Prolon C1000 Series Installation instructions

Hardware Guide
Rooftop Controller
C1000 Series
Specifications and Operational Guide
REV 6.3
www.proloncontrols.com
[email protected]
PL-HRDW-C1000RTU-C/F-EN-V63

PL-C1000 SERIES
BASIC ROOFTOP HARDWARE GUIDE
www.proloncontrols.com
Montréal
1989 rue Michelin Laval,
QC H7L 5B7
TEL:[phone]
FAX: [phone]
1-877-9PROLON
www.proloncontrols.com
[e-mail]
2
Table of Contents
GENERAL INFORMATION............................................................................................................ 3!
PL-C1000 Basic Rooftop Controller .............................................................................................................. 3!
Description ...................................................................................................................................................................3!
General Behaviour .......................................................................................................................................................3!
Operation Sequence ..................................................................................................................................... 4!
General ........................................................................................................................................................................4!
Occupied Mode............................................................................................................................................................4!
Unoccupied Mode ........................................................................................................................................................5!
COMPONENTS ................................................................................................................................. 6!
Component Identification............................................................................................................................... 6!
LEDs.............................................................................................................................................................. 7!
Input and Output Identification ...................................................................................................................... 8!
Addressing Dipswitch Configuration for Network Communication ................................................................ 9!
Jumper to supply power to the RJ45 plug ..................................................................................................... 9!
INPUTS ............................................................................................................................................. 10!
Temperature Sensors.................................................................................................................................. 10!
Occupancy Mode (Night Setback)............................................................................................................... 11!
Dry Contact originating from an External Timer:........................................................................................................11!
OUTPUTS ......................................................................................................................................... 12!
Output Specifications .................................................................................................................................. 12!
Typical Connection of the Triac Outputs 1 through 4 .................................................................................. 13!
Typical Connection of Output #5 ................................................................................................................. 13!
DMUX-4J Connection on Output 2 for Stage 3 or 4 Cooling....................................................................... 14!
PTA2 Connection on Output 2 for Analog Cooling...................................................................................... 15!
POWER SOURCE & NETWORK................................................................................................. 16!
Power Source.............................................................................................................................................. 16!
Network Communication ............................................................................................................................. 16!
Technical Specifications ................................................................................................................... 17!
Compliance........................................................................................................................................ 18!
FCC User Information ................................................................................................................................. 18!
Industry Canada .......................................................................................................................................... 18!
OVERALL DIMENSIONS.............................................................................................................. 19!

PL-C1000 SERIES
BASIC ROOFTOP HARDWARE GUIDE
www.proloncontrols.com
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1989 rue Michelin Laval,
QC H7L 5B7
TEL:[phone]
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3
GENERAL INFORMATION
PL-C1000 Basic Rooftop Controller
Description
The ProLon C1000 Basic Rooftop is a microprocessor-
based controller designed to operate rooftops or other
mechanical HVAC systems. It acts as a master when
used on a network with other ProLon zone controllers.
General Behaviour
Although fully programmable, the ProLon C1000 Basic Rooftop controller uses pre-established control
sequences or ’’profiles’’ to operate specific HVAC equipment with dedicated output functions. Those can
be fully optimized to obtain the best results for each type of system. Numerous parameters enable the
modification or fine tuning of the fan, the cooling outputs, the action of the heating outputs (On-or-Off /
pulsed / modulating), the proportional bands, integration times, differentials, operational ranges,
setpoints and a whole range of limits and safeguards. The various programming options also allow the
user to modify the unoccupied mode settings, morning warm-up and supply air pre-heating sequences
as well as each zone weight and network demand control strategy best suited for the building space it is
controlling. All these parameters can be accessed by using the ProLon Focus software.

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Operation Sequence
General
The ProLon C1000 Basic Rooftop controller receives readings from three temperature sensors located
outside, in the return duct and in the supply duct. Also, as a Master device, it receives data from the
zone controllers sent on the network bus. A dry contact originating from an external timer signals the
occupancy status (optional) to the Master. The controller then analyzes all the data and demands sent
by the zones and commands the appropriate outputs to respond accordingly, within parameters set by
the temperature sensors and other safety limits. The Master sends back information on its network such
as supply air temperature, occupancy status and other relevant data for the zone controllers to use.
Occupied Mode
The controller operates the fan. When there is a cooling demand from the zones, the Rooftop controller
will activate the cooling outputs as long as all temperature limits, delays and other related parameters
are respected. Once the demand is satisfied, the outputs are deactivated within the prescribed minimum
on/off time delays.
When there is a heating demand from the zones, the Rooftop controller will activate the heating outputs
as long as all temperature limits, delays and other related parameters are respected. Once the demand
is satisfied, the outputs are deactivated within the prescribed minimum on/off time delays.
When there is no cooling or heating demand from the zones, only the fan is enabled. If the heating
equipment permits, a supply air pre-heating sequence may be enabled. This allows cold mixed air to be
heated to a more comfortable level for subsequent use by the zones for ventilation.

