Prolon C1000 Series Installation instructions

HARDWARE GUIDE
Rooftop Controller C1000 Series
Specifications and Operational Guide
REV. 6.1.6
PL-HRDW-RTU-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 Basic Rooftop Controller........................................................................................................................... 4
Description ..................................................................................................................................................................... 4
General Behaviour ........................................................................................................................................................ 4
Operating Sequence .................................................................................................................................................... 5
General ............................................................................................................................................................................ 5
Occupied Mode ............................................................................................................................................................. 5
Unoccupied Mode ........................................................................................................................................................ 5
Components ........................................................................................................................................6
Component Identification.......................................................................................................................................... 6
LEDs .................................................................................................................................................................................. 7
Addressing Dipswitch Configuration for Network Communication ............................................................... 7
Jumper to Supply Power to the RJ45 Plug............................................................................................................. 8
Input and Output Identification ............................................................................................................................... 8
Inputs...................................................................................................................................................9
Temperature Sensors ................................................................................................................................................... 9
Occupancy Mode (Night Setback).......................................................................................................................... 10
Proof of Fan ..................................................................................................................................................................10
Outputs.............................................................................................................................................. 11
Output Specifications................................................................................................................................................ 11
Typical Connection of the Triac Outputs 1 through 4....................................................................................... 12
Typical Connection of Output #5............................................................................................................................ 12
DMUX-4J Connection on Output 2 for Stage 3 or 4 Cooling........................................................................... 13
PTA2 Connection on Output 2 for Analog Cooling ........................................................................................... 14
Power Source & Network................................................................................................................... 15
Power Source ............................................................................................................................................................... 15
Network Communication ......................................................................................................................................... 15
Technical Specifications.................................................................................................................... 16
Compliance ........................................................................................................................................ 17
FCC User Information................................................................................................................................................. 17
Industry Canada ......................................................................................................................................................... 17
Overall Dimensions ........................................................................................................................... 18

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Table of Figures
Figure 1 - Component Identification ............................................................................................................................ 6
Figure 2 - LEDs Identification.......................................................................................................................................... 7
Figure 3 - Addressing Dipswitches ................................................................................................................................ 7
Figure 4 - RJ45 Jumper ...................................................................................................................................................... 8
Figure 5 - Input and Output Identification................................................................................................................... 8
Figure 6 - RJ45 Pinout ........................................................................................................................................................ 8
Figure 7 - Connecting the Sensors ................................................................................................................................. 9
Figure 8 - Night Setback Contact Conection .............................................................................................................10
Figure 9 - Connecting the Proof of Fan Contact to the Controller.......................................................................10
Figure 10 - Conection of Outputs 3 and 4 .................................................................................................................. 12
Figure 11 - Connecting the Analog Output (External Power)................................................................................ 12
Figure 12 - Connecting the DMUX-4J (Powered by C1000).................................................................................... 13
Figure 13 - Connecting the PTA2 (Powered by C1000)............................................................................................ 14
Figure 14 - Connecting the 24VAC Power Source..................................................................................................... 15
Figure 15 - Connecting to the Network....................................................................................................................... 15
Figure 16 - C1000 Size Diagram....................................................................................................................................18

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General Information
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.
PL-C1000 Basic Rooftop Controller

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Operating 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 equip-
ment 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.
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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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)
Components
Figure 1 - Component Identification
NET
BIAS TERM
INT
BIAS TERM
Component Identification

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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: transmission to main bus
Reserved
Green light: reception from main bus
Status light for analog output 5 (Heat #2 / W2)
Status light for triac output 4 (Heat #1 / W1)
Status light for triac output 3 (Cool #2 / Y2)
Status light for triac output 2 (Cool #1 / Y1)
Status light for triac output 1 (Fan)
Red light: transmission to interface
Figure 2 - LEDs Identification
LEDs
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 3 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.
Figure 3 - Addressing Dipswitches

