Prolon VC1000 Installation instructions

PROLON VC1000 SERIES
VAV CONTROLLER HARDWARE GUIDE
www.prolon.net
Montréal
1989 rue Michelin Laval,
QC H7L 5B7
TEL:[phone] FAX: [phone]
1-800-461-1381
1-877-9PROLON
www.prolon.net
[e-mail]
2
Table of Contents
GENERAL INFORMATION............................................................................................................3
PL-VC1000: Independent or Networked Intelligent Zone Controller..............................................................3
Description..................................................................................................................................................................3
General Behaviour......................................................................................................................................................3
Operation Sequence.......................................................................................................................................4
General.......................................................................................................................................................................4
Occupied Mode...........................................................................................................................................................4
Unoccupied Mode.......................................................................................................................................................4
Selection Table...............................................................................................................................................5
COMPONENTS..................................................................................................................................6
Component Identification................................................................................................................................6
LEDs...............................................................................................................................................................7
Communication Cards....................................................................................................................................8
Jumper to supply power to the RJ45 plug......................................................................................................8
Airflow Sensor (Optional)................................................................................................................................9
Address Configuration for Networking............................................................................................................9
Damper Direction Configuration ...................................................................................................................10
Input and Output Identification......................................................................................................................11
INPUTS..............................................................................................................................................12
Room Sensors..............................................................................................................................................12
ProLon Analog Room Sensor (PL-RSC)...................................................................................................................12
ProLon Digital Sensor and Interface (PL-T1000)......................................................................................................13
Damper Control Mode Changeover..............................................................................................................14
Duct Temperature Sensor (PL-CODS).....................................................................................................................14
Radiant Floor Control....................................................................................................................................14
Slab Temperature Sensor.........................................................................................................................................14
Night Setback ...............................................................................................................................................15
Dry Contact originating from an External Timer........................................................................................................15
OUTPUTS .........................................................................................................................................16
Output Specifications....................................................................................................................................16
Configuration of Outputs 1 to 4.....................................................................................................................17
Typical Connection of the Triac Outputs 1 to 4 ............................................................................................18
Typical connection of the analog output.......................................................................................................19
POWER SOURCE / NETWORK...................................................................................................20
Power Source ...............................................................................................................................................20
Network Communication...............................................................................................................................20
“LIGHT” CARD...............................................................................................................................21
OVERALL DIMENSIONS..............................................................................................................22

PROLON VC1000 SERIES
VAV CONTROLLER HARDWARE GUIDE
www.prolon.net
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1989 rue Michelin Laval,
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TEL:[phone] FAX: [phone]
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3
GENERAL INFORMATION
PL-VC1000: Independent or Networked Intelligent Zone
Controller
Description
The PL-VC1000 series ProLon zone
controllers use a microprocessor with
proportional and integral action. This
action allows for a precise set-up of
the variable air volume box, either in
a network or independently.
General Behaviour
The ProLon VC1000 controllers are programmable, thus every parameter may be optimized to obtain
the best results for each zone. It is possible to modify the action of each output (heating/cooling (and/or)
On-or-Off/pulsed), the proportional bands, the integration times, the differentials, the operational ranges
and the setpoints. The opening time of the damper can also be configured, thus avoiding any overuse
once fully opened or closed. This also means that the damper can be controlled by more powerful
motors with different opening times. Also, the damper can now be controlled by a self-configuring
Halomo motor, enabling accurate positioning of the damper. The various programming options also
allow a person to modify the unoccupied mode setpoints, the deadbands, the maximum and minimum
setpoints for each zone, as well as the minimum damper position in ventilation mode and in heating
mode for each zone. All these parameters can be modified using the ProLon Focus software or with the
ProLon digital interface (T1000 series).

