to ON only for controllers on an
FX-ZFR Series Wireless Field Bus application. For
all hard-wired SA and FC bus applications, ensure
that switch 128 is set to Off.
Note: Do not connect a controller with switch 128
set to ON to an active (hard-wired) SA or FC
bus. When a controller with switch 128 set to
ON and a device address from 4 to 127 is
connected to a wired field bus, the entire field
bus is rendered inoperable until the controller
is disconnected or switch 128 is set to Off.
Refer to the FX-ZFR Series Wireless Field Bus
System Technical Bulletin (LIT-12011660) for more
information on device addresses in wireless
applications.
4. Set a unique and sequential device address for each
of the controllers connected on the SA or FC bus
starting with device address 4.
To ensure the best bus performance, set sequential
device addresses with no gaps in the device address
range (4, 5, 6, 7, 8, 9, and so on). The controllers do
not need to be physically connected on the bus in
their numerical device address order.
5. Write each FX-PCG's device address on the white
label below the DIP switch block on the controller's
cover.
Table 6 describes the FC bus and SA bus devices
addresses for Johnson Controls® MS/TP
communications bus applications.
Refer to the FX-PC Series Controllers MS/TP
Communications Bus Technical Bulletin
(LIT-12011670) or MS/TP Communications Bus for
BCM System Technical Bulletin (LIT-12011908) for
more information on controller device addresses and
how to set them on MS/TP buses.
Refer to the Modernization Guide for Legacy N2
Controllers (LIT-12012005) for more information on
controller device addresses and how to set them on
N2 buses.
Table 6: SA/FC Bus Device Address Descriptions
for MS/TP Controllers
Use on DescriptionDevice
Address
0
(Switch
128 Off)
1 to 3
(Switch
128 Off)
Reserved for FC Bus Supervisory Controller
(not for use on FX-PC controllers).
Reserved for peripheral devices (not for use
on FX-PC controllers).
18FX-PCG16 General Purpose Programmable Controller Installation Instructions
Table 6: SA/FC Bus Device Address Descriptions
for MS/TP Controllers
Use on DescriptionDevice
Address
4 to 127
(Switch
128 Off)
0 to 3
(Switch
128 ON)
4 to 127
(Switch
128 ON)
Used for MS/TP master devices (FX-PC
controllers) that are hardwired to an SA Bus
or FC Bus.
Reserved addresses for wired slave devices
(not for use on FX-PC controllers).
Note: FX-PCG controllers ship with switch 128
ON and the remaining address switches off
rendering the controllers wired slave devices,
which do not operate on MS/TP buses.
Valid for MS/TP Master controllers on wireless
FC Buses only.
Note: Do not connect a controller with switch
128 ON to an active (hard-wired) SA or FC
bus. When a controller with switch 128 ON
and a device address from 4 to 127 is
connected to a wired field bus, the entire field
bus is rendered inoperable until the controller
is disconnected or switch 128 is set to Off.
19FX-PCG16 General Purpose Programmable Controller Installation Instructions
Removing the Controller Cover
Important: Electrostatic discharge can damage
controller components. Use proper
electrostatic discharge precautions during
installation, setup, and servicing to avoid
damaging the controller.
Important: Disconnect all power sources to the
controller before removing the cover and
changing the position of any jumper or the
EOL switch on the controller. Failure to
disconnect power before changing a jumper
or EOL switch position can result in damage
to the controller and void any warranties.
The controller cover is held in place by four plastic latches
that extend from the base and snap into slots on the
inside of the housing cover.
To remove the controller cover:
1. Place your fingernails under the two cover lift tabs
(Figure 3) on the sides of the housing cover and
gently pry the top of the cover away from the base to
release the cover from the two upper latches.
2. Pivot the top of the cover further to release it from the
lower two latches.
3. Replace the cover by placing it squarely over the
base, and then gently and evenly push the cover on
to the latches until they snap into the latched position.
Figure 10: FX-PCG with Cover Removed Showing
EOL Switch and Jumper Positions
Figure 11: End-of-Line Switch Positions
To set the EOL switch on a controller:
1. Determine the physical location of the controller on
the FC bus.
2. Determine if the controller must be set as a
terminating device on the bus.
Note: 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 about EOL termination rules and
EOL switch settings on FC buses.
