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Prolon VC2000 Series Technical Reference Manual

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Summary of Contents for Prolon VC2000 Series

  • Page 2 © Copyright 2024 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...

  • Page 3: Table Of Contents

    Low Signal Quality Best Practices (Focus PC only) ......................6-12 Section 7 - Connection Using Laptop How to Connect a Computer to Prolon Controllers ......................7-1 Section 8- Navigating using laptop & Prolon Focus Prolon Focus - Computer Access and Controller ........................8-1 Testing the System ................................

  • Page 4: Section 1 - Introduction

    Section 1 Introduction...

  • Page 5: About Us

    The New Standard in Light Commercial Building Automation About Us Founded in 1998, Prolon is a manufacturer of an HVAC control system dedicated to small and medium sized commercial buildings. Its product lineup consists of application-specific configurable controllers designed for all types of HVAC equipment, meeting the needs of retro-fit as well as new construction projects.

  • Page 6: Prolon Key Concepts

    Prolon goes above and beyond the competition with its Prolon Focus software platform. Here’s why: Focus is a free utility software used to access and navigate within the Prolon ecosystem. It is complete with built-in graphics and intuitive configuration menus, so no programming is involved.

  • Page 7: Prolon Product Guide

    Wall Temperature Sensors Bluetooth Adapter T200, T500 and T1000 PL-485-BT • With or without digital display (LCD Screen) • Connect any laptop, smartphone or tablet to any Prolon device. • Configure every parameter of a VAV Controller * • Compatible with iOS and Android devices equipped with • Use remote sensor(s) for space temperature averaging * Bluetooth LE • Choose among a variety of casing and label colors! • Range extends up to 300ft...
  • Page 8 M2000 & C1050 Series Rooftop Controller Heat Pump Controller • Compatible with both VAV & VVT systems • Water or Air sourced heat pumps • Available for zoning, as well single-space rooftop units • Compatible with dual fuel units • Internal schedule with 24/7/365 scheduling • Control multiple compressors, auxiliary heat, fan, and • Demand-control ventilation available economizer...

  • Page 9: Factory Wired Control Cabinets

    Factory Wired Control Cabinets Prolon offers its M2000 and C1050 controllers in prewired, UL certified NEMA1 panels ready for installation on any project. Their compact design allows multiple panels to be installed in a tight workspace and leave a clean, professional appearance.

  • Page 10: Section 2 - System Architecture

    Section 2 System Architecture...

  • Page 11: Typical Prolon System Architecture

    Typical Prolon System Architecture Internet Tablet / Laptop PL-NC2000 Laptop Connection/ Mobile device (App) PL-BT-485 NET Communication Bus PL-M2000-RTU PL-VC2000 PL-VC2000 PL-VC2000 PL-T1000 PL-T1000 PL-T1000 NET Communication Bus PL-M2000-RTU PL-VC2000 PL-T1100 PL-C1050-FLX PL-T1000 NET Communication Bus PL-M2000-HP PL-VC2000 PL-VC2000 PL-VC2000...

  • Page 12: Master - Follower Communication Principle

    Master - Follower Communication Principle Although they can all operate as stand-alone, Prolon controllers, once they are connected, all play a specific role on a network, which is determined by their application firmware: They are either a Master or a Follower.

  • Page 13: Function-Related Network Positioning Of Controllers

    Such is the case with the Prolon FlexIO controller (C1050-FLX / M2000-FLX) that can either work stand-alone but also under the authority of a Master controller such as the Roof Top Unit (C1050-RTU / M2000-RTU). The FlexIO controller then becomes an I/O expansion module, further pushing the design possibilities of the RTU controller.

  • Page 14: Int/Net Communication Bus Hierarchy

    INT/NET Communication Bus Hierarchy All controllers, thermostats and communicating wall sensors have at least one, if not two communication ports, allowing them to communicate on various network buses at once. INT Communication Bus NET Communication Bus Also known as “Interface”, is the upper echelon Also known as “Network”, this communication bus is used by Master controllers to allow them to talk with their own communication bus connecting the Network Controller...

  • Page 15: Section 3 - Network Topology

    Section 3 Network Topology...

