Prolon VC2000 Installation manual

INSTALLATION AND
STARTUP GUIDE
REV 7.0.0
PL-TRA-STARTUP-EN
www.proloncontrols.com
1-877-977-6566
[e-mail]
17510 Rue Charles, Suite 100, Mirabel, QC, J7J 1X9

REV 7.0.0 / PL-TRA-STARTUP-EN 2
Table of Contents
Prolon Installation and Start Up Guide.....................................................................................................................3
Part 1 - Project Preparation & Cabling......................................................................................................................3
Part 2 - Installing the Components ...........................................................................................................................4
VAV Zone Controller................................................................................................................................................................................. 4
Sensors and Accessories......................................................................................................................................................................... 4
Part 3 - Electrical Installation / Connections ............................................................................................................5
VAV Zone Controller................................................................................................................................................................................. 5
Network Cabling ....................................................................................................................................................................................... 6
Unit Controller ........................................................................................................................................................................................... 7
Part 4 - Start Up .........................................................................................................................................................8
Powering up the zones ........................................................................................................................................................................... 8
Powering up the Unit Controller.......................................................................................................................................................... 8
Quick verication (without the Prolon Focus software and computer) .................................................................................. 8
Part 5 - Prolon Focus (Computer Access and Control)..............................................................................................9
Computer and software.......................................................................................................................................................................... 9
Opening a session on Prolon Focus.................................................................................................................................................... 9
Setting up a new system ........................................................................................................................................................................ 9
Absolute override authorization.......................................................................................................................................................... 9
Adjusting the bypass damper.............................................................................................................................................................10
Cooling and heating operations........................................................................................................................................................10
Inverting a zone damper’s opening direction ...............................................................................................................................10
Date and time ..........................................................................................................................................................................................10
Schedule ....................................................................................................................................................................................................10
Rename zones and units.......................................................................................................................................................................11
Save .............................................................................................................................................................................................................11
Exit ..............................................................................................................................................................................................................11
Advanced Congurations.....................................................................................................................................................................11

REV 7.0.0 / PL-TRA-STARTUP-EN 3
v.7
PROLON INSTALLATION AND START UP GUIDE
Part 1: Project preparation & cabling
1- Using a oor plan, determine the system’s zone
controller locations as well as the unit controller’s
(control panel) location
- Mark them on your plans for later access.
2- The master controller must be addressed but the
zone controllers are addressed via the software.
Their location and address in the network are not
important.
3- As a result, determine the shortest path for the
network cables as well as the supply cables which
connect the controllers together. The
communication loop must be an open daisy
chain.
4- Once the network path has been determined,
Identify the two controllers that will be at each
extremity of the network. Mark them on your
plans.
Wiring the zones in a network
System layout and cabling
Prolon Installation and Start Up Guide
Part 1 - Project Preparation & Cabling
1. Using a oor plan, determine the system’s zone controller
locations as well as the unit controller’s (control panel)
location. Mark them on your plans for later access.
2. The unit and zone controllers must be addressed. Their
relative location on the network bus is not important.
3. As a result, determine the shortest path for the network
cables as well as the supply cables which connect the
controllers together. The communication loop must
be an open daisy chain and must not exceed 3200ft
(1000m).
4. Once the network path has been determined, identify
the two controllers that will be at each extremity of
the network. Mark them on your plans.
Wiring the Zones in a Network
System Layout and Cabling
3
v.7
PROLON INSTALLATION AND START UP GUIDE
Part 1: Project preparation & cabling
1- Using a oor plan, determine the system’s zone
controller locations as well as the unit controller’s
(control panel) location
- Mark them on your plans for later access.
2- The master controller must be addressed but the
zone controllers are addressed via the software.
Their location and address in the network are not
important.
3- As a result, determine the shortest path for the
network cables as well as the supply cables which
connect the controllers together. The
communication loop must be an open daisy
chain.
4- Once the network path has been determined,
Identify the two controllers that will be at each
extremity of the network. Mark them on your
plans.
Wiring the zones in a network
System layout and cabling
Communication
room sensors
Supply/Outputs
Network
Unit sensors
Wire to unit
4 wire cable (#22/4 shielded cable
recommended)
#18/2 or #18/3 wire, LVT standard
#24/2 wire, twisted and shielded, low capacitance
(“LOW-CAP”) grounded at control cabinet,
max length 3200ft (1000m)
#18/2 or # 18/3 wire, twisted and shielded
grounded at control cabinet
#18/8 (or #18/10) wire, LVT standard
1
3
5
2
4
T1000 Sensor T200 Sensor T1000 Sensor