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Unoccupied Mode
The fan can be configured to operate in intermittent mode. When there is a cooling or heating demand
from any single zone, the Rooftop controller will activate the fan and the cooling outputs as long as all
temperature limits, delays and other related parameter are respected. Once the demand is satisfied, the
fan and cooling outputs are deactivated within the minimum on/off time delays set.
During the unoccupied period, the Rooftop controller can be driven by the highest demand on the
network and will operate the fan and relevant outputs accordingly.

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6
COMPONENTS
Component Identification
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
A
B
C
D
E
G
H
F
BIAS TERM
NET
BIAS TERM
INT
I
J
K
Legend:
A= Addressing Dipswitch
B= Output 1 Dipswitch
C= Output 2 Dipswitch
D= Output 3 Dipswitch
E= Output 4 Dipswitch
F= Master reset button
G= Terminal Blocks for Inputs and Outputs
H= LEDs
I= Jumpers for terminating and bias resistors for the NET port
J= Jumpers for terminating and bias resistors for the INT port
K= Jumper to supply voltage to INT port (RJ45 jack)

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7
LEDs
Green pulsing:
indicates that the
CPU is online
Green light: Internal
5VDC power source OK Status light for
triac output 1
(Fan)
Status light for
triac output 2
(Cool #1 / Y1)
Status light for
triac output 3
(Cool #2 / Y2)
Status light for
triac output 4
(Heat #1 / W1)
Status light for
analog output 5
(Heat #2 / W2)
Green light:
Reception from
main bus
Red light:
transmission to
main bus
Reserved
Green light: Internal
24VDC power source OK
Red light:
transmission to
interface
Green light:
reception from
interface

PL-C1000 SERIES
BASIC ROOFTOP HARDWARE GUIDE
www.proloncontrols.com
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8
Input and Output Identification
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.
For incoming communication from a remote computer or network controller, an RJ45 type connector is
available. 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.
Controller’s power source
Unit’s R&Cterminals (24VAC)
NET$Port:$Outgoing$RS485$Network$communication$to$
Zones$(Modbus)
Common for all inputs
Outside air temperature sensor (10K thermistor)
Return air temperature sensor (10K thermistor)
Supply air temperature sensor (10K thermistor)
External dry contact for night setback
Output 5 (Analog 0-10VDC)
Preheating / Heat (W2)
Output 4 Heat (W1)
Output 3 Cooling (Y2)
Output 3 Cooling (Y1)
Output 1 Fan (G)
INT$Port:$Incoming$RS485$Network$communication$
(Modbus)
OUT5OUT4
OUT3
OUT2
OUT1
24VACCOM
Outputs Inputs Net
Power
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
PL-C1000-RTU
Interface
RJ45 Pinout
1"""2"""3"""4"""5"""6"""7"""8
AB GND
(+)(-)

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BASIC ROOFTOP HARDWARE GUIDE
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9
Addressing Dipswitch Configuration for Network
Communication
A unique address must be configured on each controller 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, and 64 respectively). The last
switch (#8) is reserved. The value of each switch that is in the ON
position is added together to form the numerical address of the
controller.
The example in Figure 1 shows the switches 1, 2 and 4 in the ON position. Therefore, the
corresponding values are 1, 2 and 8, giving an address sum of 11.
The ProLon network allows a maximum of 127 addresses, therefore 127 controllers.
Jumper to supply power to the RJ45 plug
The RJ45 jumper lets the user select if 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:
No power 24 VAC 24 VDC
12 3 4 5 6 7
Figure 1: Addressing Dipswitches

