Prolon C1000 Series Installation instructions

HARDWARE GUIDE
VAV Zone Controller C1000 Series
Specifications and Operational Guide
REV. 7.1.0
PL-HRDW-VAV-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 VAV Zone Controller .................................................................................................................................. 4
Description ..................................................................................................................................................................... 4
General Behaviour ........................................................................................................................................................ 4
Operating Sequence............................................................................................................................5
General ............................................................................................................................................................................ 5
Occupied Mode ............................................................................................................................................................. 5
Unoccupied Mode ........................................................................................................................................................ 5
Selection Guide ...................................................................................................................................6
Lon Card .......................................................................................................................................................................... 6
Flow Sensor .................................................................................................................................................................... 6
Components ........................................................................................................................................7
Component Identification.......................................................................................................................................... 7
LEDs .................................................................................................................................................................................. 8
Address Configuration for Networking (Modbus or BACnet) ........................................................................... 8
Jumper to Supply Power to the RJ45 Plug............................................................................................................. 9
Airflow Sensor (Optional) ........................................................................................................................................... 9
Damper Direction Configuration...................................................................................................... 10
Input and Output Identification ............................................................................................................................. 11
Room Sensors .............................................................................................................................................................. 12
Analog Room Sensor (PL-RS Series) ....................................................................................................................... 12
Digital Room Sensors................................................................................................................................................. 12
Multi-Function Analog Input ................................................................................................................................... 14
Supply Air Temperature Sensor (PL-CODS) ..........................................................................................................14
Radiant Floor Slab Temperature Sensor................................................................................................................ 14
Discharge Air Temperature Sensor......................................................................................................................... 15
Digital Input ................................................................................................................................................................. 16
Occupancy originating from an External Timer .................................................................................................16
Standby mode originating from a Motion Detector ......................................................................................... 16
Outputs.............................................................................................................................................. 17
Output Specifications................................................................................................................................................ 17
Configuration of Digital Outputs 1 to 4................................................................................................................18
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
Technical Specifications.................................................................................................................... 21
Compliance ........................................................................................................................................22
FCC User Information.................................................................................................................................................22
Industry Canada .........................................................................................................................................................22
Overall Dimensions ...........................................................................................................................23

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Table of Figures
Figure 1 - Part Number ..................................................................................................................................................... 6
Figure 2 - Component Identification ............................................................................................................................ 7
Figure 3 - LEDs Identification.......................................................................................................................................... 8
Figure 4 - Addressing Dipswitches ................................................................................................................................ 9
Figure 5 - Jumper ............................................................................................................................................................... 9
Figure 6 - Airflow Sensors................................................................................................................................................ 9
Figure 7 - Damper Configuration................................................................................................................................. 10
Figure 8 - Input and Output Identification................................................................................................................ 11
Figure 9 - RJ45 Pinout ..................................................................................................................................................... 11
Figure 10 - Typical Wiring of the PL-RSC Room Sensor to the Controller.......................................................... 12
Figure 11 - Connecting the Digital Sensor to the Controller (CAT5 Cable) ....................................................... 13
Figure 12 - Connecting the Digital Sensor to the Controller (RJ45 Adapter) ................................................... 13
Figure 13 - Connecting the Supply Air Sensor to the Controller......................................................................... 14
Figure 14 - Connecting the Slab Temperature Sensor to the Controller........................................................... 15
Figure 15 - Connecting the Discharge Temperature Sensor to the Controller................................................ 15
Figure 16 - Connecting an External Timer to the Controller ................................................................................16
Figure 17 - Outputs 3 and 4 Active.............................................................................................................................. 18
Figure 18 - Output in SINK mode .................................................................................................................................. 18
Figure 19 - Connection of Active Outputs 3 and 4.................................................................................................. 18
Figure 20 - Connection of Passive Outputs 3 and 4................................................................................................ 19
Figure 21 - Connecting the Analog Output (Controller Powered)...................................................................... 19
Figure 22 - Connecting the Analog Output (External Power) .............................................................................. 19
Figure 23 - Connecting the 24VAC Power Source....................................................................................................20
Figure 24 - Connecting to the Network .....................................................................................................................20
Figure 25 - C1000 Size Diagram....................................................................................................................................23

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Description
The Prolon C1000 series zone controllers are designed for variable air volume zoning systems. The
built-in microprocessor offers precise digital control to maximize performance. The outputs and control
sequences are all fully configurable, either locally or remotely, using free software or from the digital
room sensor. The C1000 requires an external actuator (sold separately) when damper control is needed.
When in a network, the C1000s can share information such as the occupancy state, the demand, the
supply temperature and more.
General Behaviour
The Prolon C1000 controllers are configurable so that every parameter may be tuned to obtain optimal
results for each zone. It is possible to modify the action of each output (heating or cooling, ON/OFF
or pulsed), the proportional bands, the integration times, the differentials, the operational ranges and
the setpoints. The various programming options also allow the user to modify the unoccupied mode
setpoints, the deadbands, the maximum and minimum setpoints for each zone, as well as the minimum
damper positions in ventilation mode and heating mode for each zone. All these parameters can be
modified using the Prolon Focus software or with the Prolon digital sensor (T1000 series).
General Information
PL-C1000 VAV Zone Controller