REV 7.0.0 / PL-TRA-STARTUP-EN 4
Part 2 - Installing the Components
Sensors and Accessories
1. Room sensor: Install 60” from the oor. Avoid sunny or outdoor
walls, diusers and return grills. (Especially with bypass boxes.)
Beware of electrical boxes (light dimmers)!
(PL-T200 / PL-T500 / PL-T100)
2. Outside air temperature sensor: Install under air inlet hood or on
the unit’s north side IN THE SHADE!
(PL-OAS)
3. Supply air temperature sensor: Install after the bypass damper
junction. (PL-DS)
Return air temperature sensor: Install before the bypass damper
junction (no turbulence). (PL-DS)
4. Static pressure sensor: To be installed 2/3 of the main ventilation
duct’s length. (PL-MLP)
5. Proof of fan (ow switch): Install near the supply air temperature
sensor (no turbulence). Plug the high pressure (+) Pitot tube in the
air duct. Remove the low pressure cap and leave free. (AFS)
6. CO Sensor: Install in the return duct before the bypass junction.
(CO)
7. Bypass damper actuator: Mark the damper position on the shaft
and validate its opening direction.
1
23
VAV Zone Controller
•Verify / validate the rotation direction of each zone damper.
•Close the damper and rotate the actuator clamp to the closed posi-
tion using the clutch button.
•Install the zone controller on the damper and set in place with
screws and bracket.
•While pressing the actuator’s clutch button, turn the clamp manually,
the damper should turn freely (slight o axis movement).
•Adjust mechanical stoppers to prevent overtravel. Full rotation of
actuator should match that of damper.
•Get the identication address of each zone and write it down inside
the cover (or the back plate) of its’zone thermostat (very convenient
for service calls).
v.7
Part 2 : Installing the components
VAV Zone Controller
oVerify / validate the rotation direction of each zone
damper.
oInstall the zone controller on the damper and set in place
with screw.
oWhile pressing the actuator’s clutch button, turn the clamp,
the damper should turn freely (a slight off axis movement).
oAdjust mechanical stoppers on actuator to match the full
rotation of the damper.
oGet the identification address of each zone and write it
down inside the cover (or the back plate) of its’ zone
thermostat (very convenient for service calls).
Sensors and Accessories
PL-T200/T500/T1000
Room sensor: Install 60in from the floor.
Avoid sunny or outdoor walls, diffusers and return grills.
Beware of electrical boxes (lit dimmers)!
Outside air temperature sensor: Install under air inlet hood or on the unit’s north side
IN THE SHADE!!!
PL-OAS
PL-DS
Supply air temperature sensor: Install after the bypass damper junction
Return air temperature sensor: Install before the bypass damper junction (no turbulence)
PL-MLP
Static pressure sensor: To be installed 2/3rds of the main ventilation duct’s length.
AFS
Proof of fan (flow switch): Install near the supply air temperature sensor (no turbulence).
Plug the high pressure (+) Pitot tube in the air duct. Remove the low pressure cap and
leave free.
CO2
CO2 Sensor: Install in the return duct before the bypass junction.
xMB24-SR
Bypass damper actuator: Mark the damper position on the shaft and validate its
opening direction.
6
v.7
Part 2 : Installing the components
VAV Zone Controller
oVerify / validate the rotation direction of each zone
damper.
oInstall the zone controller on the damper and set in place
with screw.
oWhile pressing the actuator’s clutch button, turn the clamp,
the damper should turn freely (a slight off axis movement).
oAdjust mechanical stoppers on actuator to match the full
rotation of the damper.
oGet the identification address of each zone and write it
down inside the cover (or the back plate) of its’ zone
thermostat (very convenient for service calls).
Sensors and Accessories
PL-T200/T500/T1000
Room sensor: Install 60in from the floor.
Avoid sunny or outdoor walls, diffusers and return grills.
Beware of electrical boxes (lit dimmers)!
Outside air temperature sensor: Install under air inlet hood or on the unit’s north side
IN THE SHADE!!!
PL-OAS
PL-DS
Supply air temperature sensor: Install after the bypass damper junction
Return air temperature sensor: Install before the bypass damper junction (no turbulence)
PL-MLP
Static pressure sensor: To be installed 2/3rds of the main ventilation duct’s length.
AFS
Proof of fan (flow switch): Install near the supply air temperature sensor (no turbulence).
Plug the high pressure (+) Pitot tube in the air duct. Remove the low pressure cap and
leave free.
CO2
CO2 Sensor: Install in the return duct before the bypass junction.
xMB24-SR
Bypass damper actuator: Mark the damper position on the shaft and validate its
opening direction.
4
v.7
Part 2 : Installing the components
VAV Zone Controller
oVerify / validate the rotation direction of each zone
damper.
oInstall the zone controller on the damper and set in place
with screw.
oWhile pressing the actuator’s clutch button, turn the clamp,
the damper should turn freely (a slight off axis movement).
oAdjust mechanical stoppers on actuator to match the full
rotation of the damper.
oGet the identification address of each zone and write it
down inside the cover (or the back plate) of its’ zone
thermostat (very convenient for service calls).
Sensors and Accessories
PL-T200/T500/T1000
Room sensor: Install 60in from the floor.
Avoid sunny or outdoor walls, diffusers and return grills.
Beware of electrical boxes (lit dimmers)!
Outside air temperature sensor: Install under air inlet hood or on the unit’s north side
IN THE SHADE!!!
PL-OAS
PL-DS
Supply air temperature sensor: Install after the bypass damper junction
Return air temperature sensor: Install before the bypass damper junction (no turbulence)
PL-MLP
Static pressure sensor: To be installed 2/3rds of the main ventilation duct’s length.
AFS
Proof of fan (flow switch): Install near the supply air temperature sensor (no turbulence).
Plug the high pressure (+) Pitot tube in the air duct. Remove the low pressure cap and
leave free.
CO2
CO2 Sensor: Install in the return duct before the bypass junction.
xMB24-SR
Bypass damper actuator: Mark the damper position on the shaft and validate its
opening direction.
5
7