Refer to the N2 Communications Bus Technical
Bulletin (LIT-636018) for detailed information about
EOL termination rules and EOL switch settings on N2
buses.
3. If the controller is a terminating device on the bus, set
the EOL switch to ON. If the controller is not a
terminating device on the bus, set the EOL switch to
Off.
Setting the End-of-Line (EOL) Switch
Each controller has an EOL switch, which, when set to
ON, sets the controller as a terminating device on the
bus. See Figure 10 for the EOL switch location. The
default EOL switch position is Off.
When an FX-PC controller is connected to power with
its EOL switch set to ON, the amber EOL LED on the
controller cover is lit.
20FX-PCG16 General Purpose Programmable Controller Installation Instructions
Setting the Input and Output Jumpers
Binary Output (BO) Source Power Selection Jumpers
Universal Input Current Loop Jumpers
The Universal Input (UI) current loop fail-safe jumpers
are on the circuit board under the controller cover near
the UI terminals (Figure 10). When a UI is defined (in the
system software) as a 4-20 mA Analog Input and the UI’s
current loop jumper is in the Disabled (default) position
(Figure 13), the 4-20 mA current loop circuit opens
whenever power to the controller is interrupted or off.
Risk of Electric Shock: Disconnect supply power to
the controller before attempting to adjust the Binary
Output Source Power Selection Jumpers. Failure to
disconnect the supply power may result in electric shock.
Mise En Garde: Risque de décharge électrique:
Débrancher l'alimentation de l'controller avant tout
réglage du Binary Output Source Power Selection
Jumpers. Le non-respect de cette précaution risque de
provoquer une décharge électrique.
Important: Do not connect an external power source
to a BO when the BO power source jumper
is in the internal power (INT) position.
Connecting external power to a BO that
sources internal power can damage the
controller and void any warranties.
The BO source power selection jumpers determine
whether a BO provides internal power (sourced from the
controller) to the output load (INT position) or requires
an external power source (EXT position) for the output
load. Figure 12 shows an example of a controller BOs
and the associated power selection jumpers to the right
of the BOs terminal block.
Figure 12: Example Binary Outputs and the
Associated Source Power Jumper Positions
Figure 13: Current Loop Jumper Positions
Setting the current loop jumper to the Enabled position
(Figure 13) connects an internal 100 ohm resistor across
the UI terminals, which maintains the 4-20 mA current
loop circuit even when power to the controller is
interrupted or off.
Important: Current Loop jumpers must be in the
Disabled (default) position for all UIs that
are not set up to operate as 4-20 mA analog
inputs.
Table 7 identifies the current loop jumpers associated
with each UI on the FX-PCG16 controller.
Table 7: FX-PCG16 UI Inputs and Jumper Labels
Jumper Label on Circuit BoardUniversal Input
Label
J74IN1
J73IN2
Setting Up an Integral or Local Display
FX-PCG1621 models have an integral LCD and push
button user interface that allows you to set up and monitor
the FX-PCG, the FX-PCG I/O points, and the modules
and I/O points connected on the SA bus. FX-PCG1611
models do not have an integral display, but can be
connected to an FX-DIS1710 Local Controller Display.
For detailed information on setting up and operating either
an integral user interface or a remotely connected
FX-DIS1710 display, refer to the FX-DIS1710 Local
Controller Display Technical Bulletin (LIT-12011666).
21FX-PCG16 General Purpose Programmable Controller Installation Instructions
Commissioning Controllers
You commission FX-PCG controllers with the FX-PCT
software, either via a Bluetooth®Wireless Commissioning
Converter, a ZigBee® wireless dongle, or in BACnet
Router mode when connected to a Facility Explorer
Supervisory Controller. Refer to the Controller Tool Help
(LIT-12011147) for detailed information on commissioning
controllers.
Table 8: Status LEDs and Descriptions of LED States
LED ColorLED Label
State
On SteadyGreenPOWER
Off SteadyRedFAULT
Blink - 2 HzGreenSA BUS
Blink - 2 HzGreenFC BUS
AmberEOL
Off (Except on
terminating
devices)
Description of LED StatesNormal LED
Off Steady = No Supply Power or the controller’s polyswitch/resettable fuse
is open. Check Output wiring for short circuits and cycle power to controller.
