Prolon C1000 Series Installation instructions

HARDWARE GUIDE
Humidifier Controller C1000 Series
Specifications and Operational Guide
REV. 7.1.0
PL-HRDW-HU-C1000-C/F-EN
www.proloncontrols.com |[e-mail]
17 510, rue Charles, Suite 100, Mirabel, QC, J7J 1X9

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Table of Contents
General Information............................................................................................................................ 4
PL-C1000 Humidity Controller ................................................................................................................................... 4
Description ..................................................................................................................................................................... 4
General Behaviour ........................................................................................................................................................ 4
Operating Sequence............................................................................................................................5
Humidification............................................................................................................................................................... 5
Dehumidification .......................................................................................................................................................... 5
Components ........................................................................................................................................6
Component Identification.......................................................................................................................................... 6
LEDs .................................................................................................................................................................................. 7
Address Configuration for Networking................................................................................................................... 7
Jumper to Supply Power to the RJ45 Plug............................................................................................................. 8
Input and Output Identification ............................................................................................................................... 8
Inputs...................................................................................................................................................9
Outside Temperature Sensor..................................................................................................................................... 9
Relative Humidity Sensors.......................................................................................................................................... 9
Proof of Fan ..................................................................................................................................................................10
Outputs.............................................................................................................................................. 11
Output Specifications................................................................................................................................................ 11
Configuration of Outputs 3 and 4 .......................................................................................................................... 12
Typical Connection of the Triac Outputs 3 and 4............................................................................................... 12
Typical Connection of the Analog Output ........................................................................................................... 13
Power Source / Network.................................................................................................................... 14
Power Source ............................................................................................................................................................... 14
Network Communication .........................................................................................................................................14
Technical Specifications.................................................................................................................... 15
Compliance ........................................................................................................................................ 16
FCC User Information.................................................................................................................................................16
Industry Canada .........................................................................................................................................................16
Overall Dimensions ........................................................................................................................... 17

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Table of Figures
Figure 1 - Component Identification ............................................................................................................................ 6
Figure 2 - LEDs Identification.......................................................................................................................................... 7
Figure 3 - Addressing Dipswitches ................................................................................................................................ 7
Figure 4 - Jumper ............................................................................................................................................................... 8
Figure 5 - Input and Output Identification.................................................................................................................. 8
Figure 6 - RJ45 Pinout ....................................................................................................................................................... 8
Figure 7 - Connecting the Outside Air Sensor............................................................................................................ 9
Figure 8 - Connecting the Humidity Sensors ............................................................................................................. 9
Figure 9 - Connecting the Proof of Fan......................................................................................................................10
Figure 10 - Output in SOURCE mode .......................................................................................................................... 12
Figure 11 - Output in SINK mode ................................................................................................................................. 12
Figure 12 - Connection of Active Outputs 3 and 4.................................................................................................. 12
Figure 13 - Connection of Passive Outputs 3 and 4................................................................................................ 13
Figure 14 - Connecting the Analog Output (Controller Powered)...................................................................... 13
Figure 15 - Connecting the Analog Output (External Power) .............................................................................. 13
Figure 16 - Connecting the 24VAC Power Source.................................................................................................... 14
Figure 17 - Connecting to the Network......................................................................................................................14
Figure 18 - C1000 Size Diagram.................................................................................................................................... 17

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Description
The PL-C1000 humidity controller is a microprocessor-based controller designed to regulate the relative
humidity level in a room or return duct. Both humidification and dehumidification sequences are avai-
lable. It features a variety of control strategies, including outdoor temperature reset, unoccupied mode
setpoint offsets, safety limits and more.
General Behaviour
Although fully configurable, the ProLon C1000 humidity controller monitors dedicated inputs and uses
pre-established control sequences to drive dedicated outputs to control standard humidification or
dehumidification equipment. These sequences can be fully optimized to obtain the best results for
each type of system. The various configuration options allow the user to modify the outside tempera-
ture reset scale, the dehumidification control points, the high humidity limits in the supply and more. A
sequence to request fan reactivation in night mode is also available. All these parameters can be accessed
and modified by using the ProLon Focus software.
General Information
PL-C1000 Humidity Controller

