LX Application Specific, Remote I/O, and Free Programmable Controllers InstallationInstructions1 Refer to the QuickLIT Web site for the most up-to-date version of this document.Application RequirementsFollow these recommendations for proper installation and subsequent operation of each controller:•Properly inspect the product for shipping damage. Do not install damaged controllers.•Record the Neuron® ID located on both sides of the device to commission the device later.•Operate the controller under the following conditions:-Ambient temperature: 32 to 158°F (0 to 70°C)-Relative humidity: 0 to 90%, noncondensingNorth American Emissions ComplianceUnited StatesCanadaInstallationDimensions IMPORTANT:Prevent any static electric discharge to the controller. Static discharge can damage the controller and void the warranties.Compliance Statement (Part 15.19)This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:1.This device may not cause harmful interference, and2.This device must accept any interference received, including interference that may cause undesired operation.Warning (Part 15.21)Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.The term IC before the certification/registration number only signifies that the Industry Canada technical specifications were met.Industry Canada StatementLe terme « IC » précédant le numéro d'accréditation/inscription signifie simplement que le produit est conforme aux spécifications techniques d'Industry Canada.Figure 1: Dimensions - Remote I/O 401 and 520 ControllersLX Application Specific, Remote I/O, and Free Programmable ControllersInstallation InstructionsLX-RTUL-1, LX-FCUL-1, LX-UVL-1, LX-HPUL-1, LX-IOxxx-1,LX-PRG5xx-1, LX-PRG4xx-1, LX-PRG300-1, LX-PRG203-1Code No. LIT-12011498Issued April 28, 2014Supersedes November 5, 2012LX Application Specific, Remote I/O, and Free Programmable Controllers Installation Instructions2Figure 2: Dimensions - Remote I/O 301 Controllers4896752312121SERVICE12345678DO1C+-++-++-+I1O1910111213AO1-AO2I2I3I4I5I6O7O2O3O4O5O6NETWORK24VAC/DCCOMDO2CDO3CDO4CDO5CSpecifications:5 triac outputs-Isolate 24Vac 1A2 analog outputs-0-10V / 0-12V-100ma max.5 Inputs-10k/digital/0-10v-Software configurable114.3 mm (4.5 in.)165.1 mm (6.5 in.)25.4 mm (1 in.)127mm(5in.)33.3 mm (1.32 in.)Figure 3: Dimensions - LX Application Specific Controllers LX Application Specific, Remote I/O, and Free Programmable Controllers Installation Instructions 3Figure 4: LX-PRG203-1 and LX-PRG300-1 Dimensions Figure 5: LX-PRG4x0-1 and LX-PRG5x0-1 Dimensions LX Application Specific, Remote I/O, and Free Programmable Controllers Installation Instructions4MountingYou can mount each controller on a DIN rail, in a panel, or on a wall. The controllers are equipped with two mounting holes 0.25 x 0.165 in. (6.35 x 4.191 mm).DIN RailTo mount the controller on a DIN rail:1.Ensure the DIN rail is properly mounted on the wall.2.Clip the controller onto the DIN rail.Wall MountTo mount the controller on a wall:1.Use the side clips to separate the controller’s front and back plates.2.Use the holes on the back plate to mark the wall location.3.Drill the holes.4.Clean the surface and mount the controller using the appropriate screws.Location Considerations•Ensure you have proper clearance of controller enclosures, wiring terminals, and service pin for easy access, hardware configuration, and maintenance.•Ensure proper ventilation of each controller and avoid areas where corroding; deteriorating; or explosive vapors, fumes, or gases may be present. Orient each controller with the ventilation slots and power supply/output terminal block connector towards the top to permit proper heat dissipation.WiringFollow these wiring recommendations:•Remove the front plate from the back plate to help with the wiring process. Use a small flat screwdriver to tighten the terminal connector screws once the wires are inserted.•Keep power cables apart from other types of wiring to avoid ambient noise transmission to other wires.•Use wires or flat cables ranging from 22 to 14 AWG (0.644-1.630 mm) per pole. Power cables must remain between 18 to 14 AWG (1.024-1.630 mm) diameter.•Do not connect the universal inputs, analog/digital outputs, or common terminals to earth or chassis ground unless otherwise stated.