  • Page 16: Network Layout

    Network Layout Acceptable Not acceptable Whether it’s on the INT or NET comm networks, all Prolon • A Star configuration is not acceptable controllers communicate over an RS-485 network topology, that requires a DAISY CHAIN wiring configuration. Each daisy chain segment is an open loop design, with two distinct extremities to the chain (a beginning and an end).

  • Page 17: Addressing Principles

    Addressing Principles All Prolon controllers must have a valid address to be able to communicate on a network. Some Prolon controllers use physical dipswitches, others must be addressed using software or a digital wall sensor with display. (Consult section #5: “Controller addressing methods”)

  • Page 18: Typical Prolon Wiring Schematics

    Typical Prolon Wiring Schematics BIAS ON TERM ON BIAS ON 24Vac PL-NC2000 Network Controller + PL-M2000 Unit Controller(s) (INT Comm Bus) PL-NC2000 NETWORK CONTROLLER (optional) BIAS OFF BIAS OFF BIAS OFF TERM OFF TERM OFF TERM ON BIAS OFF BIAS OFF...
  • Page 19 Typical Prolon Wiring Schematics ProLon Communication and Power Supply (24 VAC) Wiring : Zone controller and Digital Sensor Recommended wiring for communication: #24/2, stranded, twisted and shielded, low-capacitance. Recommended wiring for 24vac supply: #18/2, stranded PL-VC2000 Zone Controller + Digital Wall Sensor • Recommended wiring for communication:...
  • Page 20 PL-C1050 Single-Zone Controller + Digital Wall Sensor • Recommended wiring for communication: #22/2, stranded, twisted and shielded, low- 24VAC capacitance. Net A A (+) • Recommended wiring for 24vac supply: Net B B (-) #18/2, stranded. 24VAC WALL SENSOR (PL-T1000/PL-T500/PL-T200) 24 VAC Transformer...