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Operating Sequence
Humidification
The C1000 humidity controller obtains an outside air temperature reading from either a connected sensor
or transmitted from a network master. The current outside temperature determines the relative humidity
setpoint to maintain in the zone or return using a configurable reset scale. Proof of fan operation is
required to enable humidification. The C1000 has a dedicated input for the proof of fan, but it can also
be transmitted to the C1000 from a network master.
The C1000 has two outputs available for humidification: a digital ON or OFF (differential) triac output and
an analog (0-10VDC) modulating or pulsing output, which uses a proportional and integral control loop
to maintain the setpoint.
A humidity sensor can optionally be installed in the supply duct, which then enables high humidity limit
control. Humidification also stops when the outside temperature becomes too warm.
In unoccupied mode, the C1000 can request that the network master restarts the fan if the humidity gets
too low.
Dehumidification
The C1000 request dehumidification when the humidity level goes beyond its user-configurable setpoint.
Proof of fan operation is required to enable dehumidification. The C1000 has a dedicated input for the
proof of fan, but it can also be transmitted to the C1000 from a network master.
The C1000 has two different means of requesting dehumidification. The first is a digital ON or OFF (differ-
ential) triac output which is activated based on a request for dehumidification. The second is a by sending
a network based signal to any ProLon Rooftop controller. The ProLon Rooftop controller will then take the
necessary steps to begin dehumidification.
A humidity sensor can optionally be installed in the supply duct, which then enables high humidity limit
control. Humidification also stops when the outside temperature becomes too warm.
In unoccupied mode, the C1000 can request that the network master restarts the fan if the humidity gets
too high.

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Legend:
A - Addressing dipswitch
B - Jumpers for terminating and bias resistors for the NET port (see J)
C - Jumpers for terminating and bias resistors for the INT port (see K)
D - Output 4 (Humidification) SOURCE/SINK dipswitch
E - Output 3 (Dehumidification) SOURCE/SINK dipswitch
F - Reset Button
G - Terminal Blocks for 24 VAC
H - Terminal Blocks for Outputs 3, 4, 5
I - Inputs (4 total)
J - RS485 NET port for network communication
K - RS485 INT port for interface communication
L - Jumper to supply voltage to INT port (see K)
Figure 1 - Component Identification
Components
Component Identification
NET
BIAS TERM
INT
BIAS TERM

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STATHBEATOUT5OUT4OUT3OUT2OUT1
Green light: Reception
from Interface
Green pulsing, indicates
that the CPU is online
Green light: Internal
24VDC power source OK
Green light: Internal 5
VDC power source OK
Red light: Sending to network bus
Green light: Reception from network bus
Status light for analog output 5 (humidification)
Status light for triac output 4 (humidification)
Status light for triac output 3 (dehumidification)
Red light: Sending to interface
Figure 2 - LEDs Identification
LEDs
Address Configuration for Networking
The C1000 has various LEDs which are linked to different functions and outputs of the controller. Each
LED is individually identified to help the user make a quick visual diagnostic of the controller’s activity
and status.
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 3 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.
Figure 3 - Addressing Dipswitches

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Jumper to Supply Power to the RJ45 Plug
Input and Output Identification
Figure 4 - Jumper
Figure 5 - Input and Output Identification
No power 24 VAC 24 VDC
Figure 6 - RJ45 Pinout
GND
B (-)
A (+)
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 digital sensor or interface. NOTE: If multiple
C1000 controllers are connected together through the RJ45 plug, only one C1000 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:
All the inputs and outputs of the C1000 use pluggable screw type terminal blocks with elevator style
clamping, which make connections easier and more secure.
The C1000 Humidity Controller has 2 separate communication ports offering the same functionality on
each. Both act as ports for incoming Modbus communications from other ProLon devices or interfaces,
such as a Network Controller or remote computer with ProLon Focus software.
The “INT” Port (see below) uses an RJ45 type connector. The RJ45 connector allows the use of premade
CAT5 cables for simple plug-and-play RS485 communication. This RJ45 connector follows the Modbus
pinout specification for RS485 communication.
STAT
NETSNDNETREC INTSND
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM
+
COM
24VAC
COM
24VAC
COM
24VACCOM
INTREC
HBEATOUT5OUT4OUT3
RESET
PL-C1000-HU
INTERFACE
INT Port: Incoming RS485 Network communication (Modbus)
NET Port: Incoming RS485 Network communication (Modbus)
External dry contact for proof of fan
Supply humidity sensor (0-5VDC)
Common for all the inputs
Room / Return humidity sensor (0-5VDC)
Outside temperature sensor (10K thermistor)
Output 5 - Humidier (Analog 0-10 / 2-10 VDC)
Output 4 - Humidier (Digital - ON/OFF)
Output 3 - Dehumidier (Digital - ON/OFF)
Power source of the controller - 24VAC