On Steady = Power Connected
Off Steady = No Faults
On Steady = Device Fault; no application loaded; Main Code download
required, if controller is in Boot mode, or a firmware mismatch exists between
the FX-PCG and the FX-ZFR1811 Wireless Field Bus Router.
Blink - 2 Hz = Download or Startup in progress, not ready for normal operation
Blink - 2 Hz = Data Transmission (normal communication)
Off Steady = No Data Transmission (N/A - auto baud not supported)
On Steady = Communication lost, waiting to join communication ring
Blink - 2 Hz = Data Transmission (normal communication)
Off Steady = No Data Transmission (auto baud in progress)
On Steady = Communication lost, waiting to join communication ring
On Steady = EOL switch in ON position
Off Steady = EOL switch in Off position
Troubleshooting Controllers
Observe the Status LEDs on the front of the controller
and see Table 8 to troubleshoot the controller. To
troubleshoot an integral or local controller display, refer
to the FX-DIS1710 Local Controller Display Technical
Bulletin (LIT-12011666).
Repair Information
If a controller fails to operate within its specifications,
replace the controller. For a replacement controller,
contact your Johnson Controls® representative.
22FX-PCG16 General Purpose Programmable Controller Installation Instructions
Accessories
Table 9: Accessories Ordering Information
DescriptionProduct Code Number
Bluetooth Commissioning Converter, with Bluetooth® TechnologyFX-BTCVT-1
Local Controller Display (for use with FX-PCG1611 model only)FX-DIS1710-0
Wireless Field Bus RouterFX-ZFR1811-0
Transformer, 120 VAC Primary to 24 VAC secondary, 20 VA, Wall PlugTP-2420
Y65T31-0
ZFR-USBHA-0
Transformer, 120/208/240 VAC Primary to 24 VAC Secondary, 40 VA, Foot Mount,
8 in. Primary Leads and Secondary Screw Terminals, Class 2
Note: Additional Y6x-x Series transformers are also available. Refer to the Series
Y63, Y64, Y65, Y66, and Y69 Transformers Product Bulletin (LIT-125755) for more
information.
Power transformer (Class 2, 24 VAC, 50 VA maximum output), no enclosureAS-XFR050-0
Replacement SA Bus Terminal Blocks, 4-Position, Brown, Bulk PackAP-TBK4SA-0
Replacement FC Bus Terminal Blocks, 4-Position, Blue, Bulk PackAP-TBK4FC-0
Replacement Power Terminal Blocks, 3-Position, Gray, Bulk PackAP-TBK3PW-0
USB Dongle with ZigBee® Driver provides a wireless connection through FX-PCT
to allow wireless commissioning of the wirelessly enabled FX-PCG, FX-PCA,
FX-PCX, and FX-PCV field controllers. Also allows use of the FX-ZFR Checkout
Tool (FX-ZCT) in FX-PCT.
Note: The ZFR-USBHA-0 replaces the IA OEM DAUBI_2400 ZigBee USB dongle.
For additional information on the ZFR-USBHA-0 ZigBee dongle, refer to the FX-ZFR
Series Wireless Field Bus System Technical Bulletin (LIT-12011660) or FX-ZFR
Series Wireless Field Bus System Quick Reference Guide (LIT-12011696).
See Table 9 for controller accessories ordering
information.
Technical Specifications
Table 10: FX-PCG Technical Specifications
Product Code Numbers
Supply Voltage
Power Consumption
Ambient Conditions
Controller Addressing for BACnet
MS/TP
FX-PCG16x1-x General Purpose Programmable Controller
Controller
FX-PCG1621-0-x Controller with Display and Push-button User Interface
24 VAC (nominal, 20 VAC minimum/30 VAC maximum), 50/60 Hz, power supply
Class 2 (North America), Safety Extra-Low Voltage (SELV) (Europe)
14 VA maximum for FX-PCG1611 only
20 VA maximum for FX-PCG1621 (with integral display) only
Note: VA rating does not include any power supplied to the peripheral devices
connected to Binary Outputs (BOs) or Configurable Outputs (COs), which can
consume up to 12 VA for each BO or CO; for a possible total consumption of an
additional 84 VA (maximum).