•Use a floating transformer configuration for the transformer powering each controller.Power WiringWhen you are powering devices, use the following method to calculate the power requirements of the required transformer:1.Add up the maximum power consumption of all controllers and multiply this sum by 1.3.2.If the resulting number is higher than 100 VA, consider using multiple transformers.Use an external fuse on the 24 VAC/DC side (secondary side) of the transformer to protect all controllers against power link spikes. !CAUTION: Risk of Electric Shock.Disconnect 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.IMPORTANT:Maintain consistent polarity when you connect the controllers and devices to the transformer. Connect the COM terminal of each controller and each peripheral to the same terminal on the secondary side of the transformer. Fuse24VACTransformerController 2Controller 124VAC/DC24V COMAC24VAC/DC24V COMFigure 6: Power Wiring - ACLX Application Specific, Remote I/O, and Free Programmable Controllers Installation Instructions 5 Input WiringEach controller has physical connections for inputs that are software configurable from LX wizards. You can configure each input in the software wizard to ensure proper input readings.Wiring Digital and Resistive 10k Ohm InputsUse this input configuration to monitor digital dry contacts as well as 10k ohm potentiometers and 10k ohm NTC thermistors. Resistive 1k Ohm InputsFigure11 shows an input configuration used to monitor 1k ohm platinum Resistive Temperature Detector (RTDs). Resistive PT100 InputsFigure12 shows an input configuration used to monitor PT100 platinum RTDs.Note:The LX-RTUL-1, LX-FCUL-1, LX-UVL-1, LX-HPUL-1, and LX-PRG203-1 controllers do not have resistive 1k ohm or PT100 inputs.Wiring Current InputsCurrent inputs have a range of 4 to 20 mA. Connect the current input according to Figure13 if you are using a 2-wire or 4-wire 20mA transducer. Note:On the LX-PRG400-1, LX-PRG410-1, LX-PRG500-1, and LX-PRG510-1 controllers you can use the onboard 15 VDC output to supply the current loop (Figure14).Connect the current input according to Figure15 if the transducer is powered by its own power source. Wiring Voltage InputsVoltage inputs have a range of 0 to 10 VDC. Connect the voltage input according to Figure15. Fuse24VDCController 2Controller 124VAC/DC24V COM24VAC/DC24V COM24VDCFigure 7: Power Wiring - DC UIxCOMNTC Thermistor10kFigure 8: 10K Ohm Thermistor InputUIxCOMPotentiometer10kFigure 9: 10k Ohm Potentiometer Input UIxCOMDigital Dry ContactNO-NCFigure 10: Digital Dry Contact (Normally Open [NO] and Normally Closed [NC]) UIxCOMPlatinum RTD1kFigure 11: 1k Ohm Platinum RTD Input UIxCOMPlatinum RTDPT100Figure 12: PT100 Platinum RTD InputUIxCOM24VDCResistor - 249 / ¼W4-20mATransducer+-Figure 13: Current Input - 2-Wire TransducerUIxCOMResistor - 249 / ¼W4-20mATransducer+-Figure 14: Current Input - Transducer with Own Power Source UIxCOM0-10VTransducer+-Figure 15: Voltage Input - Transducer with Own Power SourceLX Application Specific, Remote I/O, and Free Programmable Controllers Installation Instructions6Output WiringEach controller has physical connections for triac outputs and/or universal outputs, depending on the type and model (excluding the LX-IO520-1 controller). The outputs are all software configurable. Table1 shows the controller outputs.Note:Before you connect output equipment to the controller, refer to the installation instructions from the equipment manufacturer.Wiring Triac OutputsDigital outputs are all made of triacs and voltage is not present on the output terminals; therefore, you need to add an external power source, if necessary.Note:You must connect an external load to measure the state of a triac output. Wiring Universal OutputsYou can configure universal outputs to provide either a linear signal ranging from 0 to 10 VDC or a 4 to 20 mA signal (LX-PRG400-1, LX-PRG410-1, LX-PRG500-1, and LX-PRG510-1 controllers only) or a discrete signal of 0 or 12 VDC. You can use the discrete signal to generate a Pulse Wave Modulation (PWM) or a simple two-state signal. The outputs are protected by an auto-reset fuse. The 4 to 20 mA signal is configurable by jumper (only available for models LX-PRG400-1, LX-PRG410-1,LX-PRG500-1, and LX-PRG510-1). You must connect a