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Inputs
Outside Temperature Sensor
Relative Humidity Sensors
Figure 7 - Connecting the Outside Air Sensor
Figure 8 - Connecting the Humidity Sensors
The C1000 Humidity controller has an analog input dedicated to monitoring outside air temperature (see
Figure 7) and will integrate this reading into its control sequence. The sensor used is a standard 10k type 3
thermistor. If the C1000 is connected to a ProLon network, it can instead receive the outside temperature
from another device on the network.
The C1000 Humidity controller has two inputs dedicated the relative humidity readings in the room (or
return duct) and the supply (optional). This information is then integrated into its control sequences. The
sensors used must provide a 0-5VDC signal (see Figure 8).
Room/Return
humidity sensor
(0-5VDC signal)
Supply humidity
sensor
(0-5VDC signal)
A
NET
B
OCC
SUPPLY
GND
RA
OA
Outside air sensor
A
NET
B
OCC
SUPPLY
GND
RA
OA

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Proof of Fan
Figure 9 - Connecting the Proof of Fan
The C1000 Humidity controller has an input dedicated for a proof of fan contact (see Figure 9). To confirm
that there is a proof of fan, the contact must be closed. If the C1000 is connected to a network, the net-
work master can transmit the proof of fan information through the network instead. However, if no proof
of fan signal is available, the dedicated input must be short-circuited to ground (terminal #15).
Proof of
fan
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM

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Outputs
Output Specifications
Output Type Action Application
3Triac Source: 24VAC
MAx Current: 300 mA On-or-Off Dehumidification in differential mode
4Triac Source: 24VAC
MAx Current: 300 mA On-or-Off Humidification in differential mode
5
Configurable Analog Output:
- 0 to 10 VDC
- 2 to 10 VDC
Max Current: 40 mA
Modulating Proportional/
Pulsed
Humidification with
proportionnal and
integral action
The C1000 Humidity controller contains 3 configurable outputs. Two of the outputs are dedicated to
humidification (Output 4 and Output 5). Output 4 is an ON-OFF triac output and Output 5 is an analog
0-10VDC modulating or pulsing output, which follows a proportional and integral algorithm (PI). This PI
function is fully customizable via the ProLon Focus software.
The remaining output (Output 3) is dedicated to dehumidification. Output 3 is an ON-OFF triac output.
An integrated resettable fuse protects each of the outputs of the C1000 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.

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Configuration of Outputs 3 and 4
Typical Connection of the Triac Outputs 3 and 4
The digital triac outputs are configurable (SOURCE/SINK) via a switch located on the board. Simply move
the switch to obtain either a SOURCE active output (1) or a SINK passive output (2).
1) Switch position to obtain a SOURCE active output (see Figure 10):
2) Switch position to obtain a SINK passive output (see Figure 11):
Figure 10 - Output in SOURCE mode
Figure 11 - Output in SINK mode
Figure 12 - Connection of Active Outputs 3 and 4
24VAC
COM
OUT5OUT4
Switch for
Output 4
24 VAC Output (ON/O )
Output 4 Common
OUT5OUT4
Switch for
Output 4
Isolated dry contact
(On/O)
Two types of configurations are possible:
1) Active output (SOURCE). The C1000 is actively powering the load. (see Figure 12)
OUT5OUT4
24V
COM
External Load