Operating: 0 to 50°C (32 to 122°F); 10 to 90% RH noncondensing
Storage: -40 to 80°C (-40 to 176°F); 5 to 95% RH noncondensing
DIP switch set; valid controller device addresses 4–127 (Device addresses 0–3 and
128–255 are reserved and not valid controller addresses.)
DIP switch set; valid control device addresses 1-255Controller Addressing for N2
23FX-PCG16 General Purpose Programmable Controller Installation Instructions
Table 10: FX-PCG Technical Specifications
Communications Bus
Input and Output Capabilities
Analog Input/Analog Output Resolution
and Accuracy
Terminations
Mounting
Housing
Dimensions(Height x Width x Depth)
Compliance
RS-485: selectable BACnet MS/TP or N2
3-wire FC bus between the supervisory controller and other controllers
4-wire SA bus between controller, network sensors and other sensor/actuator devices,
includes a lead to source 15 VDC supply power (from controller) to bus devices.
N2 Open Protocol:
N2/FC Bus: 1.5 mm (18 AWG) standard 3-wire, twisted, shielded cable recommended
between the supervisory controller and field controllers
H8SX/166xR Renesas® 32-bit microcontrollerProcessor
640 KB flash memory and 128 KB RAMMemory
2 - Universal Inputs: Defined as 0-10 VDC, 4-20 mA, 0-600k ohm, or Binary Dry
Contact
2 - Binary Input: Defined as Dry Contact Maintained or Pulse Counter/Accumulator
Mode
3 - Binary Outputs: Defined as 24 VAC Triac (selectable internal or external source
power)
4 - Configurable Outputs: Defined as 0-10 VDC or 24 VAC/DC Field-Effect
Transistor (FET) BO
Input: 16-bit resolution
Output: 16-bit resolution, +/- 200 mV accuracy in 0-10 VDC applications
Input/Output: Fixed Screw Terminal Blocks
SA/FC Bus and Supply Power: 4-Wire and 3-Wire Pluggable Screw Terminal
Blocks
SA/FC Bus Port: RJ-12 6-Pin Modular Jacks
Horizontal on single 35 mm DIN rail mount (preferred), or screw mount on flat surface
with three integral mounting clips on controller
Enclosure material: ABS and polycarbonate UL94 5VB; Self-extinguishing, Plenum
Rated
Protection Class: IP20 (IEC529)
150 x 164 x 53 mm (5-7/8 x 6-1/2 x 2-1/8 in.) including terminals and mounting clips
Note: Mounting space requires an additional 50 mm (2 in.) space on top, bottom
and front face of controller for easy cover removal, ventilation and wire terminations.
0.4 kg (0.9 lb)Weight
United States: UL Listed, File E107041, CCN PAZX, UL 916, Energy Management
Equipment
FCC Compliant to CFR47, Part 15, Subpart B, Class A
Canada: UL Listed, File E107041, CCN PAZX7 CAN/CSA C22.2 No.205, Signal
Equipment
Industry Canada Compliant, ICES-003
Europe: Johnson Controls, Inc. declares that this product is in compliance with the
essential requirements and other relevant provisions of the EMC Directive.
Australia and New Zealand: RCM Mark, Australia/NZ Emissions Compliant
BACnet International: BACnet Testing Laboratories (BTL) Protocol Revision 4
Listed BACnet Application Specific Controller (B-ASC)
24FX-PCG16 General Purpose Programmable Controller Installation Instructions
The performance specifications are nominal and conform to acceptable industry standard. For application at conditions
beyond these specifications, consult the local Johnson Controls® office. Johnson Controls, Inc. shall not be liable
for damages resulting from misapplication or misuse of its products.
APAC Single Point of Contact:NA/SA Single Point of Contact:European Single Point of Contact:
JOHNSON CONTROLS
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GERMANY
JOHNSON CONTROLS
507 E MICHIGAN ST
MILWAUKEE WI 53202
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JOHNSON CONTROLS
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WUXI JIANGSU PROVINCE 214142
CHINA
507 E. Michigan Street, Milwaukee, WI 53202
Johnson Controls®is a registered trademark of Johnson Controls, Inc.
All other marks herein are the marks of their respective owners.© 2016 Johnson Controls, Inc.
Building Efficiency
www.johnsoncontrols.comPublished in U.S.A.
25FX-PCG16 General Purpose Programmable Controller Installation Instructions
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