REV 7.0.0 / PL-TRA-STARTUP-EN 5
v.7
Part 3 : Electrical Installation / Connections
VAV Zone Controller
Inputs
oWall sensor (PL-T200/T500/T1000) :
#18/2 + #24/2 (supply & communication)
–or- LVT 4-conductor cable* connected
to terminals #9 to #12 *Small gauge,
shielded cable preferable.
oChangeover sensor (if required):
directly to terminals #13 & #14
Supply
o5VA per zone / max 100VA per circuit
oLink the #1 & 2 terminals in a daisy chain
Respect the live / common on all
controllers
oGround the common (at central
transformer)
oMetallic ground all the controllers’
commons. (multiple transformers)
oDigital output (24Vac or dry contact): For dry contact, connect
to terminals #5 and #6 (no jumper between #4 and #5). For
24Vac output, connect to terminals #3 and #6 (jumper installed
between terminals #4 and #5)
oAnalog output (0-10Vdc) : connect to
terminals #7(-) and #8(+). Respect the
polarities.
Network cabling
* Enable
terminating resistor
jumpers (TERM) at
both ends of the
daisy chain (Unit
controller and/or
zone controllers).
Input/Outpout wiring for a
VC-2000
Part 3 - Electrical Installation / Connections
VAV Zone Controller
Inputs
•Wall Sensor (PL-T200/T500/T1000): 4 wire cable (#22/4
shielded cable recommended) connected to terminals
#9 to #12.
• Changeover Sensor (if required): directly to terminals
#13 & #14.
Supply
• 5VA per zone / max 100VA per circuit.
• Link the #1 & #2 terminals in a daisy chain.
• Respect the live / common polarity on all controllers.
• Ground the common (at central transformer).
• Ground all controllers’ commons. (if using multiple
transformers).
• Analog Output (0-10VDC): connect to terminals #7(-)
and #8(+). Respect the polarities.
Digital Output (24VAC or dry contact): For dry contact, connect to terminals #5
and #6 (no jumper between #4 and #5). For 24VAC output, connect to terminals
#3 and #6 (jumper installed between terminals #4 and #5).
5