  • Page 21: Section 4 - I/O And Wiring Diagrams

    Section 4 I/O and Wiring Diagrams...
  • Page 22 PL-VC2000(-PI) (VAV) Network communication General Purpose Analog Input (0-5 VDC, 4-20mA, 10K thermistor) Supply, Radiant, Zone, Occupancy, Discharge Network communication Digital Sensor (T1000, T500 or T200) / Remote computer with Focus General Purpose Analog Input (0-5 VDC, 4-20mA, 10K thermistor) Supply, Radiant, Zone, Occupancy, Discharge Analog Output: Demand, Duct Heater, Fan Powered Box Series or Parallel, Radiant Floor,...
  • Page 23 PL-C1050-VAV INT Port: Incoming Modbus RS485 communication from digital sensor -OR- Remote computer with Prolon Focus Software 24VAC Power supply to digital sensor (24 VAC) NET Port: Incoming Modbus RS485 communication -OR- BACnet MS/TP Digital Input for Night Setback / Stanby Mode...
  • Page 24 PL-T1100 (Thermostat) NET A Network communication NET B 24 VAC Power source of the controller 24 VAC Digital Output - Sink, TRIAC 24 VAC NET A (Max current: 300mA) Network communication NET B Analog Output (0-10VDC) 24 VAC Power source of the controller (Max current: 40mA) 24 VAC AUX IN...
  • Page 25 PL-T1000 (Digital Wall Sensor) INT + Interface communication INT - 24 VAC Power source of the controller 24 VAC AUX IN Auxiliary / Radiant Floor temperature sensor (10K thermistor) RJ45 PL-T500 / PL-T200 (Digital Wall Sensor) INT + Interface communication INT - 24 VAC Power source of the controller...
  • Page 26 PL-M2000-MUA (Air Make-Up) Bottom Row: Common for all inputs CO2 (4-20mA) / Building Pressure (0-5VDC) INT Port : Incoming RS485 Zone Temperature (10K Thermistor) Network Communication Outside Temperature (10K Thermistor) (modbus) Supply Temperature (10K Thermistor) Manual Reset Proof of Fan AO 3 - Variable Frequency Drive Proof Outside Air Damper Open AO 2 - Cooling...
  • Page 27 Zone temperature setpoint (0-10K potentiometer)/ RTUS Zone temperature sensor (10K thermistor) / Return humidity sensor (0-5 VDC) INT Port: Prolon Digital Temperature RTUS Outside Humidity (0-5VDC) / Enthalpy Contact Sensor - OR - Incoming RS485 Network Zone temperature sensor (10K thermistor) /...
  • Page 28 PL-C1050-RTU PL-C1050-RTUS INT Port: Prolon Digital PL-C1050-RTU/RTUS (Zoning & Single-Zone Rooftop Controller) INT Port: Incoming RS485 Temperature Sensor Network communication - OR - (Modbus) Incoming RS485 Network Communication (Modbus) PL-C1050-RTU PL-C1050-RTUS PL-C1050-RTUS: Power supply to digital sensor (24 VAC) INT Port: Prolon Digital...
  • Page 29 - OR - Network controller (Dual Zone temperature setpoint (0-10K potentiometer) RJ45 and Terminal Blocks) Zone temperature setpoint (0-10K potentiometer) INT Port: Prolon Digital Temperature Zone temperature sensor (10K thermistor) Sensor - OR - Incoming RS485 Network INT Port: Prolon Digital Temperature...
  • Page 30 PL-C1050-HP PL-C1050-HPS PL-C1050-HP/HPS (Zoning & Single-Zone Heat Pump Controller) INT Port: Prolon Digital Temperature Sensor INT Port: Incoming RS485 - OR - Network communication Incoming RS485 Network Communication (Modbus) (Modbus) PL-C1050-HP PL-C1050-HPS PL-C1050-HPS: Power supply to digital sensor (24 VAC)
  • Page 31 PL-M2000-BLR (Modulating Boiler) Bottom Row: Common for all inputs INT Port : Incoming RS485 Network Communication Disable Boiler Call (Dry Contact) (modbus) Use Max Heat Setpoint (Dry Contact) AO3 - Modulating Boiler Stage 2 Proof of Pump 2 (AO1) (Dry Contact) (0-10 / 2-20 / 0-5 VDC) Proof of Pump 1 (DO5) (Dry Contact) AO2 - Modulating Boiler Stage 1...
  • Page 32 PL-M2000-BLR (Staged Boiler) Bottom Row: Common for all inputs INT Port: Incoming RS485 Network communication Disable Boiler Call (Dry Contact) (Modbus) Use Max Heat Setpoint (Dry Contact) AO3 - Valve (0-10 / 2-10 / 0-5 VDC) Proof of Pump 2 (AO1) (Dry Contact) Proof of Pump 1 (DO5) (Dry Contact) Return Water temp sensor (10K thermistor) Supply Water temp sensor (10K thermistor)
  • Page 33 PL-C1050-BLR (Modulating Boiler) INT Port: Incoming RS485 Network communication (Modbus) 24VAC NET Port: Incoming RS485 Network communication (Modbus) External dry contact for proof of pump Supply water temperature sensor (10K thermistor) Common for all the inputs Return water temperature sensor (10K thermistor) Outside air temperature sensor (10K thermistor) Output 5 - Modulating Boiler (Analog 0-10 / 2-10 / 0-5 VDC)