diode in parallel when controlling a relay with a universal output to protect the controller from back-emf current, which occurs when the relay is turned off. Use diodes that are part of the 1N400x family and place them closer to the relay. Communications WiringThe recommended cable type for LONWORKS® communications is 22 AWG (0.65 mm), twisted pair, unshielded. The LONWORKS communication wire is polarity insensitive and can be laid out in a bus, star, loop, or free topology. For loop topology, polarity is important, take special care when connecting the LONWORKS network to avoid a short circuit.Note:Use the bus topology network configuration for all LON communication wiring; it allows you to troubleshoot the network easily.Table 1: Controller OutputsControllerTriac OutputsUniversal OutputsJumper 0-10 VDC/4-20mALX-FCUL-152LX-HPUL-152LX-RTUL-152LX-ULVL-152LX-PRG203-153LX-PRG300-108LX-PRG400-1012XLX-PRG410-1012XLX-PRG500-1012XLX-PRG510-1012XLX-IO301-180LX-IO401-1120LX-IO520-100 DOxCx-xACRelayA2A1Figure 16: Digital Output with External Power Supply 0-10VDCCommonUOxCOMFigure 17: 0 to 10 VDC Analog Output UOxCOMJUMPERSETTINGS0-10V4-20mA4-20mACommonFigure 18: 4 to 20 mA Analog Output and Jumper Configuration 12VDC RelayA2A1UOxCOMFigure 19: 0 or 12 VDC Discrete OutputLX Application Specific, Remote I/O, and Free Programmable Controllers Installation Instructions7Connect both wires to the LON 1 or 2 terminals of the controller. When you insert multiple wires into the terminals, ensure you properly twist the wires together prior to inserting them into the terminal connectors. For more information and detailed explanations on network topology and wire length restrictions, please refer to the Echleon® Corporation document Junction Box and Wiring Guideline for Twisted Pair LONWORKS® Networks. Two network terminators are required for the bus topology network configuration. Place one network terminator at each end of the bus topology channel.One network terminator is required for the free topology network configuration. You can put the network terminator anywhere on the channel.Memory Erase JumperEach controller features a memory erase jumper. Use the memory erase jumper to erase the Neuron chip's memory. If an incorrect NXE file is loaded into the controller, the Neuron chip's memory is corrupted and you cannot communicate with the controller. Use the memory erase jumper to correct this problem by resetting the Neuron chip's memory; the chip is then in an application-less state. The memory erase jumper is labeled J2 on the ASCs and the LX-PRG203-1, J4 on the LX-IO301-1 and LX-PRG301-1 controllers; and J20 on the LX-IO401-1, LX-IO520-1, LX-PRG4xx-1, and LX-PRG5xx-1 controllers.To erase the Neuron chip's memory using the memory erase jumper, do the following:1.Disconnect the power to the controller.2.Place a jumper on the proper pins on the controller. IMPORTANT:Use the proper network terminators for the network topology. Failure to use the correct network terminators may result in communication errors between controllers. Do not use multiple gauges of cable on the same communication bus. Controller 2Controller 1LON1LON2LON NetworkLON1LON2Figure 20: Communications WiringFigure 21: Memory Erase Jumper Location (J2) on ASCs and LX-PRG203-1 ControllersFigure 22: Memory Erase Jumper Location (J4) on LX-IO301-1 and LX-PRG300-1 ControllersLX Application Specific, Remote I/O, and Free Programmable Controllers Installation Instructions83. Reconnect power to the controller.Note:The orange colored service Light-Emitting Diode (LED) blinks rapidly indicating that it is erasing the Neuron chip’s memory. When the service LED stops blinking and remains solid, the erase procedure is complete.Note:The erase procedure normally takes between 2 and 10 seconds to complete.4.Disconnect the power to the controller and remove the jumper. 