PROLON VC1000 SERIES
VAV CONTROLLER HARDWARE GUIDE
www.prolon.net
Montréal
1989 rue Michelin Laval,
QC H7L 5B7
TEL:[phone] FAX: [phone]
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4
Operation Sequence
General
The ProLon controller, located on the ventilation box, receives the zone temperature and setpoints from
the room sensor, and optionally the duct temperature from a duct temperature sensor. The controller
then analyzes the received information and commands the damper motor and the different outputs to
respond accordingly.
Occupied Mode
When there is a cooling demand in the zone and the supply temperature is colder than the zone
temperature, the damper opens proportionally to the demand. Once the demand is satisfied, the damper
returns to its minimum ventilation position.
When there is a heating demand in the zone, the controller activates the designated auxiliary heating
outputs. If the zone has a terminal duct heater, the damper opens first to the minimum heating position
and the designated auxiliary heating outputs activate. If the supply temperature is warmer than the zone
temperature, the damper is used as the first heating output and opens proportionally to the demand.
Once the demand is satisfied, the damper returns to the minimum ventilation position.
When the controller has no cooling or heating demand (deadband), and the supply temperature is also
within this deadband, the controller opens the damper to 100% to allow maximum ventilation of the
zone.
The user can modify the setpoints by adjusting the room temperature sensor at all times.
Unoccupied Mode
In unoccupied mode, the damper can be configured to fully open or to operate in a fashion similar to that
of occupied mode. The room temperature setpoints in the unoccupied mode are adjustable.
The Override button located on the room thermostat bypasses the unoccupied mode for a specified
length of time.

PROLON VC1000 SERIES
VAV CONTROLLER HARDWARE GUIDE
www.prolon.net
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1989 rue Michelin Laval,
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Selection Table
Model Description Inputs / Outputs
1 Input for the Prolon Interface
4 Dedicated Inputs
4 Configurable Digital Outputs (DO)
1 Configurable Analog Output (AO)
1 Input for the Prolon Interface
4 Dedicated Inputs
4 Configurables Digital Outputs (DO)
1 Configurable Analog Output (AO)
1 Airflow Input
1 Input for the Prolon Interface
4 Dedicated Inputs
4 Configurable Digital Outputs (DO)
1 Configurable Analog Output (AO)
1 Airflow Input
Table of Models
Intelligent Controller
Pressure Dependant
PL-VC1000F
Intelligent Controller
Pressure Independant
Low Velocity
PL-VC1000F-PIL
Intelligent Controller
Pressure Independant
High Velocity
PL-VC1000F-PIH
(0 - 1000 ft/min)
(0 - 2600 ft/min)
1 Input for the Prolon Interface
4 Dedicated Inputs
1 Configurable Digital Output (DO)
1 Configurable Analog Output (AO)
Intelligent Controller
Pressure Dependant
PL-VC1000LT

PROLON VC1000 SERIES
VAV CONTROLLER HARDWARE GUIDE
www.prolon.net
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1989 rue Michelin Laval,
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COMPONENTS
Component Identification
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
P1 P2
High Low
B
A
C
D
E
F
G
H
I
J
BIAS TERM
NET
BIAS TERM
INT
K
L
M
N
O
Legend:
A= Communication Card (optional)
* B = Airflow sensor (optional)
C= Addressing Dipswitch
* D = Output 1 Dipswitch
* E = Output 2 Dipswitch
* F = Output 3 Dipswitch
G= Output 4 Dipswitch
H= Connector for Inputs and Outputs
I= LEDs
J= Connector for Halomo Motor
K= Jumpers for NET network resistors
L= Jumpers for INTERFACE (RJ45) network resistors
M= Damper Motor Clutch
N= Reset Button
O= Jumper to supply voltage to RJ45 port
* Absent on the PL-VC1000-LT models

PROLON VC1000 SERIES
VAV CONTROLLER HARDWARE GUIDE
www.prolon.net
Montréal
1989 rue Michelin Laval,
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LEDs
Green pulsing,
indicates that the
CPU is online
Green light: Internal 5 VDC
power source OK
* Status light for
triac output 1
* Status light for
triac output 2
* Status light for
triac output 3
Status light for
triac output 4
Status light for
analog output 5
Green light:
Reception from
main bus
Red light:
Sending to main
bus
Green light: BACnet
in use
Green light:
Reception from
interface
Green light: Internal
24VDC power source OK
Red light:
Sending to
interface
OUT1 OUT2 OUT3 OUT4 OUT5 STATHBEAT
* Absent on the PL-VC1000-LT models