  • Page 34 PL-C1050-BLR (Staged Boiler) INT Port: Incoming RS485 Network communication (Modbus) 24VAC NET Port: Incoming RS485 Network communication (Modbus) External dry contact for proof of pump Supply water temperature sensor (10K thermistor) Common for all the inputs Return water temperature sensor (10K thermistor) Outside air temperature sensor (10K thermistor) Output 5 - Valve (Analog 0-10 / 2-10 / 0-5 VDC)
  • Page 35 PL-M2000-FLX (FlexIO Controller) Bottom Row: Common for all inputs Analog Input 9 INT Port : Incoming RS485 Analog Input 8 Network Communication Analog Input 7 (modbus) Analog Input 6 Analog Input 5 Analog Input 4 Analog Output 3 Analog Input 3 Analog Output 2 Analog Input 2 Analog Output 1...
  • Page 36 PL-C1050-FLX (FlexIO Controller) INT Port: Incoming RS485 Network communication (Modbus) 24VAC 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...
  • Page 37 PL-M2000-CHL (Chiller Controller) Bottom Row: Common for all inputs Alarm INT Port : Incoming RS485 Water Pressure Network Communication Condenser Water Temperature Leaving (modbus) Condenser Water Temperature Entering Proof of Pump 2 Proof of Pump 1 Chiller 4 Return Water Temperature VFD Pump 2 Supply Water Temperature VFD Pump 1...
  • Page 38 PL-C1050-CHL (Chiller Controller) INT Port: Incoming RS485 Network communication (Modbus) 24VAC NET Port: Incoming RS485 Network communication (Modbus) Proof of Pump Supply water temperature Common for all the inputs Return water temperature Condenser water temp entering (Water Cooled Chiller) / Outside air temperature (Air Cooled Chiller) Chiller 3 Chiller 2...
  • Page 39 Bottom Row: Common for all inputs INT Port: Incoming Modbus RS485 AI8 - Alarm communication from digital sensor -OR- Remote computer with Prolon AI7 - Proof of Fan Focus Software AI6 - Zone Setpoint AI5 - Zone Air Temperature AI3 - Supply Air Temperature...
  • Page 40 Bottom Row: Common for all inputs INT Port: Incoming Modbus RS485 AI8 - Alarm communication from digital sensor -OR- Remote computer with Prolon AI7 - Proof of Fan Focus Software AI6 - Zone Setpoint AI5 - Zone Air Temperature AI4 - Cold Water Temperature (optional)
  • Page 41 PL-C1050-FCU (Fan Coil Unit Controller with two-pipe system) INT Port: Incoming Modbus RS485 communication from digital sensor -OR- Remote computer with Prolon Focus Software 24VAC Power Supply to digital sensor (24VAC) NET Port: Incoming RS485 network communication (Modbus) DI - Alarm / Proof of fan...
  • Page 42 PL-C1050-FCU (Fan Coil Unit Controller with four pipe system) INT Port: Incoming Modbus RS485 communication from digital sensor -OR- Remote computer with Prolon Focus Software 24VAC Power Supply to digital sensor (24VAC) NET Port: Incoming RS485 network communication (Modbus) DI - Alarm / Proof of fan...
  • Page 43 PL-C1050-HU (Humidity Controller) INT Port: Incoming RS485 Network Communication (Modbus) 24VAC NET Port: Incoming RS485 Network Communication (Modbus) External dry contact for proof of fan Supply humidity sensor (0-5 / 0-10 VDC) Common for all the inputs Room / Return humidity sensor (0-5 / 0-10 VDC) Outside temperature sensor (10K thermistor) Output 5 - Humidi er (Analog 0-10 / 2-10 VDC) Output 4 - Humidi er (Digital - ON/OFF)
  • Page 44 PL-C1050-WLC (Water Loop Controller) INT Port: Incoming RS485 Network communication (Modbus) 24VAC NET Port: Incoming RS485 Network communication (Modbus) Auxiliary Digital Input Supply water temperature sensor (10K thermistor) Common for all the inputs Return water temperature sensor (10K thermistor) Auxiliary temperature sensor (10K thermistor) Output 5 - Water Tower Stage 2 (Analog 0-10 VDC) Output 4 - Water Tower Stage 1...
  • Page 45 Panel Wiring Single M2000 (PL-PANEL-M2000-RTU) Internal Electrical Wiring Diagram 3A 250V Cartridge Fuse Legend R1 - R2 - R3 - R4 - R5: Single pole, double throw relays XF: Interconnection carrying 24VAC Field Wiring Details ALL TERMINALS: Use Copper Conductors Only, 105°C/220°F, Maximum Torque Conductor Mounting: 0.5Nm Terminal Function Ratings...
  • Page 46 Panel Wiring Single C1050 (PL-PANEL-C1050-RTU) Internal Electrical Wiring Diagram 24VAC 3A 250V Cartridge Fuse Legend R1 - R2 - R3 - R4 : Single pole, double throw relays XF: Interconnection carrying 24VAC 4-25...
  • Page 47 Panel Wiring Master (PL-PANEL-NC2000) 1 2 3 4 5 6 7 8 R5-1 R4-1 R3-1 R2-1 R1-1 3A 250V Cartridge Fuse USB Cable to 10” Display Tablet (Available only for PL-PN2-NC-HMI-M2-RTU/S) Legend: Interconnection carrying M2000 INT B(-) Interconnection carrying 24 VAC Interconnection carrying M2000 INT A(+) Single pole, double throw relay 4-26...