REV 7.0.0 / PL-TRA-STARTUP-EN 6
v.7
Part 3 : Electrical Installation / Connections
VAV Zone Controller
Inputs
oWall sensor (PL-T200/T500/T1000) :
#18/2 + #24/2 (supply & communication)
–or- LVT 4-conductor cable* connected
to terminals #9 to #12 *Small gauge,
shielded cable preferable.
oChangeover sensor (if required):
directly to terminals #13 & #14
Supply
o5VA per zone / max 100VA per circuit
oLink the #1 & 2 terminals in a daisy chain
Respect the live / common on all
controllers
oGround the common (at central
transformer)
oMetallic ground all the controllers’
commons. (multiple transformers)
oDigital output (24Vac or dry contact): For dry contact, connect
to terminals #5 and #6 (no jumper between #4 and #5). For
24Vac output, connect to terminals #3 and #6 (jumper installed
between terminals #4 and #5)
oAnalog output (0-10Vdc) : connect to
terminals #7(-) and #8(+). Respect the
polarities.
Network cabling
* Enable
terminating resistor
jumpers (TERM) at
both ends of the
daisy chain (Unit
controller and/or
zone controllers).
Input/Outpout wiring for a
VC-2000
Network Cabling
• Check for continuous daisy-chain to all zone controllers. Do not link in a star pattern.
• Check the A / B network polarity on all zones and unit controller; must all be identical.
• Join all shields at each controller’s junction and connect one end only to the ground lug in the central panel only
(unit controller).
• Check / activate terminating resistor jumpers (“TERM”) on each of the controls located at both ends of the commu-
nication network.
•The network cable must be shielded and twisted, 2 conductors AWG #24, low capacitance only, max length
3200ft (1000m).
•FASTEN YOUR WIRES TOGETHER AND SECURE THEM TO THE VAV BOX! (TIE-WRAPS, TAPE, ETC).
The neutral of the 24VAC supply of the
zones must be connected to ground.

REV 7.0.0 / PL-TRA-STARTUP-EN 7
v.7
Network cabling (continued)
oCheck for continuous daisy-chain to all zone controllers. Do not link in a star pattern.
oCheck the A / B network polarity on all zones and unit controller; must all be in phase.
oJoin all shields at each controller’s junction and connect one end only to the ground lug in the central
panel only (unit controller).
oCheck / activate terminating resistor jumpers (“TERM”) on each of the controls located at both ends of
the communication network.
oThe network cable must be shielded and twisted, 2 conductors AWG #24, low capacitance only.
oFASTEN YOUR WIRES TOGETHER AND SECURE THEM TO THE BOX! (TIE-WRAPS, TAPE,
ETC)
Unit controller
oCheck that all (input and output) connections match that of the supplied wiring diagram.
oCheck that all shielded cables have their shield grounded at the central panel’s ground lug.
oCheck that the multi-conductor control cable to the unit is connected and 24vac is available.
oThe control panel’s 24vac power is fed by the RTU.
oNever connect temperature or other sensors using spare conductors of AC carrying control cable, as
this might cause magnetic interference and lead to erratic data reading. Sensors must use dedicated
shielded wiring.
M2000 wiring details
Unit Controller
• Check that all (input and output) connections match that of the supplied wiring diagram.
•Check that all shielded cables have their shield grounded at the central panel’s ground lug.
• Check that the multi-conductor control cable to the unit is connected and 24VAC is available.
•The control panel’s 24VAC power is fed by the RTU.
• Never connect temperature or other sensors using spare conductors of AC carrying control cable, as this might
cause magnetic interference and lead to erratic data reading. Sensors must only use dedicated shielded wiring.
M2000 Wiring Details
7