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Jumper to Supply Power to the RJ45 Plug
Input and Output Identification
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:
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.
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-RTU/RTUS
INTERFACE
RTUS
INT Port: ProLon Digital Temperature
Sensor - OR - Incoming RS485
Network Communication (Modbus)
RTU
INT Port: Incoming RS485
Network communication
(Modbus)
RTUS
Net Port: ProLon Digital Temperature
Sensor - OR - Incoming RS485
Network Communication (Modbus)
RTU
Net Port: Outgoing RS485
Network communication
to Zones (Modbus)
External dry contact for night setback or proof of fan
Supply air temperature sensor (10K thermistor)
Common for all inputs
Return air temperature sensor (10K thermistor)
Outside air temperature sensor (10K thermistor)
Output 5 (Analog 0-10VDC) Preheating / Heat (W2)
Output 4 Heat (W1)
Output 3 Cooling (Y2)
Output 2 Cooling (Y1)
Output 1 Fan (G)
Controller’s power source Unit’s R&C terminals (24VAC)

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Inputs
Temperature Sensors
The C1000 Rooftop controller has three analog inputs that monitor outside air, return air and supply air
temperatures (see Figure 7) 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.
Outside air sensor
Return air sensor
Supply air sensor
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM
Figure 7 - Connecting the Sensors

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Occupancy Mode (Night Setback)
Proof of Fan
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 8). 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.
The C1000 has a digital input that can be used to receive the proof of fan signal. Please refer to Figure 9
to see how to correctly connect it. To indicate proof of fan, the contact must be closed.
Figure 8 - Night Setback Contact Conection
Figure 9 - Connecting the Proof of Fan Contact to the Controller
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM
Timer
Proof of
fan
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM

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Outputs
Output Specifications
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 Type Action Application
1Triac source 24VAC,
Max Current: 300 mA On-or-Off Fan
2Triac source 24VAC,
Max Current: 300 mA On-or-Off Cooling (1st Stage)
3Triac source 24VAC,
Max Current: 300 mA On-or-Off Cooling (2nd Stage)
4Triac source 24VAC,
Max Current: 300 mA On-or-Off
Heating (1st or 2nd
Stage) /
Preheat Permission
5
Configurable Analog Output:
- 0 to 10 VDC
- 2 to 10 VDC
- 0 to 5 VDC
Max Current: 40 mA
Modulating Proportional /
Pulse /
On-or-Off
Preheating only /
Preheat + Heating /
Heating (1st or 2nd
Stage)

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Typical Connection of the Triac Outputs 1 through 4
Typical Connection of Output #5
Figure 11 - Connecting the Analog Output (External Power)
Figure 10 - Conection of Outputs 3 and 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 10).
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 11).
OUT5OUT4OUT3
(W1)
Equipment Terminal Board
(Y2)
OUT5OUT4
OUT3
(+)
SSR
External Load
(-)

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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 12). 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.
Figure 12 - Connecting the DMUX-4J (Powered by C1000)
Y4
Y3
Y2
Y1
G
R
C
NO4
DMUX-4J RTU
C4
NO3
C3
NO2
C2
NO1
C1
PWR+
PWR-
IN+
IN-
COM
24VAC
COM
24VAC
COM
24VAC
COM
24VAC
COM
24VACCOM
OUT5OUT4OUT3OUT2OUT1
RESET
24VAC
AC DC
J9
AUTO
O
A
J10
TRIAC NORM
OFF ON
MODE
DMUX-4J Jumpers

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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.
Figure 13 - Connecting the PTA2 (Powered by C1000)
Y
G
R
C
6
1
PTA2 V.1
24 VAC
COM
RTU
2
3
4
+
COM
24VAC
COM
24VAC
COM
24VAC
COM
24VAC
COM
24VACCOM
OUT5OUT4OUT3OUT2OUT1
RESET

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Power Source & Network
Power Source
Network Communication
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 14). 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.
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 connec-
tions are made using the network terminal blocks located on the C1000 controller (see Figure 15).
Figure 14 - Connecting the 24VAC Power Source
Figure 15 - Connecting to the Network
A
NET
B
( A )
( B )
Towards Network
24VAC
COM
24VACCOM
OUT1
( R )
( C )
To HVAC Equipment Terminal (Class 2)
24VAC

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Technical Specifications
Supply: 24 VAC ±10%, 50/60 Hz, Class 2
Consumption: 2 VA (Consumption), 32 VA (Input)
Inputs: • Outdoor – thermistor 10K
• Return – thermistor 10K
• Supply – thermistor 10K
• External clock or Proof of fan– dry contact
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 / 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)
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.

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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 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.

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Overall Dimensions
© 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. 6.1.6
PL-HRDW-RTU-C1000-C/F-EN
5.3"
(135 mm)
6.5"
(165 mm)
2.2"
(55 mm)
Figure 16 - C1000 Size Diagram