  • Page 48: Section 5 - Connections, Setup & Start-Up

    Section 5 Connections, Setup & Start-up...

  • Page 49: Connecting Sensors & Peripherals

    Connecting Sensors & Peripherals Prolon controllers come equipped with one or more inputs designed to monitor the many variables required by their control sequences (temperature, humidity, pressure, dry contact, etc.). These inputs all share a single electrical common connection. (Refer to I/O section for specific hardware / profile input configuration.)

  • Page 50: Input Jumper Configuration

    Input Jumper Configuration The VC2000, C1050 and M2000 Prolon controllers come equipped with analog input configuration jumpers that allow the user to select the signal mode of the associated analog input. These come factory-set for their given application but can be modified in the field to accommodate the signal provided by an active transmitter, or when the controller is reprogrammed into another application with different input signal mapping.

  • Page 51: Controller Addressing Methods

    It has a factory default address of #101, PL-T1000, PL-T500 and PL-T200 which can be changed via software or the keypad menu Prolon Digital Wall Sensors (PL-T1000/T500/T200) DO NOT structure on the device (see Thermostat Hardware Guide for HAVE ADDRESSES.

  • Page 52: Cabling

    Cabling Prolon controllers use readily available HVAC industry standard wiring for its connections. Some care must be taken however in choosing the proper wire for the application. • Passive temperature sensors: Twisted & shielded con- • Power supply / control outputs: LVT low voltage control trol wire, typically #18 gauge.

  • Page 53: System Start-Up

    System Start-up Before powering up any Prolon control system for the first time, a safety check list should be performed on all devices, their wiring, and connections. This will ensure a successful start-up. (Consult: Installation Checklist PL-INSTL- CHECKLIST-EN document for complete details).
  • Page 54 The heartbeat confirms normal controller operation. Typically, air handler controllers (RTU/S, HP/S, FCU, MUA) are powered from the unit’s own 24VAC source. Zone controllers and thermostats use dedicated supply transformers. (Consult the Prolon PL-TRA-Startup-EN Installation & Startup Guide for more details) For addition details, you may also consult the Prolon Troubleshooting guide.

  • Page 55: Section 6 - Tree-Com Wireless Communication Module

    Section 6 TREE-COM Wireless Communication Module...

  • Page 56: Pl-Tree-Com Principles

    PL-TREE-COM Principles The Prolon PL-TREE-COM is a wireless communication device that transmits and receives Modbus RS485 data over radio frequency communication (2.4GHz) Its goal is to wirelessly extend, complement, or replace standard RS485 wired daisy-chains, where a physical connection would be impractical or uneconomical. (Figure 1) The TREE-COM modules communicate on dedicated wireless subnet "channels", where a unique "ROOT" module talks...
  • Page 57 5. Channel number configuration A unique channel number on each TREE-COM must be configured by setting the first 7 switches on the channel number dipswitch block to the desired value. These switches are numbered from 1 to 7 and represent a binary value from 0 to 64 (0, 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 value of the TREE-COM channel used.
  • Page 58 8. LEDS The PL-TREE-COM comes equiped with five LEDs to indicate device status. (Figure 6) 8a) HBEAT (BLUE): This LED simply indicates that the device is powered and operating. It should blink once every second, regardless of RS485 or Wireless communication. 8b) CONN (BLUE)*: This LED indicates if other devices have been found on the same subnet as this device. If so, then the devices are ready to share their RS485 information.