PROLON VC1000 SERIES
VAV CONTROLLER HARDWARE GUIDE
www.prolon.net
Montréal
1989 rue Michelin Laval,
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TEL:[phone] FAX: [phone]
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8
Communication Cards
The network communication protocol of the ProLon PL-VC1000 Controller is
adjustable to fit your needs. When there is no communication card installed,
the ProLon controller automatically uses Modbus RTU over RS485 as the
default protocol. The addressing of each card is done by using the seven first
small switches on the addressing dipswitch (see Figure 1). A maximum of
127 units can be addressed on the same network.
The ProLon PL-VC1000 controller offers you a
choice of communication protocols. It is as
simple as choosing the communication card that
corresponds to your desired protocol. For
example, plugging in the Lon card enables Lon
communication. Other cards can be made
available upon request.
When a communication card is installed, the
default Modbus communication protocol is
bypassed (see Figure 2).
BACnet
To enable BACnet communication, no additional communication card is
required! Simply move switch #8 of the addressing dipswitch to the ‘ON’
position to start BACnet MS/TP (RS485) communication.
Jumper to supply power to the RJ45 plug
The RJ45 jumper lets the user select the voltage that will appear on pin #7 of the RJ45 plug. This can be
used to power a device attached to the RJ45 plug, such as the PL-HNI digital interface. NOTE: If
multiple VC1000 controllers are connected together through the RJ45 plug, only one VC1000 should be
supplying power onto the RJ45, otherwise you will be mixing your supply sources and possibly cause
damage. The jumper setups are as follows:
No power 24 VAC 24 VDC
Optional
Communication
Card
Neuron chip
or other
Figure 1: No
communication card
Addressing
Dipswitch
No
communication
card installed
Figure 2: Activating other
communication protocols

PROLON VC1000 SERIES
VAV CONTROLLER HARDWARE GUIDE
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1989 rue Michelin Laval,
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Airflow Sensor (Optional)
Adding an airflow sensor to the ProLon controller lets it regulate the temperature and the airflow into a zone,
independently of the static pressure variations of the system. Two different airflow sensors are offered (see
Figure 3):
Low velocity sensor (0 - 1000 ft/min)
High velocity sensor (0 - 3000 ft/min)
Low Airflow
Sensor
LowHigh P2P1
Grey
Color
High Airflow
Sensor
LowHigh P2P1
Brown
Color
Figure 3: Airflow Sensors
Address Configuration for Networking
A unique address on each controller must be configured by setting the
first 7 switches on the addressing dipswitch to the desired value.
These switches are numbered from 1 to 7 and represent a binary value
from 1 to 64 (1, 2, 4, 8, 16, 32, 64 respectively). The value of each
switch that is in the ON position is added together to form the numerical
address of the controller.
The example on Figure 4 shows the switches 1, 2 and 4 on the ON position. So the corresponding
values are 1, 2 and 8, giving an address sum of 11. (1+2+8=11)
The ProLon network allows a maximum of 127 addresses, therefore 127 controllers.
12 3 4 5 6 7
Figure 4: Addressing Dipswitches