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10
INPUTS
Temperature Sensors
The C1000 Rooftop controller has three analog inputs that monitor outside air, return air and supply air
temperatures (see Figure 2) and will integrate these readings into its control sequence. The sensors
used are standard 10k type 3 thermistors that share a single common connection.
Alternatively, the supply air temperature can be retrieved from a zone controller that has its own supply
sensor and belongs to the C1000’s network.
The outside air temperature can be also be provided by an alternate source. 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.
Figure 2: Connecting the sensors

PL-C1000 SERIES
BASIC ROOFTOP HARDWARE GUIDE
www.proloncontrols.com
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1989 rue Michelin Laval,
QC H7L 5B7
TEL:[phone]
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11
Occupancy Mode (Night Setback)
Dry Contact originating from an External Timer:
Temperature setback savings can be obtained by using a dry contact originating from an external timer
to switch the controller from occupied to unoccupied mode. The timer contact used must be connected
to the "OCC" and the "GND" terminals (see Figure 3). To indicate occupied mode, the contact must be
open. To indicate unoccupied mode, the contact must be closed. As a network Master, the Rooftop
controller will then send the occupancy status to all known slaves on his network.
Timer
13 14 15 16 17 18 19
OA
RA
A
B
GND
SUPPLY
OCC
NET
Figure 3: Night setback contact connection

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www.proloncontrols.com
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12
OUTPUTS
The C1000 Basic Rooftop controller contains 5 customizable outputs, 4 being Triac type switch outputs
and one being 0-10Vdc analog modulating / pulsed / On-or-Off output. Some outputs are configurable
and follow a proportional and integral algorithm (PI) to ensure precise adjustment of the device. All
configurations are 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 a round, yellow-coloured PTC that will change to orange and heat up on an overload
condition. Once power has been removed from the C1000, the fuse will cool down and automatically
reset. Fix the faulty wiring and you will be able to activate the output once again.
Output Specifications
Output Type Action Application
1
Triac s ourc e 24VAC
Max Current: 300 mA
On-or-Off Fan
2
Triac s ourc e 24VAC
Max Current: 300 mA
On-or-Off Cooling (1st Stage)
3
Triac s ourc e 24VAC
Max Current: 300 mA
On-or-Off Cooling (2nd Stage)
4
Triac s ourc e 24VAC
Max Current: 300 mA
On-or-Off
Heating (1st or 2nd stage)
OR
Preheat permission
5
Configurable Analog
Output:
- 0 to 10 VDC
- 2 to 10 VDC
- 0 to 5 VDC
Max Current: 40 mA
Modulating
proportional
OR
Pulsed
OR
On-or-Off
Preheating only
OR
Preheat + Heating
OR
Heating (1st or 2nd stage)

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BASIC ROOFTOP HARDWARE GUIDE
www.proloncontrols.com
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1989 rue Michelin Laval,
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13
Typical Connection of the Triac Outputs 1 through 4
On the C1000 Rooftop controller, all triac outputs must be set to SOURCE mode because they all share
a single source supply: the equipment’s transformer. All triac outputs have a SOURCE / SINK
configuration switch; they must be set to “SWITCH” (move switch towards terminal blocks). Only the
terminal blocks marked 24 VAC are used for each output (see Figure 4).
Out 5
Out 4Out 3
Output
Com
24 v
Com
24 v
7 8 9 10 11 12
(W1)
(Y2)
Equipment terminal board
Figure 4: Connection of outputs 3 and 4
Typical Connection of Output #5
Output 5 is an analog output 0-10 VDC. It can be configured to modulate a 0 to 10 VDC load, to pulse a
0 or 10 VDC Triac relay or to control a 10 VDC On/Off relay (see Figure 5).
Out 5Out 4
Out 3
Output
Com
0-10v
External
Load
7 8 9 10 11 12
SSR
(+)
(-)
Figure 5: Connecting the analog output (external power)