5.Reconnect the power. The service LED blinks twice and becomes solid indicating the controller is application-less.6.Download the correct NXE and XIF files.Strain Relief and Terminal Block CoverIn certain jurisdictions, terminal block covers are required to meet local safety regulations. Strain reliefs and terminal block covers are available for controllers housed in the large enclosures and are used to relieve tension on the wiring and conceal the controllers’ wire terminals. Strain reliefs and terminal block covers are optional and are sold separately.Prior to connecting all wires, it is recommended that you install the strain relief. Three screws are provided for its installation under the bottom part of the enclosure. You can then use tie wraps to group wires together and attach them securely to the strain relief in an effort to relieve undue tension. If necessary, clip the terminal block cover to the strain relief as shown in Figure24.MaintenanceEach controller requires minimal maintenance, but it is important to:•clean the outside of the front plate and/or the inside of the back plate, use a dry cloth.•verify the tension of all wires and cables each time you service the controller.DisposalThe Waste Electrical and Electronic Equipment (WEEE) Directive sets regulations for the recycling and disposal of products. The WEEE2002/96/EG Directive applies to stand-alone products that can function on their own and are not a part of another system or piece of equipment. For this reason, Johnson Controls® products are exempt from the WEEE Directive. Nevertheless, they are marked with the WEEE symbol (Figure25), indicating the devices are not disposed with municipal waste. Figure 23: Memory Erase Jumper Location (J20) on LX-IO401-1, LX-IO520-1, LX-IO410-1, LX-PRG4xx-1, LX-PRG5xx-1 Controllers!CAUTION: Risk of Electric Shock.Disconnect power supply before making any 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.Figure 24: Large Enclosure Strain Relief and Terminal Block Cover InstallationLX Application Specific, Remote I/O, and Free Programmable Controllers Installation Instructions 9Dispose of products at the end of their useful life according to local regulations and the WEEE Directive.TroubleshootingTable2 describes some troubleshooting scenarios. Figure 25: WEEE SymbolTable 2: Troubleshooting (Part 1 of 2)ProblemPossible SolutionController is powered but does not turn on.Fuse Is BlownCheck the fuse integrity; also ensure that the green power LED is on.Power Supply PolarityVerify that consistent polarity is maintained between all controllers and the transformer. Ensure that the COM terminal of each controller is connected to the same terminal on the secondary side of the transformer. Controller cannot communicate on a FTT network.Absent or Incorrect Supply VoltageCheck power supply voltage between 24 VAC/DC ±15% and COM pins, and ensure that it is between acceptable limits.Check for tripped fuse or circuit breaker.Overloaded Power TransformerVerify the transformer is powerful enough to supply all controllers.Network Not Wired ProperlyDouble-check the wire connections are correct.Absent or Incorrect Network TerminationCheck the network terminations.Incorrect NXE File Has Been LoadedUse the memory erase jumper to reset the Neuron chip’s memory, then load the proper NXE into the controller using FX Workbench.Controller communicates well over a short network but does not communicate on large network.Network LengthCheck that the total wire length does not exceed the specifications of the Junction Box and Wiring Guideline for Twisted Pair LONWORKS Networks.Wire TypeCheck that the wire type agrees with the specification of the LONWORKS Junction Box and Wiring Guideline for Twisted Pair LONWORKS Networks.Network Wiring ProblemDouble check that the wire connections are correct.Absent or Incorrect Network TerminationCheck the termination(s). Incorrect or broken termination(s) make the communication integrity dependent upon a controller's position on the network.Extra CapacitanceEnsure no extra capacitance is connected to the network other than the standard FTT circuit, and a maximum of a 3 meter stub (in bus topology).Number of Devices on Network Segment ExceededThe number of controllers on a channel should never exceed 64. Use a router or a repeater in accordance with LONWORKS Junction Box and Wiring Guideline for Twisted Pair LONWORKS Networks.Network TrafficQuery node statistic to check errors.Use a LON protocol analyzer to check network traffic.Hardware input is not reading the correct value.Input Wiring ProblemCheck that the wiring is correct according to this manual and according to the peripheral device's manufacturer.Next >