Prolon C1000 Series Installation instructions

HARDWARE GUIDE
FlexIO Controller C1000 Series
Specifications and Operational Guide
REV. 6.2.2
PL-HRDW-FLX-C1000-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 FLX Controller ...............................................................................................................4
Description ..................................................................................................................................................................... 4
Features ........................................................................................................................................................................... 4
Components...................................................................................................................................5
Component Identification.......................................................................................................................................... 5
LEDs .................................................................................................................................................................................. 6
Address Configuration for Networking................................................................................................................... 6
Jumper to Supply Power to the RJ45 Plug ............................................................................................................. 7
Input and Output Identification ............................................................................................................................... 7
Inputs...................................................................................................................................................8
Temperature sensors.................................................................................................................................................... 8
Contact ............................................................................................................................................................................ 8
Pressure, Gas or Humidity (Voltage Signal)............................................................................................................ 9
Pressure, Gas or Humidity (4-20mA Signal)............................................................................................................ 9
Outputs.............................................................................................................................................. 10
Output Specifications................................................................................................................................................10
Configuration of Digital Outputs............................................................................................................................ 10
Typical Connection of Digital Outputs.................................................................................................................. 11
Typical Connection of the Analog Outputs ......................................................................................................... 12
Power Source / Network.................................................................................................................... 13
Power Source ............................................................................................................................................................... 13
Network Communication ......................................................................................................................................... 13
Technical Specifications.................................................................................................................... 14
Compliance ........................................................................................................................................ 15
FCC User Information................................................................................................................................................. 15
Industry Canada ......................................................................................................................................................... 15
Overall Dimensions ........................................................................................................................... 16

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Table of Figures
Figure 1 - Component Identification ............................................................................................................................ 5
Figure 2 - LEDs Identification.......................................................................................................................................... 6
Figure 3 - Addressing Dipswitches ................................................................................................................................ 6
Figure 5 - Input and Output Identification................................................................................................................... 7
Figure 4 - RJ45 Jumper ...................................................................................................................................................... 7
Figure 6 - RJ45 Pinout ........................................................................................................................................................ 7
Figure 7 - Connecting a temperature sensor to analog input 1............................................................................ 8
Figure 8 - Connecting a dry contact to analog input 1............................................................................................ 8
Figure 9 - Connecting voltage based sensors ............................................................................................................ 9
Figure 10 - Connecting current based sensors .......................................................................................................... 9
Figure 11 - Output in SOURCE mode...........................................................................................................................10
Figure 12 - Output in SINK mode ................................................................................................................................. 11
Figure 13 - Connection of active outputs 3 and 4................................................................................................... 11
Figure 14 - Connection of passive outputs 3 and 4 ................................................................................................ 11
Figure 16 - Connecting the analog output (external power) ............................................................................... 12
Figure 15 - Connecting the analog output (controller powered)........................................................................ 12
Figure 17 - Connecting the 24VAC power source .................................................................................................... 13
Figure 18 - Connecting to the network...................................................................................................................... 13
Figure 19 - C1000 Size Diagram....................................................................................................................................16

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Description
The C1000 FlexIO is a general purpose HVAC controller whose inputs and outputs can be individually con-
figured for use in various applications. Unlike most ProLon controllers, the FlexIO is not aimed at a specific
HVAC sequence or piece of equipment, and instead can be used to perform any outlying functions that
are not usually covered by existing ProLon devices. Outputs can be configured to respond to a variety of
standard HVAC input signal types, ranging from temperatures, pressure, gas and more.
Features
• Many input types available: Temperature, Dry Contact, Pressure, Gas, Humidity
• Configurable names and display options for each input and output
• Configurable scales for pressure and gas inputs accommodates any sensor
• Outputs can act based on any local input, or on data received from a network master
• Can receive up to 5 different occupancy states from an NC2000, allowing for versatile lighting
control
• Various output logic sequences are available: ON/OFF, PI Loop, Direct or Reverse acting, Pulsed
• Outputs can be interlocked with each other
• Outputs can be automatically overridden based on outside temperature and/or occupancy
• Operates standalone or can be integrated into a ProLon network
General Information
PL-C1000 FLX Controller

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Components Identification
Legend:
A-Addressing dipswitch
B-Jumpers for terminating and bias resistors for the NET port (see K)
C-Jumpers for terminating and bias resistors for the INT port (see J)
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 communication (terminal block)
L-Inputs (4 total)
M-Terminal Blocks for Outputs 1 to 5
N-Terminal Blocks for 24 VAC
NET
BIAS TERM
INT
BIAS TERM
Figure 1 - Component Identification
Components

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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.
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 - Addressing Dipswitches
Figure 2 - LEDs Identification
LEDs
Address Configuration for Networking
Aunique 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 below 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.

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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 FlexIO Controller 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.
No power 24 VAC 24 VDC
Figure 4 - RJ45 Jumper
Figure 6 - RJ45 Pinout
Figure 5 - Input and Output Identification
STAT
NETSNDNETREC INTSND
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM
+
COM
24VAC
COM
24VAC
COM
24VAC
COM
24VAC
COM
24VACCOM
INTREC
HBEATOUT5OUT4OUT3OUT2OUT1
RESET
PL-C1000-FLX
INTERFACE
INT Port: Incoming RS485
Network communication (Modbus)
NET Port: Incoming RS485
Network communication (Modbus)
Digital Input
Analog Input 3
Common for all the inputs
Analog Input 2
Analog Input 1
Analog Output
(0-10 / 2-10 / 0-5 VDC)
Digital Output 4
(ON/OFF, PWM)
Digital Output 3
(ON/OFF, PWM)
Digital Output 2
(ON/OFF, PWM)
Digital Output 1
(ON/OFF, PWM)
Power source of the controller
24 VAC
Jumper to Supply Power to the RJ45 Plug
Input and Output Identification
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:

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The C1000 FlexIO controller inputs can be used to monitor digital contacts. Please refer to Figure 8 to see
how to correctly connect them.
10K Type 3
Thermistor
Figure 7 - Connecting a temperature sensor to analog input 1
Figure 8 - Connecting a dry contact to analog input 1
Contact
Inputs
The C1000 FlexIO controller’s inputs can be configured to accept a wide range of signal types. It is
important to note that if the chosen signal type is 4-20mA, an external 250 Ohm resistor will be required
(see p.10).
For the C1000 Digital Input, it can only accept contact signals.
Displayed below are examples of input wiring for most signal types. It is important to also configure the
input appropriately in the controller’s software configuration.
Temperature Sensors
Contact
The C1000 FlexIO controller inputs can be used to monitor temperatures. The temperature sensors used
are standard 10k type 3 thermistors (see figure 7).
The outside air temperature and supply air temperature can optionally be provided by an alternate source,
such as a network master. If a network controller is present on the network, it can retrieve the outside
temperature reading from one controller and distribute it to any other controllers on the network.

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The C1000 FlexIO controller inputs can be used to monitor the voltage signal produced by pressure, gas
or humidity sensors. Please refer to Figure 4 for correct wiring.
Note: When nothing is connected, the input will read the maximum possible reading.
It is important to ensure that the sensor shares the same common as the C1000 so that there is no 24 VAC
feedback sent back to the controller, which can interfere with the controller’s ability to maintain accurate
analog input readings.
Figure 10 - Connecting current based sensors
Figure 9 - Connecting voltage based sensors
Sensor
GND
24VAC
Signal
Sensor
4-20 mA
250 Ohms
GND
24VAC
Signal
The C1000 FlexIO controller inputs can be used to monitor the current signal produced by pressure, gas
or humidity sensors. The C1000 requires a 250 Ohm resistor in parallel with the COMMON. Please refer to
Figure 10 for correct wiring.
It is important to ensure that the sensor shares the same common as the C1000 so that there is no 24 VAC
feedback sent back to the controller, which can interfere with the controller’s ability to maintain accurate
analog input readings.
Pressure, Gas or Humidity (Voltage Signal)
Pressure, Gas or Humidity (4-20mA Signal)

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The C1000 FlexIO controller contains 5 customizable outputs; four triac ON/OFF outputs (24VAC) and one
analog output (0-10VDC). Output configuration is performed via the ProLon Focus software.
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.
Figure 11 - Output in SOURCE mode
24VAC
COM
OUT5OUT4
Switch for
Output 4
24 VAC Output (ON/O )
Output 4 Common
Outputs
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 11):
Configuration of Digital Outputs
Output Specifications
Output Type Action
DO 1 Triac source 24VAC,
Max Current: 300 mA
On-or-Off /
Pulse Width Modulation
DO 2 Triac source 24VAC,
Max Current: 300 mA
On-or-Off /
Pulse Width Modulation
DO 3 Triac source 24VAC,
Max Current: 300 mA
On-or-Off /
Pulse Width Modulation
DO 4 Triac source 24VAC,
Max Current: 300 mA
On-or-Off /
Pulse Width Modulation
AO
Configurable Analog Output:
- 0 to 10 VDC
- 2 to 10 VDC
- 0 to 5 VDC
Max Current: 40 mA
On-or-Off /
Pulse Width Modulation /
Modulating Proportional

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2) Switch position to obtain a SINK passive output (see Figure 12):
Figure 12 - Output in SINK mode
Figure 14 - Connection of passive outputs 3 and 4
OUT5OUT4
Switch for
Output 4
Isolated dry contact
(On/O)
OUT5OUT4
External 24 V
External Load
24 N
Two types of configurations are possible:
1) Active output (SOURCE). The C1000 is actively powering the load. (see Figure 13)
2) Passive output (SINK). The C1000 opens and closes a contact to allow an external source to power
the load (see Figure 14).
Typical Connection of Digital Outputs
Figure 13 - Connection of active outputs 3 and 4
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 15)
2) The C1000 only provides the control signal to the load, which is powered by an external source
(see Figure 16)
Figure 15 - Connecting the analog output (controller powered)
Figure 16 - Connecting the analog output (external power)
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
Typical Connection of Analog Outputs

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The ProLon C1000 controller is powered by a 24 VAC power source connected using the "COM" terminal
and the "24 VAC" terminal (see Figure 17). 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.
Figure 17 - Connecting the 24VAC power source
Figure 18 - Connecting to the network
Towar d
network
OUT1
COM 24VAC
Supply
NL
120VAC24VAC
Power Source / Network
Power Source
Network Communication
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 board (see
Figure 3). The network connections are made using the NET terminal block located on the ProLon C1000
controller (see Figure 18).

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Supply: 24 VAC ±10%, 50/60 Hz, Class 2
Consumption: 2 VA (Consumption), 32 VA (Input)
Inputs: 3 analog inputs with individually configurable signal ranges (thermistor, dry contact, 0-5 VDC,
1-5 VDC, 0.5-4.5 VDC), and 1 digital input
Digital outputs: 4 triac outputs, 10-30 VAC source or sink, 300 mA max (resettable fuse)
Analog output: 1 output 0-10 VDC / 2-10 VDC / 0-5 VDC, 40 mA max (resettable fuse)
Indication lights (LED): State of each output / Communication / Supply / 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)
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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© Copyright 2018 ProLon. All rights reserved.
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.
REV. 6.2.2
PL-HRDW-FLX-C1000-EN
5.3"
(135 mm)
6.5"
(165 mm)
2.2"
(55 mm)
Figure 19 - C1000 Size Diagram
Overall Dimensions