Prolon C1050 Series Installation instructions

HARDWARE GUIDE
Water Loop Controller C1050 Series
Specifications and Operational Guide
REV. 7.3.1
PL-HRDW-WLC-C1050-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-C1050 Water Loop Controller...................................................................................................................................................................4
Description............................................................................................................................................................................................................4
General Behaviour..............................................................................................................................................................................................4
Components .................................................................................................................................................................... 5
Component Identication...............................................................................................................................................................................5
LEDs .........................................................................................................................................................................................................................6
Address Conguration for Networking......................................................................................................................................................6
Input and Output Identication....................................................................................................................................................................7
Inputs ............................................................................................................................................................................... 8
Analog Input.........................................................................................................................................................................................................8
Temperature Sensors ........................................................................................................................................................................................8
Auxiliary Digital Input .......................................................................................................................................................................................9
Outputs .......................................................................................................................................................................... 10
Output Specications .................................................................................................................................................................................... 10
Conguration of Digital Outputs 1 to 4................................................................................................................................................... 10
Typical Connection of Digital Outputs 1 to 4.........................................................................................................................................11
Typical Connection of Analog Output......................................................................................................................................................12
Power Source / Network ............................................................................................................................................... 13
Power Source .....................................................................................................................................................................................................13
Network Communication..............................................................................................................................................................................13
Technical Specications ............................................................................................................................................... 14
Compliance .................................................................................................................................................................... 15
FCC User Information......................................................................................................................................................................................15
Industry Canada ...............................................................................................................................................................................................15
Overall Dimensions....................................................................................................................................................... 16

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Table of Figures
Figure 1 - Component Identication..................................................................................................................................................................5
Figure 2 - LEDs Identication................................................................................................................................................................................6
Figure 3 - Addressing Dipswitches......................................................................................................................................................................6
Figure 4 - Input and Output Identication.......................................................................................................................................................7
Figure 5 - Analog input ...........................................................................................................................................................................................8
Figure 6 - Connecting the Water Temperature Sensors..............................................................................................................................8
Figure 7 - Connecting the Auxiliary Digital Input..........................................................................................................................................9
Figure 8 - Output in SOURCE mode................................................................................................................................................................. 10
Figure 9 - Output in SINK mode.........................................................................................................................................................................11
Figure 10 - Connection of Active Outputs 3 and 4......................................................................................................................................11
Figure 11 - Connection of Passive Output 3 and 4......................................................................................................................................11
Figure 12 - Connecting the Analog Output (Controller Powered) ........................................................................................................12
Figure 13 - Connecting the Analog Output (External Power).................................................................................................................12
Figure 14 - Connecting the 24VAC Power Source........................................................................................................................................13
Figure 15 - Connecting to the Network...........................................................................................................................................................13
Figure 16 - C1050 Size Diagram......................................................................................................................................................................... 16

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Description
The PL-C1050 Water Loop controller is designed to control a water loop system comprised of a boiler and a water tower
with an internal pump. The built-in microprocessor oers precise digital control to maximize performance. The available
control sequences are fully congurable, either locally or remotely with free software. The C1050 oers a variety of func-
tions such as bypass valve control, cooling tower damper control and more.
General Behaviour
The C1050 Water Loop controller has a single output dedicated to heating, while the remaining four outputs are all dedi-
cated to various cooling actions.
When the supply water temperature drops below a congurable setpoint, the heating output (Output 1), which is con-
nected to a boiler, activates.
When the supply water temperature rises too high, the following actions can take place, in any congurable order: a
damper at the top of the water tower opens (Output 2), a spray pump activates (Output 3), the cooling tower’s rst stage
(or permission) activates (Output 4), and nally the cooling tower’s second stage activates (Output 5). Output 5 can either
be ON-OFF or modulating proportional. The setpoints and dierential bands for each output are congurable, as well
as the minimum value for Output 5.
Alternatively, Output 2 can control a bypass valve that diverts the return water into the cooling tower when it gets too
hot, instead of directly going to the boiler. Note that this is the only sequence that makes use of the return water tem-
perature.
General Information
PL-C1050 Water Loop Controller

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Components
Legend:
A-Analog Input Signal Mode Jumpers
B-Addressing dipswitch
C-Jumpers for terminating and bias resistors for the INT port (see I)
D-Jumpers for terminating and bias resistors for the NET port (see K)
E-SOURCE/SINK dipswitch for Output 4
F-SOURCE/SINK dipswitch for Output 3
G-SOURCE/SINK dipswitch for Output 2
H-SOURCE/SINK dipswitch for Output 1
I-INT port for RS485 communication (terminal block)
J-Alternate terminal blocks for 24 VAC (provides power to an optional digital sensor)
K-NET port for RS485 communication (terminal block)
L-Inputs (4 total)
M-Terminal Blocks for Outputs 1 to 5
N-Terminal Blocks for 24 VAC
INT
BIAS THERM
DO1
DO2
DO3
DO4
AO
DO124V DO2 DO3 DO4 AO HBEAT STAT
NETREC NETSND INTREC INTSND
UI1
UI2
COM
UI3
DI
-
24VAC
COM
INT
+
B
NET
A
RS485
NET
RS485
INT
NET
BIAS THERM
UI3
UI2
UI1
Figure 1 - Component Identification
Component Identification