  • Page 59: Pl-Tree-Com Installation Scenarios

    PL-TREE-COM Installation Scenarios Single-Zone Unit Controllers with Digital Wall Sensor The RTUS, HPS or FCU controllers can be connected to their respective communicating digital wall sensor, using the PL-TREE- COM device. **Important** A PL-RS wall sensor CANNOT be connected using a PL-TREE-COM (M2000 only). The PL-TREE-COM connected to the communicating wall sensor must be set as the "ROOT".
  • Page 60 Master Controller with multiple Follower Controllers (fully wireless network) Follower Controllers (VC2000, C1050-VAV, T1100, FLX, BLR, etc.) can be connected wirelessly to a Master Unit Controller such as a PL-M2000-HP or RTU or a PL-C1050-RTU or HP. Each controller must have its own dedicated PL-TREE-COM device The PL-TREE-COM connected to each Follower Controller must be in set as the "LEAF".
  • Page 61 PL-TREE-COM Installation Scenarios Master Controller with multiple Follower Controllers (wired/wireless - hybrid network) Example 1 It is possible to create hybrid networks, where wireless communication supports and complements wired daisy-chains. In this situation, a PL-TREE-COM will be added to the daisy-chain to gap the link between the Master and all its Followers. (Figure 11) The PL-TREE-COM on the M2000 Master's side must be connected in the NET port and be set as the "ROOT".
  • Page 62 Example 2 A wired communication network can be spliced and re-united using TREE-COM modules, regardless of their location within a Prolon network. (Figure 12) The TREE-COM that is hardwired to the Modbus Master (PL-M2000-RTU) must be set in "ROOT" mode The TREE-COM hardwired to the Follower controllers must be set to "LEAF"...
  • Page 63 PL-TREE-COM Installation Scenarios PL-NC2000 connected to a group of Master (PL-M2000 or PL-C1050) The communication network between any Master Controller and the PL-NC2000 can be connected wirelessly using the PL- TREE-COM. (Figure 13) The PL-TREE-COM connected to the PL-NC2000 via the RS-485 OUT port must be set as the "ROOT". The PL-TREE-COM connected to individual PL-M2000, or PL-C1050 via the INT communication port must be set as the "LEAF".

  • Page 64: Measuring Signal Quality With Nfc

    Measuring Signal Quality with NFC The incoming signal quality from a "ROOT" must be measured at a "LEAF" device, using the Prolon Focus app on a mobile device with NFC capabilities. A measurement only becomes possible on a “LEAF” device, once it has established a connection with its "ROOT" module. Measuring a "ROOT" module using NFC will not yield signal quality, but rather number of associated "LEAF" modules it is able to communicate with. To use this feature, the NFC function must first be enabled on the mobile device. The NFC reading may take a few seconds to display.

  • Page 65: Android

    Android To access NFC, tap on the vertical ellopsis icon at the Tap on "Settings". top right of the screen. Approach and hold the back of the mobile device very Once detected, a popup will show you the information near the powered up TREE-COM module. about the TREE-COM found.

  • Page 66: Ios

    To scan the TREE-COM, tap on the settings icon in the Tap on "Scan PL-TREE-COM". left bottom corner. When ready to detect, approach and hold the back of Once detected, a popup will show you the information the mobile device very near the powered up TREE- about the TREE-COM found.

  • Page 67: Low Signal Quality Best Practices (Focus Pc Only)

    Low Signal Quality Best Practices (Focus PC only) A signal quality of 30% to 60% is considered low quality. To communicate succesfully with signals in this range, it is best to increase the number of retries in Focus (PC) to 10 or 20 attempts, so to reduce the likelyhood of failure. Here is the procedure: 1. Click on “Project” on the top left of your Focus screen. 2. Click on “Setup”. 6-12...
  • Page 68 3. Click on “Connection". 4. Enter the desired Retry number. 6-13...

  • Page 69: Section 7 - Connection Using Laptop

    Section 7 Connection Using Laptop...

  • Page 70: How To Connect A Computer To Prolon Controllers

    CAT5e cable are provided with PL-485-BT converter. and CAT5e cable are provided with PL-485-BT converter. * The PL-485-BT converter can be used to connect a PC/Mobile device to ANY Prolon controller. This example only shows connections to PL-M2000-XXX and PL-NC2000.

  • Page 71: Section 8- Navigating Using Laptop & Prolon Focus

    Section 8 Navigating Using Laptop & Prolon Focus...

  • Page 72: Prolon Focus - Computer Access And Controller

    Upon opening the software, the following window will appear: > Log in my Cloud account > Continue as a Guest • Select: “Continue as a guest”. * *Guest mode will be used for the purpose of this guide. For Cloud account information, please refer to the Prolon Focus User Guide. Guest Mode •...
  • Page 73 • Upon selecting a new project, Focus will ask the user how to connect to the system: > Serial connection: choose this option to connect to a NC-2000 using a USB cable, or any Prolon controller using a USB- to-RS485 interface. > IP connection: choose this option to connect to a NC-2000 over the Ethernet port using a static IP address.
  • Page 74 • A bright colored icon (green, red, or blue) will appear at the top of the screen, symbolizing the unit. • If the controller created is a “Master”, such as the RTU, move the mouse’s cursor and point the icon, right-click on the mouse to browse the command menu.