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General
The Prolon controller, located on the VAV box, receives the zone temperature and setpoints from the
zone sensor, and optionally the duct temperature from a duct temperature sensor. The controller then
analyzes the information and commands the damper actuator 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 maximum position to allow maximum ventila-
tion 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 digital zone sensors offer a method to temporarily bypass the unoccupied mode for a specified
length of time.
Operating Sequence

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Selection Guide
Flow Sensor
This option specifies whether or not a flow sensor should be included with the C1000 VAV controller, as
well as the velocity range of the flow sensor.
In all cases, the C1000 includes:
• 2 Independent Communication Ports
• 3 Analog Inputs
• 1 Binary Input
• 4 Configurable Digital Outputs (24 VAC Source or Sink)
• 1 Configurable Analog Output (0-10VDC)
The external damper actuators can be controlled by either the Analog Output (modulating actuator), by
two of the Digital Outputs (floating actuator), or both.
Figure 1 - Part Number
PL - C1000 - VAV - PIL
Flow Sensor
BLANK: No Flow Sensor
PIL: Low Velocity 0-1100 FPM
PIH: Low Velocity 0-3000 FPM

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Legend:
A - Addressing dipswitch
B - Jumpers for RS485 terminating and bias resistors for the NET port (see J)
C - Jumpers for RS485 terminating and bias resistors for the INT port (see K)
D - SOURCE/SINK dipswitch for Output 4
E - SOURCE/SINK dipswitch for Output 3
F - SOURCE/SINK dipswitch for Output 2
G - SOURCE/SINK dipswitch for Output 1
H - Reset Button
I - Jumper to supply voltage to INT port (see J)
J - INT port for RS485 communication (RJ45 jack)
K - NET port for RS485 or Lon communication (terminal block)
L - Inputs (4 total)
M - Terminal Blocks for Outputs 1 to 5
N - Terminal Blocks for 24 VAC
O - Airflow Sensor (optional)
Figure 2 - Component Identification
Components
Component Identification
NET
BIAS TERM
INT
BIAS TERM

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STATHBEATOUT5OUT4OUT3OUT2OUT1
Green light: Reception
from INT port
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 NET port
Green light: Reception from NET port
Status light for analog output 5
Status light for triac output 4
Status light for triac output 3
Status light for triac output 2
Status light for triac output 1
Red light: Sending to INT port
Figure 3 - LEDs Identification
LEDs
Address Configuration for Networking (Modbus or BACnet)
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 of 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).
Modbus and BACnet networks over RS485 allow a maximum of 127 addresses, therefore 127 controllers.
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.

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Jumper to Supply Power to the RJ45 Plug
Airflow Sensor (Optional)
Figure 5 - Jumper
Figure 6 - Airflow Sensors
No power 24 VAC 24 VDC
Figure 4 - Addressing Dipswitches
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 a 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:
Adding an airflow sensor to the Prolon VAV controller lets it regulate the temperature AND the airflow
of a zone, independently of the static pressure variations of the system. Two different airflow sensors are
offered (see Figure 6):
•Low velocity sensor (0 - 1100 ft/min)
•High velocity sensor (0 - 3000 ft/min)
Low Airow
Sensor
High Airow
Sensor
Grey
Color
Brown
Color

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Damper Direction Configuration
Figure 7 - Damper Configuration
The default damper opening direction of a C1000 VAV controller is counter clockwise (CCW). This parame-
ter 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 C1000 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 C1000 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 C1000 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
STAT
RESET
J11
1. Opening direction is
REVERSED when jumper
is placed HERE.
STAT
RESET
J11
2. When finished, put
jumper back here.
3. Observe green STAT
LED after RESET.

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Input and Output Identification
Figure 8 - Input and Output Identification
Figure 9 - RJ45 Pinout
GND
24V
B (-)
A (+)
INT Port: Incoming Modbus RS485 communication from digital
sensor or remote computer with ProLon Focus software
Digital Input for Night Setback / Standby Mode
Multi-function Analog Input
Common for all the inputs
Temperature setpoint (0-10K potentiometer)
Room temperature sensor (10K thermistor)
Output 5 (Analog 0-10VDC) (Max Current: 40 mA)
Output 4 - Isolated or Source, TRIAC 24 VAC
(Max Current: 300 mA)
Output 3 - Isolated or Source, TRIAC 24 VAC
(Max Current: 300 mA)
Output 2 - Isolated or Source, TRIAC 24 VAC
(Max Current: 300 mA)
Output 1 - Isolated or Source, TRIAC 24 VAC
(Max Current: 300 mA)
Power source of the controller (24 VAC - Class 2)
NET Port: Incoming Modbus RS485 communication
- OR - BACnet MS/TP
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 VAVController has two 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.