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1989 rue Michelin Laval,
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Damper Direction Configuration
The default damper opening direction of a VC1000 VAV controller is counter clockwise (CCW). This
parameter can be modified in two different ways. The first is by using a digital interface or ProLon Focus
software to manually change the setting. The second is to use the following method:
1. Reversing the Damper Direction
Whenever a VC1000 resets and a jumper is placed on the last
two pins on the far most right of port J11, the damper opening
direction will be inverted (see adjacent image).
A VC1000 can be reset in one of the following ways:
Pressing on the physical RESET button
Cycling power to the device
Please note that in the event of a device reset, a VC1000
VAV controller always performs a damper recalibration first,
where it moves the damper completely to one side and then
completely to the other side. Even if you invert the damper
opening direction, the change will not take effect until after the
calibration period.
2. Once you have finished configuring the damper opening
direction to the setting of your choice, do not forget to
REMOVE the jumper from the last two pins, or the damper
direction will invert itself again and again upon any
subsequent resets of the controller.
To ensure that the damper direction will no longer change,
move the jumper one pin to the left, as depicted in this image:
3. Confirming Damper Direction
The damper opening direction can be visually confirmed by
observing the green “STAT” LED on the VC1000 board after
performing a reset:
“STAT” LED STEADY ON for 3 seconds = COUNTER CLOCKWISE (CCW) OPENING
“STAT” LED PULSES 3 TIMES (ON/OFF) over 3 seconds = CLOCKWISE (CW) OPENING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
J11
RESET
1. Opening direction is
REVERSED when jumper
is placed HERE
STAT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
J11
RESET
2. When finished, put
jumper back here
STAT
3. Observe green
STAT LED after
RESET

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www.prolon.net
Montréal
1989 rue Michelin Laval,
QC H7L 5B7
TEL:[phone] FAX: [phone]
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Input and Output Identification
The inputs and outputs of the VC1000 use "Plug-In" screw type connectors. The connector for the
ProLon digital interface (T1000 series) is a network type RJ-45. With these connectors, the wiring is
done quickly and much more easily. All outputs are protected by resettable fuses (PTC). Output 5 can
be wired in parallel with the output 5 of other VC1000s to obtain a “highest voltage” signal.
Note that if both the PL-RSC room temperature sensor and the PL-T1000 interface are connected to the
controller at the same time, the temperature and setpoints from the PL-RSC will have priority. Otherwise
the PL-T1000 interface becomes the room temperature sensor, as well as an interface.
Power source of the controller
24 VAC
Network communication
OUT5
OUT4
OUT3
OUT2
OUT1
24VACCOM
Outputs Inputs Net
INTERFACE
Supply
Common for all the inputs
Room temperature sensor (10K thermistor)
Temperature setpoint (0-10K potentiometer)
Supply temperature sensor (10K thermistor)
External dry contact for night setback
Output 5 (Analog 0-10VDC)
(Max Current: 50 mA)
Output 4 - Isolated or Source, TRIAC
24 VAC (Max current: 750 mA)
Output 3 - Isolated or Source, TRIAC
24 VAC (Max current: 750 mA)
PL-T1000 digital sensor /
Remote computer with ProLon Focus software
Prolon VC1000 card
HBEAT
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
NETREC NETSND STAT INTSNDINTREC
COM
24VAC
COM
24VAC
COM
+
COM
24VAC
24VAC
COM
ROOM
SETPT
GND
SUPPLY
OCC
A
B
NET
RESET
Output 2 - Isolated or Source, TRIAC
24 VAC (Max current: 750 mA)
Output 1 - Isolated or Source, TRIAC
24 VAC (Max current: 750 mA)
*
*
*
* Absent on the PL-VC1000-LT models

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INPUTS
Room Sensors
Two models are available:
PL-RSC: Room temperature sensor with setpoints and override
PL-T1000: ProLon programming interface and digital sensor
Each zone is managed independently; the setpoint may be set by software or by directly connecting a
room sensor.
ProLon Analog Room Sensor (PL-RSC)
The PL-RSC series room sensors provide the VC1000 with a room temperature and setpoint. They are
connected using a 3-conductor cable (see Figure 5). Note that if a shielded cable is used to connect the
PL-RSC, the shield must be grounded at the GND (pin 1) of the VC1000 to which it is connected. To
activate the schedule override from the PL-RSC, hold the override button for 3 seconds.
Figure 5: Typical wiring of the PL-RSC room sensor to the controller