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Two types of configuration are possible:
1) The C1000 powers the load and provides a control signal (see Figure 14).
2) The C1000 only provides the control signal to the load, which is powered by an external source
(see Figure 15)
2) Passive output (SINK). The C1000 opens and closes a contact to allow an external source to power
the load (see Figure 13).
OUT5OUT4
External 24 V
External Load
24 N
Figure 13 - Connection of Passive Outputs 3 and 4
Figure 14 - Connecting the Analog Output (Controller Powered)
Figure 15 - Connecting the Analog Output (External Power)
Typical Connection of the Analog Output
OUT5OUT4
0-10v
COM
Controlled
Load
24 VAC power
(From terminal block
#2 of the controller)
24v
0-10v
COM
OUT5OUT4
0-10v
COM
Controlled
Load
External
24 VAC
source
N
24v
0-10v
COM

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Power Source / Network
Power Source
Network Communication
Figure 16 - Connecting the 24VAC Power Source
Figure 17 - Connecting to the Network
The ProLon C1000 controller is powered by a 24 VAC power source connected using the "COM" terminal
and the "24 VAC" terminal (see Figure 16). The common for all inputs and outputs are 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.
OUT1
COM 24VAC
Supply
NL
120VAC24VAC
The ProLon C1000 controller works autonomously or networked. When networked, it will communicate
in real-time with other controllers. The C1000 controller’s default communication protocol is Modbus
RTU over RS485. The addressing is done with the addressing dipswitch located on the C1000 card (see
Figure 3). The network connections are made using the NET terminal block located on the ProLon C1000
controller (see Figure 17).
Tow a rd
network

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Supply: 24 VAC ±10%, 50/60 Hz, Class 2
Consumption: 2 VA (Consumption), 32 VA (Input)
Inputs: • Outside air – thermistor 10K
• Return/room humidity – 0-5 VDC
• Supply humidity – 0-5 VDC
• Proof of fan – dry contact
Digital outputs: 2 triac outputs, 10-30 VAC source or sink, 300 mA max (resettable fuse)
Analog output: 1 output 0-10 VDC / 2-10 VDC, 40 mA max (resettable fuse)
Indication lights (LED): State of each output / Communication / Power / State of microprocessor
Microprocessor: PIC18F6722, 8 bits, 40 MHz, 128KB FLASH memory
Casing: Molded ABS, UL94-HB
Communication: Modbus RTU (RS485), up to 127 nodes
Baud rate: 9600, 19200, 38400, 57600, 76800, 115200
Connection: Removable screw-type terminal blocks (16 AWG max) and RJ45 modular jack
Dimensions: 6.5" x 5.3" (165mm x 135mm)
Weight: 0.85 lbs (0.4 kg)
Environment: 32-122 ºF (0-50 ºC) Non-Condensing
Certification: RoHS, FCC part 15: 2012 class B
The performance specifications are nominal and conform to acceptable industry standards. ProLon Inc. will
not be liable for damages resulting from misapplication or misuse of its products.
Technical Specifications

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• FCC Compliant to CFR47, Part 15, Subpart B, Class B
• Industry Canada (IC) Compliant to ICES-003, Issue 5: CAN ICES-3 (B)/NMB-3(B)
• RoHS Directive (2002/95/EC)
FCC User Information
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, and (2) this device must accept any interference re-
ceived, including interference that may cause undesired operation.
Caution: Any changes or modifications not approved by ProLon can void the user’s authority to operate
the equipment.
Note: This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against
harmful interference in a residential installation. This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or television reception,
which can be determined by turning the equipment off and on, the user is encouraged to try to correct
the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver
is connected.
• Consult the dealer or an experienced radio/TV technician for help.
Industry Canada
This Class (B) digital apparatus meets all the requirements of the Canadian Interference-Causing
Equipment regulations.
Cet appareil numérique de la Classe (B) respecte toutes les exigences du Réglement sur le matériel
brouilleur du Canada.
Compliance

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REV. 7.1.0
PL-HRDW-HU-C1000-C/F-EN
5.3"
(135 mm)
6.5"
(165 mm)
2.2"
(55 mm)
Figure 18 - C1000 Size Diagram
Overall Dimensions
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No part of this document may be photocopied or reproduced by any means, or translated to another language without prior written
consent of Prolon. All specications are nominal and may change as design improvements are introduced. Prolon shall not be liable for
damages resulting from misapplication or misuse of its products. All trademarks are the property of their respective owners.