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LEDs
Address Configuration for Networking
The C1050 has various LEDs which are linked to dierent functions and outputs of the controller. Each LED is individually
identied to help the user make a quick visual diagnostic of the controller’s activity and status.
A unique address on each controller must be congured by setting the rst 7 switches on the addressing dipswitch to
the desired value.
These switches are numbered from 1 to 7 and represent a binary value from 1 to 64 (1, 2, 4, 8, 16, 32, 64 respectively). The
value of each switch that is in the ON position is added together to form the numerical address of the controller.
The example on Figure 3 shows the switches 1, 2 and 4 on the ON position. So the corresponding values are 1, 2 and 8,
giving an address sum of 11. (1+2+8=11)
The Prolon network allows a maximum of 127 addresses, therefore 127 controllers.
Figure 3 - Addressing Dipswitches
DO124V DO2 DO3 DO4 AO HBEAT STAT
NETREC NETSND INTREC INTSND
Green light: Reception from INT port
Blue pulsing, indicates that
the CPU is online
Blue light: Internal 24VDC power source OK
Red light: Sending to NET port
Green light: Reception from NET port
Status light for analog output 5
Status light for triac output 4
Status light for triac output 3
Status light for triac output 2
Status light for triac output 1
Red light: Sending to INT port
Figure 2 - LEDs Identification

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Input and Output Identification
All the inputs and outputs of the C1050 use pluggable screw type terminal blocks with elevator style clamping, which
make connections easier and more secure.
The C1050 Water Loop Controller has 2 separate communication ports oering the same functionality on each. Both act
as ports for incoming Modbus communications from other Prolon devices or interfaces, such as a Network Controller or
remote computer with Prolon Focus software.
Figure 4 - Input and Output Identification
DO1
DO2
DO3
DO4
AO
DO124V DO2 DO3 DO4 AO HBEAT STAT
NETREC NETSND INTREC INTSND
UI1
UI2
COM
UI3
DI
-
24VAC
COM
INT
+
B
NET
A
RS485
NET
RS485
INT
INT Port: Incoming RS485 network communication (Modbus)
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 (digital - ON/OFF)
Output 3 - Spray pump (digital - ON/OFF)
Output 2 - Valve / Damper / Cooling (digital - ON/OFF)
Output 1 - Boiler (digital - ON/OFF)
Power source of the controller (24VAC)

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Inputs
Temperature Sensors
Figure 6 - Connecting the Water Temperature Sensors
The C1050 Water Loop controller has an analog inputs dedicated to monitoring the supply and return water tempera-
tures and will integrate these reading into its control sequence. An auxiliary temperature sensor input in also available
(for visualisation purposes only) and will not aect the sequence. The sensors used are standard 10k type 3 thermistors.
HBEAT STAT
NETREC NETSND INTREC INTSND
UI1
UI2
COM
UI3
DI
-
24VAC
COM
INT
+
B
NET
A
RS485
NET RS485
INT
INT
BIAS THERM
NET
BIAS THERM
UI3
UI2
UI1
Supply water sensor
Return water sensor
Analog Input
Figure 5 - Analog input
The C1050 series controllers are equipped with three general purpose analog inputs. These inputs can be congured to
receive signals of the following types:
• Thermistor (Ω) •0-5V
• 4 -20mA •0-10V
When a thermistor is used, the thermistor must be 10KΩ TYPE 3.
Each C1050 analog input is equipped with a fast-switching barrier diode to protect against surges and short circuits.
By default, the C1050-WLC analog inputs are set up for thermistor mode. The input signal mode can be changed by set-
ting jumpers U1, U2 and U3, situated inside the casing, in the desired position:
JUMPERS

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Auxiliary Digital Input
Figure 7 - Connecting the Auxiliary Digital Input
The C1050 Water Loop controller has a digital input that used for visualisation purposes only. It can detect an open or
closed contact. The status of the input does not aect the sequence in any way.
HBEAT STAT
NETREC NETSND INTREC INTSND
UI1
UI2
COM
UI3
DI
-
24VAC
COM
INT
+
B
NET
A
RS485
NET
RS485
INT
Contact

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Outputs
Configuration of Digital Outputs 1 to 4
Output Specifications
Output Type Action Applications
1Triac Source: 24VAC
Max Current: 300 mA On-or-O Boiler
2Triac Source: 24VAC
Max Current: 300 mA On-or-O
Bypass /
Damper /
Cooling
3Triac Source: 24VAC
Max Current: 300 mA On-or-O Pump
4Triac Source: 24VAC
Max Current: 300 mA On-or-O Cooling Tower Stage 1
5
Analog Output
0 to 10VDC
Max Current: 40 mA
Modulating Proportional /
On-or-O Cooling Tower Stage 1
Figure 8 - Output in SOURCE mode
The C1050 Water Loop controller contains 5 congurable outputs. The rst 4 outputs are ON-OFF triac outputs. Output 5
is an analog 0-10VDC ON-OFF or modulating output, fully customizable via the Prolon Focus software.
An integrated resettable fuse protects each of the outputs of the C1050 against current surges and short circuits. This
protection will cut the current to the output as soon as an overload condition is detected. The fuse is round and yel-
low-colored which, upon a short circuit condition, will heat up and change to orange. When the faulty wiring or circuit is
xed, the fuse will automatically reset and allow current to ow through the output again.
The digital triac outputs are congurable (SOURCE/SINK) via a switch located on the board. Simply move the switch to
obtain either a SOURCE active output (1) or a SINK passive output (2).
1) Switch position to obtain a SOURCE active output:
Switch for
Output 4
24 VAC Output (ON/O)
Output 4 Common
DO3
DO4
AO
DO3 DO4 AO