REV 7.0.0 / PL-TRA-STARTUP-EN 8
Part 4 - Start Up
Powering up the zones
• Check if all terminating resistor jumpers are in place (both ends of the communication loop).
• Power up the zones’supply transformer(s).
• Make sure that each controller displays it’s ashing “heartbeat” light.
• If zone controllers are supplied with digital display sensors, (PL-T500/T1000), make sure the sensor display lights up
and shows ambient temperature.
• Make sure all zone dampers open in the proper direction (yellow “status” light). If not, invert rotation (procedure
described in the V.2.0 troubleshooting guide).
Powering up the Unit Controller
• The air handling unit (or RTU) must be on, as it supplies 24VAC power to the unit controller.
• Power up the controller by closing fused switch (located in the control cabinet).
• Check that the controller lights up both power indicators (red) 24VAC and 5VDC.
• Check that the controller displays it’s blinking heartbeat (written: hbeat).
• Approximately ten seconds after powering up, check the network communication status lights “NETREC” and
“NETSND” on the controller. They should briey blink together, every three seconds or so, to conrm communication
is established with the zones.
•Inspect all zone controllers as well, making sure the same status lights (NETSND in red and NETREC in green)
also blink at the same rate as the unit controller.
• About 15 seconds following power up, the unit controller should start the ventilation (output DO1 activated).
• Approximately 5 minutes following power up, the heat or the air conditioning of the unit can come on (initial power
up o-delay protection).
Quick verification (without the Prolon Focus software and computer)
• Temporarily disconnect the supply air sensor from the unit controller (do not forget to reconnect!)
Option 1 - Cooling
• To verify cooling, each zone ambient temperature must
be equal or above the zone’s cooling low setpoint limit
(default: 69ºF / 20.5ºC).
• Set all the thermostats to call for cooling.
• The Unit controller will activate its cooling output(s) if
all limits, protections and delays have been acknowledged.
• Check that all zone dampers open for cooling as
requested.
• Reconnect the supply air sensor to the unit controller.
Option 2 - Heating
• To verify heating, each zone ambient temperature must
be equal or under the zone’s heating high setpoint limit
(77 ºF / 25ºC by default).
• Set all the thermostats to call for heat.
• Check for zone terminal heating operation (if applicable).
• The Unit controller will activate its heating output(s) if
all limits, protections and delays have been acknowledged.
• Check that all zone dampers open for heating as
requested.
• Reconnect the supply air sensor to the unit controller.

REV 7.0.0 / PL-TRA-STARTUP-EN 9
Part 5 - Prolon Focus (Computer Access and Control)
Computer and software
• In order to avoid problems and delays, make sure to follow these guidelines.
• Use a laptop computer (with Windows 7 or later software) as well as the most recent version of Prolon Focus. Visit the
website www.proloncontrols.com to download the latest version.
• If you are using the Prolon RS485 communication interface for the rst time, you must install the driver software that
comes with it.
• Once installed, you must validate the communication port (COM) number your computer assigned to that interface.
• To nd out, go to the “Control Panel Settings” on your computer, then “Systems”, then on Hardware and nally click
on“Device Manager”. (Start / Control Panel / Hardware / Device Manager). Click on‘‘Ports COM & LPT’’. The COM port
identied as ‘‘USB Serial Port COMx” or“RS485 Isolated Port COMx’’ will be the one to use.
Opening a session on Prolon Focus
• Connect the communication interface to the computer (USB cable or serial depending on the model).
• Connect the network cable (CAT5e / RJ45 male plug) from the interface output to the communication port of the unit
controller in the panel (input RJ45 female jack).
• Open the Focus software by double-clicking on the Prolon icon located on your computer’s desktop.
• Click on “Create a new project”.
• Click on ‘’Serial Connection’’.
• Select amongst the list the communication port number you previously retrieved.
• A message will appear in the bottom left corner of the screen to conrm“Port COM (x) opened”.
Setting up a new system
• From the left hand list, double click the desired unit controller icon (eg: ‘’Rooftop’’ for a C1000 RTU or M2000 RTU air
conditioning controller).
• Enter the identication address (as on the controller, also determined by the position of the addressing dip-switches).
• A bright colored icon (green, red or blue) will appear at the top of the screen, symbolizing the unit.
• Move the mouse’s cursor and point the icon, right-click on the mouse to browse the command menu.
• Click on“Get List”, the unit controller will scan its’network and update the list of zones and these zone icons will begin
to appear on the screen.
• Validate the list of zones, checking all addresses and making sure they have all shown up, according to the project’s
shop drawings. If some icons are missing, ensure that the controls are supplied in 24VAC. Check the connection to the
power supply and to the network (those connections are polarized) and also check on the controller card the status of
the following blinking LED’s: hbeat, netrec and netsnd.
• Conrm that all the zones appear in one of the following three colors according to their particular request: green=
satised, red=heating, blue=cooling.
• Should an icon appear in grey, communication is lost to that zone.
Absolute override authorization
• Double-click the unit controller and select the “Cong” menu on the top left corner. Then select “Edit display” menu.
9