  • Page 75: Testing The System

    Testing the System Absolute override authorization • Back to the RTU unit controller, double-click the icon and select the “Config” menu on the top left corner. Then select “Edit display” from the menu. At the bottom of this page check the “Enable Absolute Overrides” and click “OK” to confirm your acceptance. •...
  • Page 76 • Eg: pressure read: 0.20”, adjust set point to (pressure read + 20%) = 0.24”, 0.05” = differential. 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”...
  • Page 77 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 Configuration”. At the bottom of this page, “Damper Setup”, choose the correct opening direction (clockwise or counterclockwise) and •...
  • Page 78 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 configuration file (.prl file). •...

  • Page 79: Section 9 - Setting Up A Zoning System (Focus Software)

    Section 9 Setting Up a Zoning System (Focus Software)

  • Page 80: Setting Up A Zoning System With Prolon

    Setting up a Zoning System with Prolon The Prolon Control System can be configured for 2 kinds of HVAC zoning system principles, which are commonly known as “VAV” systems and “Changeover Bypass” systems. The following principles are general descriptions of HVAC zoning applications. Although common, these principles must not be interpreted as absolute guidelines when doing system design.

  • Page 81: Creating A Changeover Bypass System ("Vvt")

    1 - Creating a Changeover Bypass System (“VVT”) 1.1 - Applying a Configuration Change When making changes to a controller, do not forget to press the "Apply" button (located on the bottom right of every configuration menu) to upload the changes to the controller. If the "Apply" button is not pressed, the change will not be uploaded to the controller. 1.2 - Configuring a Zone Demand and Voting Weight (Zone Controller menu) 1.2.1 - Zone Demand •...
  • Page 82 • In the “Temperature” menu, the “Proportional”, “Cooling Integral” and “Heating Integral” values will determine how quickly a zone’s demand will increase or decrease depending on the space temperature and the cooling and heating setpoints. (See Annex A for details). Best Practices: It is recommended to set the Cooling Integral and Heating Integral to 30min each. It is not recommended to set the integrals to less than 10 min as this may cause severe zone temperature swings.
  • Page 83 Best Practices: On most systems, it is best to leave the individual zone weight at its default (1). Should you need to increase a zone’s specific weight, set it to 2 or 3. Above that, the influence from any given zone becomes too great and may create a system imbalance. 1.3 - Configuring a Math Function (Unit Controller Menu) • Open a Unit Controller (Zoning Rooftop or Zoning Heat Pump Controller) by double-clicking on its icon. • On the top left of the screen, select “Network” and then “Math”. •...
  • Page 84 1.4 - Assign Math Functions to Cooling and Heating Outputs (Unit Controller Menu) • On the top left of the screen, select “Config” and then “Cooling”. • In the “Cooling” menu, set the “Cooling Demand Source” to “Math 1”. • In the “Heating” menu, set the “Heating Demand Source” to “Math 2”. With this configuration, the Cooling in the Unit Controller will be activated based on the values coming from the Math 1 function, which is a weighted average of all cooling demands from all the followers.
  • Page 85 1.5.1 - Unit with Cooling Stages (On-Off) • Set the Control Mode to “Demand”. • Select how many cooling stages in the “Mechanical Cooling” dropdown list (up to 4x stages). • The setpoint and differential values determine when the cooling stage turns on, and when it turns off. The differential is centered on the setpoint. Di erential Demand Setpoint • Looking at Stage 1, with a setpoint of 35% and a differential of 20%.
  • Page 86 1.5.2 - Unit with Analog Cooling (Modulating) • Select “Analog” in the “Mechanical Cooling” dropdown list. • The setpoint value indicates when the cooling is activated, and the proportional value is the 0-100% output range. Proportional Band Output=0% Output=100% Demand Setpoint •...
  • Page 87 1.6.1 - Unit with Heating Stages (On-Off) • Choose which available outputs will be used for the heating stages (Digital Output 4, Digital Output 5 and/or Analog Output 1). Each output has a dropdown menu. If a specific output is not being used, set it to “OFF” in the output’s respective dropdown list. • If using Analog Output 1 to control an on-off heating stage, be sure to select “Differential”. (“Proportional” is used for a modulating output, details in Section 3.5.2) • The setpoint and differential values determine when the heating stage turns on, and when it turns off. The differential is centered on the setpoint.
  • Page 88 1.6.2 - Unit with Analog Heating (Modulating) • Disable Digital Output 4 and Digital Output 5 by setting them to “OFF” in their respective dropdown list. • Select “Heating” in Analog Output 1. • Select “Proportional”. • The setpoint value indicates when the heating is activated, and the proportional value is the 0-100% output range. Proportional Band Output=0% Output=100%...