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Room Sensors
Two types of room temperature sensors are available:
• Analog: Analog room temperature sensor (thermistor) with setpoint knob and override button
• Digital: Digital sensor, communicating over RS485 to the C1000
Analog Room Sensor (PL-RS Series)
The PL-RS series room sensors provide the C1000 with a room temperature and setpoint. A push-button
is also present to override the schedule. The PL-RS series are connected using a 3-conductor cable (see
Figure 10). Note that if a shielded cable is used to connect the PL-RS, the shield must be grounded at the
GND (pin 1) of the C1000 to which it is connected. To activate the schedule override from the PL-RS, hold
the override button for 3 seconds.
Digital Room Sensors
Prolon offers various digital communicating sensors that can provide the C1000 with room temperature,
room setpoint, and schedule override (T1000, T500, T200 sensors), as well as giving you access to all
configuration parameters of the C1000 (T1000 only).
The digital room sensors are connected to the INT communication port on the C1000, either directly
using a standard CAT5 Ethernet network cable (see Figure 11), or by using an RJ45 adapter (PL-T1000-
ADAPT) to allow the use of a 4-conductor cable (see Figure 12).
Figure 10 - Typical Wiring of the PL-RSC Room Sensor to the Controller
PL-RS Room Sensor
Jumper from 1 to 3
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM

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Figure 11 - Connecting the Digital Sensor to the Controller (CAT5 Cable)
Figure 12 - Connecting the Digital Sensor to the Controller (RJ45 Adapter)
Digital Sensor
CAT5 Cable
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM
Digital Sensor
RJ45 ADAPTOR
(PL-T1000-ADPT)
4 Conductor Cable
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM

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Multi-Function Analog Input
The C1000 has a multi-function analog input. The function of this input varies depending on the con-
figuration that is setup using the Prolon Focus software. By default, this input is used as a supply air
temperature input.
Supply Air Temperature Sensor (PL-CODS)
When a zone controller works autonomously, a supply air temperature sensor (10K Type 3) can be con-
nected to it in order to invert the damper control method upon detection of hot or cold air (see Figure 13).
However, if that controller is part of a network that includes a Prolon Master controller (RTU, HP or other),
individual sensors for each C1000 may be unnecessary since the Master controller will distribute its own
supply air temperature reading to all controllers it is associated with.
NOTE: A supply temperature reading received from a physically attached thermistor will take precedence
over a reading received over the network.
If no Master is present and no sensor is available, the controller will then work under the assumption that
there is cold air in the supply. Alternatively, by shorting the supply temperature input (terminals 15 and
16), the controller will instead assume there is hot air in the supply.
Radiant Floor Slab Temperature Sensor
When the C1000 is configured to work as a radiant floor controller, the function of the supply temperature
input changes to become a slab temperature input. Therefore, a radiant floor slab thermistor (10K type 3)
can then be connected to the C1000 on terminals 15 and 16 (see Figure 14).
Note that if a T1000 digital sensor is connected to the C1000, the slab thermistor can instead be wired
directly to the T1000, and the T1000 will then send the slab temperature to the C1000, cutting down
wiring costs. The supply temperature input can then again be used for a supply air sensor or other.
Figure 13 - Connecting the Supply Air Sensor to the Controller
PL-CODS
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM

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Figure 14 - Connecting the Slab Temperature Sensor to the Controller
Figure 15 - Connecting the Discharge Temperature Sensor to the Controller
Slab Thermistor
(10K type 3)
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM
Discharge Air Temperature Sensor
The multi-function analog input can be configured to monitor a discharge air temperature sensor (10K
type 3). Discharge air temperature is not used in any sequence and is for display purposes only.
Discharge Thermistor
(10K type 3)
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM

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Digital Input
Occupancy originating from an External Timer
An external timer can be used to switch the C1000 between occupied and unoccupied modes. The dry
contact originating from the external timer must be connected to the "Setback" and the "GND" terminals
(17 and 15). Refer to Figure 16 to see how to correctly connect the timer.
To indicate occupied mode, the contact must be open. To indicate unoccupied mode, the contact must
be closed.
Note that if a C1000 controller is part of a network that includes a Prolon Master controller (RTU, HP or
other), an individual contact per C1000 may be unnecessary because all zone controllers share the occu-
pancy status sent on the network by that Master.
NOTE: The occupancy state received from a physically attached dry contact will take precedence over the
occupancy state received over the network. Applies only to closed contact (unoccupied mode).
Standby mode originating from a Motion Detector
A motion detector is typically used to enable the standby mode sequence. The dry contact originating
from the motion detector must be connected to the "Setback" and the "GND" terminals (17 and 15). Refer
to Figure 16 to see how to correctly connect the motion detector.
To indicate occupancy in the space (motion detected), the contact must be closed. Standby mode occurs
when the C1000 is receiving an occupancy signal from the network, but no motion is detected in the
space (contact open).
When in standby mode, the controller uses an alternate, smaller damper minimum position, and will also
stop influencing the master controller in regards to building demand (zone demand and weight sent to
the master are 0). The C1000 will still control its own space to the best of its ability.
Figure 16 - Connecting an External Timer to the Controller
Timer
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM