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14
DMUX-4J Connection on Output 2 for Stage 3 or 4 Cooling
When 3 or 4 stages of cooling are required, the C1000 Rooftop controller must be equipped with a
DMUX-4J. The DMUX-4J input is only connected to Output 2 on the C1000 Rooftop controller. The
DMUX-4J must be configured to “Sequenced Relay Control” with a 1 second pulse resolution. The “Triac
Input Selection” jumper must be set to normal signal input and the “Power Type Selection” jumper must
be set to AC power. The DMUX-4J outputs are then connected to the rooftop unit (see Figure 6). Each
of the DMUX-4J outputs have connections for “Normally Closed” and “Normally Open” operation, so use
the connection that is compatible with your rooftop unit. For more information on the DMUX-4J, consult
the Specification Sheet and the Installation Guide for the DMUX-4J.
R
C
G
Y1
Y2
Y3
Y4
PWR+
PWR-
NO1
NO3
NO2
DMUX-4J
IN+
NO4
RTU
IN-
C1
C2
C3
C4
OUT5
OUT4
OUT3
OUT2
OUT1
24VAC
COM
Outputs
1====2 3====4 5====6 7====8 9===10 11==12
COM
24VAC
COM
24VAC
COM
24VAC
COM
24VAC
24VAC
COM
RESET
Supply
!"#$%#&'(
)*+
'( ,(
)-
'.%"
"
'
$
"
,
/
"001111"!
,$.213)1)456789
Figure 6: Connecting the DMUX-4J (powered by C1000)

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BASIC ROOFTOP HARDWARE GUIDE
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15
PTA2 Connection on Output 2 for Analog
Cooling
When analog cooling is required, the C1000 Rooftop controller must be equipped with a PTA2 v.1. The
PTA2 input is connected to Output 2 on the C1000 Rooftop controller. The input pulse range must be set
to 0.1-10 sec. For more information on the PTA2, consult the Specification Sheet and the Installation
Guide for the PTA2.
!"#$!"#%
!"#&
!"#'
!"#(
'%)*++!,
!-./-.0
(1111' &1111% $11112 311114 5111(6 ((11('
+!,
'%)*+
+!,
'%)*+
+!,
'%)*+
+!,
'%)*+
'%)*+
+!,
7898#
9-//:;
7
+
<
=
(
'
2
PTA2%V.1
&
'%1)*+
RTU
%
J2
#7>*+
J1
1%%%0
A
B
+!,
Figure 7: Connecting the PTA2 (powered by C1000)

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www.proloncontrols.com
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16
POWER SOURCE & NETWORK
Power Source
The C1000 controller is powered by the HVAC equipment’s 24 VAC power supply by connecting the
common (’’C’’ wire) to the "COM" terminal block and the live (‘’R’’ wire) to the "24 VAC" terminal block
(see Figure 8). The common for all inputs and outputs is the same as the power source’s common. All
output power sources also originate from the controller’s power source.
24Vac
( R )
( C )
To HVAC equipment terminal
Out 1
24VAC
COM
Supply
1 2 3 4
Figure 8: Connecting the 24VAC power source
Network Communication
The ProLon C1000 Rooftop controller is primarily designed to work with ProLon zone controllers. When
they are networked the Rooftop and zone controllers all communicate in real-time. The network
connections are made using the network terminal blocks located on the C1000 controller (see Figure 9).
Towards network
13 14 15 16 17 18 19
A
B
NET
A
B
Figure 9: Connecting to the network

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17
Technical Specifications
Supply: 24 VAC ±10%, 50/60 Hz, Class 2
Consumption: 5 VA
Inputs: 3 analog inputs, 1 digital input
Digital outputs: 4 triac outputs, 10-30 VAC source or dry contact, 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 / Power / State of microprocessor
Microprocessor: PIC18F6722, 8 bits, 40 MHz, 128KB FLASH memory
Casing: Molded ABS
Communication: Modbus RTU (RS485), up to 127 nodes
Baud rate: 9600, 19200, 38400, 57600, 76800, 115200
Wiring: Removable screw-type terminal blocks (16 AWG max) and RJ45 modular jack
Dimensions: 157 mm x 133 mm (6.2" x 5.2" )
Environment: 0-50 ºC (32-122 ºF) Non-Condensing
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.

PL-C1000 SERIES
BASIC ROOFTOP HARDWARE GUIDE
www.proloncontrols.com
Montréal
1989 rue Michelin Laval,
QC H7L 5B7
TEL:[phone]
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[e-mail]
18
Compliance
•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 received, 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.

PL-C1000 SERIES
BASIC ROOFTOP HARDWARE GUIDE
www.proloncontrols.com
Montréal
1989 rue Michelin Laval,
QC H7L 5B7
TEL:[phone]
FAX: [phone]
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[e-mail]
19
OVERALL DIMENSIONS
165$mm
6.5"
135$mm
5.3"
1$$$$2 3$$$$4 5$$$$6 7$$$$8 9$$$10 11$$12 13$$14 15$$16 17$$18 19
55$mm
2.2"
© Copyright 2016 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 specifications 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 other trademarks are the property of their respective owners.