  • Page 89: Creating A Vav System (Variable Air Volume)

    2 - Creating a VAV System (Variable Air Volume) 2.1 - Applying a Configuration Change When making changes to a controller, do not forget to press the « Apply » button (located on the bottom right of every configuration page) to upload the changes to the controller. If the "Apply" button is not pressed, the change will not be uploaded to the controller. 2.2 - Configuring the Cooling Stages • On the top left of the screen, select “Config” and then “Cooling”.
  • Page 90 • Choose how to calculate the Supply Temperature according to the following options: > Demand (default) > Fixed > Outside Temp (i.e. outside temperature reset) > Return Temp (i.e. return temperature reset) 2.2.1 - Calculate Supply Setpoint Using “Demand” By setting “Calculate Supply Setpoint using Demand”, the target discharge temperature in the supply will be reset based on the demand coming from a Math function (in this case, source Math 1).
  • Page 91 2.2.3 - Calculate Supply Setpoint Using “Outside Temperature” By setting “Calculate Supply Setpoint using Outside Temp”, the target discharge temperature in the supply will be reset based on the outside temperature. Outside Temperature 2.2.4 - Calculate Supply Setpoint Using “Return Temperature” By setting “Calculate Supply Setpoint using Return Temp”, the target discharge temperature in the supply will be reset based on the return temperature.
  • Page 92 • Enter the Outside Temperature below which the “Morning Warm-Up Sequence” is enabled (Default 55.4ºF). • Enter the interval of time for which the “Morning Warm-Up Sequence” is enabled (Default 30min). • Click the appropriate checkbox to activate Digital Output 4, Digital Output 5 and Analog Output 1 based on the mechanical equipment’s setup. The outputs will activate their respective heating stages if the return air temperature is below their indicated value.

  • Page 93: Annex A (Proportional + Integral Control)

    Annex A (Proportional + Integral Control) This annex explains in detail how a zone’s demand is calculated. A zone’s demand is calculated by adding the integral component to the proportional component. Proportional Component Key Concepts Heating Setpoint: temperature below which a heating demand will be created. In the graphic above, heating setpoint= 70ºF, • and is usually set by the wall sensor setpoint adjustment dial or touchpad. Cooling Setpoint: temperature above which a cooling demand will be created. In the graphic above, cooling setpoint = 72ºF •...
  • Page 94 Integral Component Key Concepts • The Proportional Component is not enough to satisfy the zone demand. As long as there is a Proportional Component, the Integral Component will increase with time. • • Cooling integral: Amount of time for the Integral Component of the demand to equalize the Proportional Component for a cooling demand. • Heating integral: Amount of time for the Integral Component of the demand to equalize the Proportional Component for a heating demand.
  • Page 95 Proportional Component Heating Setpoint - Space Temperature Proportional Component = x 100 % 1/2 Proportional Band 70 °F - 69 °F Proportional Component = x 100 % 1/2 (4 °F) 1 °F Proportional Component = x 100 % = 0.5 x 100 % 2 °F Proportional Component = 50 % Integral Component...

  • Page 96: Annex B (Math Function Examples)

    (for more details, see SECTION 3.1 CONFIGURE A ZONE DEMAND AND VOTING WEIGHT). Note: In Prolon Focus, the heating demands are POSITIVE values, and cooling demands are NEGATIVE values. Each of the 10 VAV zones has the following heating or cooling demands:...
  • Page 97 The following is how the math functions are calculated Configuration 1: Using Weighted Average Functions (Cooling/Heating only) • Select Math 1 as “Weighted Average (Cooling only)” • Select Math 2 as “Weighted Average (Heating only)” (-25×2)+(-35×1)+(-45×1)+(-100×1)+(-100×2) Math 1 = -33.1% 1+1+2+1+1+2+1+1+1+2 (100×1)+(100×1)+(75×2)+(10×1) Math 2 =...

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