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Outputs
Output Specifications
Output Type Heating Cooling
1
Triac Source 24VAC
Passive Triac (dry contact)
On-or-Off
Pulsed
Max Current: 300mA
Damper
Valve
Relay
Triac
Damper
Valve
Relay
2
Triac Source 24VAC
Passive Triac (dry contact)
On-or-Off
Pulsed
Max Current: 300mA
Damper
Valve
Relay
Triac
Damper
Valve
Relay
3
Triac Source 24VAC
Passive Triac (dry contact)
On-or-Off
Pulsed
Max Current: 300mA
Valve
relay
Triac
Valve
Relay
4
Triac Source 24VAC
Passive Triac (dry contact)
On-or-Off
Pulsed
Max Current: 300mA
Valve
Relay
Triac
Valve
Relay
5
Modulating Output
On-or-Off
Pulsed
Max Current: 40mA
Configurable Signal:
- 0 to 10 VDC
- 2 to 10 VDC
- 0 to 5 VDC
Modulating Damper
Modulating Valve
SCR
Relay
Triac
Modulating Damper
Modulting Valve
Relay
The C1000 series controllers are equipped with four configurable 24VAC triac digital output and an analog
0-10VDC output to control a wide variety of equipment. All outputs are fully configurable in either heat-
ing or cooling mode, can function in pulsed or ON/OFF mode, and much more. The entire setup for each
output is fully customizable via the Prolon Focus software or the Prolon T1000 digital sensor.
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.
The analog output is equipped with a diode so that it can be wired in parallel with the analog outputs of
other VC2000s to obtain a “highest voltage” signal.

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Outputs 1 to 4 are configurable via switches located on the C1000 board. Simply move the switch to
obtain either an active output (1) or a passive output (2).
1) Switch position to obtain an active output (see Figure 17):
2) Switch position to obtain a passive output (see Figure 18):
Configuration of Digital Outputs 1 to 4
Typical Connection of the Triac Outputs 1 to 4
Figure 17 - Outputs 3 and 4 Active
Figure 18 - Output in SINK mode
Figure 19 - Connection of Active Outputs 3 and 4
24VAC
COM
24VAC
COM
OUT5OUT4OUT3
Switch for
Output 4
Switch for
Output 3
24 VAC Output (pulsed or ON/O )
Output 4 Common
24 VAC Output (pulsed or ON/O )
Output 3 Common
OUT5OUT4OUT3
Switch for
Output 4
Switch for
Output 3
Isolated dry contact
(pulsed or ON/O )
Isolated dry contact
(pulsed or ON/O )
Two types of configurations are possible:
1) Active outputs. The C1000 is actively powering the load (see Figure 19).
24VAC
COM
24VAC
COM
OUT5OUT4OUT3
External Load

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Figure 20 - Connection of Passive Outputs 3 and 4
Typical Connection of the Analog Output
2) Passive outputs. The C1000 opens and closes a contact to allow an external source to power the
load (see Figure 20).
OUT5OUT4OUT3
External 24 V
24 N
24N
Two types of configuration are possible:
1) The C1000 powers the load and provides a control signal (see Figure 20)
2) The C1000 only provides the control signal to the load, which is powered by an external source (see
Figure 21).
Figure 21 - Connecting the Analog Output (Controller Powered)
Figure 22 - Connecting the Analog Output (External Power)
OUT5OUT4
0-10v
COM
Controlled
Load
24 VAC power
(From terminal #2
of the C1000)
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 23 - Connecting the 24VAC Power Source
Figure 24 - Connecting to the Network
OUT1
COM 24VAC
Supply
NL
120VAC24VAC
Tow ard
network
The Prolon C1000 controller is powered by a 24 VAC power source (Class 2) 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. Note that if a digital sensor is being powered by the C1000, it is important to
take the power requirements of the digital sensor into account when selecting a power source for the
C1000.
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
4). The network connections are made using the NET terminal block located on the Prolon C1000 control-
ler (see Figure 23). If the optional Lon communication card is connected to the C1000 board, the controller
will automatically switch to the Lon protocol, with a unique address found on the communication card
itself.