REV 7.0.0 / PL-TRA-STARTUP-EN 10
• At the bottom of this page check the“Enable Absolute Overrides” and click “OK” to conrm your acceptance.
• Then click “Apply”.
Adjusting the bypass damper
• Click on the “Home” button in the upper right to return to the unit controller’s home page, click on “Network” then
“Other” at the bottom of the list.
• Check the “Zone Damper Override”, enter 100% and click “Apply”.
• Wait for all the zone dampers to display 100% open on the screen. If this has not been checked before, physically
conrm that the dampers are open. If necessary, inverse the zone(s) damper’s opening direction (see instructions
below).
• Return to the home page and make sure the bypass damper is fully closed (0%). Validate physically.
• Read the static pressure value on the home screen and then adjust the set point by increasing it by 20% of the reading.
To do so, click on “Cong” then “Pressure” to access the pressure management menu for the bypass damper. Adjust
the set point according to your calculations and adjust the dierential to 20% of the set point value.
• Eg: pressure read: 0.20’’, adjust set point to (pressure read + 20%) = 0.24’’, 0.05’’ = dierential.
• Return to the “Zone Damper Overrride” and enter 25%, click “Apply”.
• Check the bypass damper opening on the home page as well as physically according to the increase in pressure.
Inverse the opening direction of the bypass damper if need be.
• Return to the home page, click “Network” and then “Other” .Remove the “Zone Damper Override”. Press “Apply”.
Cooling and heating operations
• From the home page of the unit controller, point and right-click each item to be checked in order to activate the
override mode. You can check the economizer’s damper(s) (if applicable), the cooling stage(s), the heating stage(s)
and/or the modulating heating output from the unit. Physically check the proper functioning of each of these
elements.
• Return to the “Edit Display” menu, and remove the absolute overrides and click “Apply”.
Inverting a zone damper’s opening direction
• To invert the damper’s opening direction, double-click the zone controller icon to open its menu, then double-click
directly on the zone damper shown on the screen. You then access the page: “Damper Conguration”.
• At the bottom of this page, “Damper Setup”, choose the correct opening direction (clockwise or counterclockwise)
and then click “Apply”. Physically conrm.
Date and time
• From the unit controller’s home screen, check that the date and time are correct. To modify them, click on “Edit” and
then click “Copy” to copy the computer’s date and time, or manually type the change then click “OK”.
Schedule
• Also from the unit’s home screen, click “Network” and then “Schedule” to access the schedule conguration page.
• Double-click the “ON”line in the“Monday”column. While the cursor ashes in the middle of this period, type the start
“Occupied”pediod. Eg: 6 to start the ‘occupied’ period at 6:00am or 630 for 6:30am.
• Double-click the “OFF” line in the “Monday” column. While the cursor ashes in the middle of this period, enter the
time to end the “Occupied” period. Eg 16 for 16:00 (4:00pm) or 1745 for 17:45 (5:45pm).

REV 7.0.0 / PL-TRA-STARTUP-EN 11
• To copy a schedule, click the day to copy on the “Copy from”dropdown list and then check the other days which will
have the same schedule in the“Paste to” list. Click “Paste”and then click “Apply”.
Rename zones and units
• From the basic system screen, right-click a zone or unit controller’s icon, select “Rename” and type the zone or unit’s
name and click “OK”.
Save
• Click on “File” in the upper left corner. Choose “Save” or “Save As…” to save the conguration le (.prl le).
Exit
• Click on “File” in the upper left corner, choose “Exit” or click on the X in the upper right corner to close Focus.
Advanced Configurations
• Focus provides many other settings to optimize the operation of your systems. However this guide is a quick start
guide, we invite you to consult the complete documentation online www.proloncontrols.com .
11
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PK-TRA-STARTUP-EN
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No part of this document may be photocopied or reproduced by any means, or translated to another language without prior written
consent of Prolon. All specications are nominal and may change as design improvements are introduced. Prolon shall not be liable for
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