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ProLon Digital Sensor and Interface (PL-T1000)
The T1000 digital interface provides the VC1000 with a digital temperature and setpoint, as well as
giving you access to all configuration parameters of the VC1000. It is directly connected to the VC1000
using a standard Ethernet network cable (see Figure 6). This device can be used as a permanent wall
sensor or a portable commissioning tool to let you modify the programming parameters for each
controller.
PL-T1000
13 14 15 16 17 18 19
ROOM
SETPT
A
B
GND
SUPPLY
OCC
NET 21°C
Figure 6: Connecting the PL-T1000 to the controller

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Damper Control Mode Changeover
Duct Temperature Sensor (PL-CODS)
When a zone controller works autonomously, a supply air temperature sensor may be connected to it in
order to invert the damper control method upon detection of hot or cold air (see Figure 7). However, if
that controller is part of a network using a Master unit, individual sensors are unnecessary because all
zone controllers share the supply temperature reading sent on the network by that Master. If no Master
is present and no sensor is available, the controller will assume there is cold air in the supply.
Alternatively, by shorting the supply temperature input (pins 15 and 16), the controller will instead
assume there is hot air in the supply.
Figure 7: Wiring of the supply sensor to the controller
Radiant Floor Control
Slab Temperature Sensor
When the VC1000 is configured to work as a radiant floor controller, the function of the supply
temperature input pin changes to become a slab temperature input pin. Therefore, a radiant floor slab
thermistor (10 ktype 3) can then be connected to the VC1000 on pins 15 and 16. Note that if a T1000
companion thermostat is connected to the VC1000, the slab thermistor can instead be wired to the
T1000, and the T1000 will then send the slab temperature to the VC1000, cutting down wiring costs.
Figure 8: Wiring of the slab sensor to the controller

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Night Setback
Dry Contact originating from an External Timer
When using a dry contact originating from an external timer to switch from the occupied mode to the
unoccupied mode, the contact must be connected to the "Setback" (17) and the "GND" (15) pins. See
Figure 9 to see how to wire the timer correctly. To indicate occupied mode, the contact must be open.
To indicate unoccupied mode, the contact must be closed. However, if that controller is part of a network
using a Master unit, an individual contact is unnecessary because all zone controllers share the
occupancy status sent on the network by that Master.
Timer
13 14 15 16 17 18 19
ROOM
SETPT
A
B
GND
SUPPLY
OCC
NET
Figure 9: Connecting an external timer to the controller

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OUTPUTS
The VC1000 series controllers contain 4 fully customizable Triac outputs and a 0-10VDC output to drive
components. All outputs are fully programmable and follow a proportional and integral algorithm (PI) to
ensure precise control. This PI function is fully customizable via the ProLon Focus software or the
ProLon PL-T1000 digital interface.
An integrated resettable fuse protects each of the outputs of the VC1000 against current surges and
short circuits. This protection will cut the current to the output as soon as an overload condition is
detected. The fuse is round and yellow-colored which, upon a short circuit condition, will heat up and
change to orange. When the faulty wiring or circuit is fixed, the fuse will automatically reset and allow
current to flow through the output again.
Output Specifications
Output Type Heating Cooling
1 *
Triac source 24VAC
Passive Triac (dry contact)
On-or-Off
Pulsed
Max Current: 750 mA
Damper
Valve
Relay
Triac
Damper
Valve
Relay
2 *
Triac source 24VAC
Passive Triac (dry contact)
On-or-Off
Pulsed
Max Current: 750 mA
Damper
Valve
Relay
Triac
Damper
Valve
Relay
3 *
Triac source 24VAC
Passive Triac (dry contact)
On-or-Off
Pulsed
Max Current: 750 mA
Valve
Relay
Triac
Valve
Relay
4
Triac source 24VAC
Passive Triac (dry contact)
On-or-Off
Pulsed
Max Current: 750 mA
Valve
Relay
Triac
Valve
Relay
5
Modulating Output
On-or-Off
Max Current: 50 mA
Configurable signal:
- 0 to 10 VDC
- 2 to 10 VDC
- 0 to 5 VDC
Modulating Damper
Modulating Valve
SCR
Relay
Triac
Modulating Damper
Modulating Valve
Relay
* Absent on PL-VC1000-LT models

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17
Configuration of Outputs 1 to 4
Outputs 1 to 4 are configurable via switches located on the ProLon card. Simply move the switch to
obtain either an active output (1) or a passive output (2). Note that outputs 1 to 3 are absent on PL-
VC1000-LT models.
1) Switch position to obtain an active output (see Figure 10):
24 VAC Output (pulsed or On/Off)
Output 4 Common
24 VAC Output (pulsed or On/Off)
Output 3 Common
24 VAC
Com
Out 5Out 4Out 3
Output
7 8 9 10 11 12
Switch for
Output 3
Switch for
Output 4
24 VAC
Com
Figure 10: Outputs 3 and 4 active
2) Switch position to obtain a passive output (see Figure 11):
Isolated dry contact
(pulsed or On/Off)
Out 5Out 4Out 3
Output
7 8 9 10 11 12
Switch for
Output 3
Isolated dry contact
(pulsed or On/Off)
Switch for
Output 4
Figure 11: Outputs 3 and 4 passive

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Typical Connection of the Triac Outputs 1 to 4
Two types of configurations are possible:
1) Active outputs. The VC1000 is actively powering the load. (see Figure 12)
Out 5Out 4Out 3
Outputs
R
R
External Load
Com
24 v
Com
24 v
7 8 9 10 11 12
Figure 12: Connection of active outputs 3 and 4
2) Passive outputs. The VC1000 opens and closes a contact to allow an external source to power
the load (see Figure 13).
Out 5Out 4
Out 3
Outputs
R
R
External Load
24 N
24N
External 24 V
7 8 9 10 11 12
Figure 13: Connection of passive outputs 3 and 4

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Typical connection of the analog output
Two types of configuration are possible:
1) The VC1000 powers the load and provides a control signal (see Figure 14)
Out 5
Out 4Out 3
Outputs
Com
0-10v
Com
24 v
0-
10v Controlled
Load
24 V power (from pin
#2 of the controller)
7 8 9 10 11 12
Figure 14: Connecting the analog output (controller powered)
2) The VC1000 only provides the control signal to the load, which is powered by an external
source (see Figure 15)
Out 5Out 4Out 3
Outputs
Com
0-10v
Com
24 v
0-
10v Controlled
Load
(External 24 V source)
24
7 8 9 10 11 12
N
Figure 15: Connecting the analog output (external power)

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20
POWER SOURCE / NETWORK
Power Source
The ProLon controller is powered by a 24 VAC power
source connected using the "COM" pin and the "24 VAC"
pin (see Figure 16). The common for all inputs and
outputs is the same as the power source’s common
(exception: when an output is set to passive, the
common for this output will not correspond to the power
source common). All output power sources also originate
from the controller’s power source.
Network Communication
The ProLon controller works autonomously or networked. When networked, it will communicate in real-
time with other controllers. Depending on the chosen communication card, the controller can use
different protocols. The VC1000 controller’s default communication protocol is Modbus RTU over
RS485. The addressing is done with the addressing dipswitch located on the VC1000 card (see Figure
4). Default communication is used when no other optional card is connected. For example, if an optional
communication card such as the "Lon" card is connected to the VC1000 board, the controller will
automatically switch to the "Lon" protocol, with a unique address found on the communication card itself
(see Figure 2). This principle is applicable to all communication cards. Please refer to the respective
ProLon guides for each protocol. The network connections are made using the NET pins located on the
ProLon controller, depending on the chosen network platform (see Figure 17).
Towards
network
13 14 15 16 17 18 19
ROOM
SETPT
A
B
GND
SUPPLY
OCC
NET
Figure 17: Connecting to the network
N
L
120Vac24Vac
Out 1
24VAC
COM
Supply
1 2 3 4
Figure 16: Connecting the 24VAC power source