Prolon C1000 Series Installation instructions

HARDWARE GUIDE
Chiller Controller C1000 Series
Specifications and Operational Guide
REV. 7.3.1
PL-HRDW-CHL-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 Chiller Controller....................................................................................................................................................................4
Description..................................................................................................................................................................................................4
General Behaviour....................................................................................................................................................................................4
Operating Sequence................................................................................................................................................. 5
Pumps...........................................................................................................................................................................................................5
Water Supply Setpoint ............................................................................................................................................................................5
Chiller Stages..............................................................................................................................................................................................5
Components.............................................................................................................................................................. 6
Component Identication......................................................................................................................................................................6
LEDs...............................................................................................................................................................................................................7
Address Conguration for Networking .............................................................................................................................................7
Input and Output Identication...........................................................................................................................................................8
Inputs......................................................................................................................................................................... 9
Temperature Sensors...............................................................................................................................................................................9
Proof of Pump ............................................................................................................................................................................................9
Outputs.................................................................................................................................................................... 10
Output Specications............................................................................................................................................................................10
Conguration of Digital Outputs.......................................................................................................................................................10
Typical Connection of Digital Outputs ............................................................................................................................................11
Typical Connection of the 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 ........................................................................................................................................................6
Figure 2 - LEDs Identication ......................................................................................................................................................................7
Figure 3 - Addressing Dipswitches ............................................................................................................................................................7
Figure 4 - Input and Output Identication..............................................................................................................................................8
Figure 5 - RJ45 Pinout....................................................................................................................................................................................8
Figure 6 - Connecting the Temperature Sensors ..................................................................................................................................9
Figure 7 - Connnecting the Proof of Pump Contacts to the Controller.........................................................................................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 - C1000 Size Diagram ................................................................................................................................................................16

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Description
The Prolon PL-C1000 Chiller Controller is a microprocessor-based controller designed to operate chiller equipment (AIR
COOLED and WATER COOLED chillers) with up to three stages, as well the associated system pumps. It features a variety
of control strategies, including outside 4 temperature reset scales, lead-lag sequences, pump exercise intervals and more.
General Behaviour
The Prolon C1000 Chiller controller monitors dedicated inputs and uses pre-established control sequences that drive
dedicated outputs to control standard Chiller equipment. The main goal of this controller is to regulate the chilled water
supply temperature. Numerous congurable parameters and sequences allow for the ne tuning of the pumps, chillers
stages, target supply temperature and a whole range of safeguards. The various programming options allow the user to
incorporate lead-lag sequences into the pumps and chiller stages, specify conditions for pump activity as well as apply
schedules and limits. All these parameters can be accessed and modied using the Prolon Focus software.
General Information
PL-C1000 Chiller Controller

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Operating Sequence
Pumps
The PL-C1000 Chiller Controller can control systems with one or two pumps. The dual pump sequence is intended
for hydronic systems where there is a secondary pump that acts as a backup to the primary pump, with both pumps
being installed in parallel. Primary pump activity is based either on a schedule or on the outside air temperature, or
both. The secondary pump, when required, will only be activated when there is no proof of operation of the primary
pump after a congurable delay. The pumps can be setup for various lead-lag sequences wherein they will alternate
between primary and secondary roles. The pumps can also be exercised after congurable periods of inactivity. Note
that the chiller stages require proof of pump to activate. Alternatively, pump control can be entirely disabled, and the
chillers can run without concern of pump status.
Water Supply Setpoint
The target water supply temperature can be a simple xed setpoint, or instead follow a reset scale based on outside
temperature, return water temperature, or even on a network provided cooling demand (which usually represents an
average cooling request coming from zones in the building). All scales and setpoints are fully congurable for any of the
methods used above.
Chiller Stages
Chiller activation is based on a call for cooling, which occurs when the supply temperature rises above the setpoint by
a congurable margin. The PL-C1000 Chiller controller can be congured to control up to three chiller stages in various
combinations (ex.: a single chiller with three stages, two single-stage chillers, etc..). For water cooled chillers, chiller activity
can be interlocked based on the entering condenser water temperature. Upon detection of multiple sequential faults,
a lockout mode can be setup to block further chiller activity until a manual intervention occurs. The chiller outputs can
also be set up for various lead-lag sequences to ensure an even distribution of the workload.

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Legend:
A-Addressing dipswitch
B-Jumpers for terminating and bias resistors for the NET port (see J)
C-Jumpers for terminating and bias resistors for the INT port (see K)
D-SOURCE/SINK dipswitch for Output 4
E-SOURCE/SINK dipswitch for Output 3
F-SOURCE/SINK dipswitch for Output 2
G-SOURCE/SINK dipswitch for Output 1
H-Reset Button
I-Jumper to supply voltage to INT port (see J)
J-INT port for RS485 communication (RJ45 jack)
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
NET
BIAS TERM
INT
BIAS TERM
Figure 1 - Component Identication
Components
Component Identification

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STATHBEATOUT5OUT4OUT3OUT2OUT1
Green light: Reception
from INT port
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: Sending to NET port
Green light: Reception from NET port
Status light for analog output 5 (Chiller 3)
Status light for triac output 4 (Chiller 2)
Status light for triac output 3 (Chiller 1)
Status light for triac output 2 (Pump 2)
Status light for triac output 1 (Pump 1)
Red light: Sending to INT port
Figure 2 - LEDs Identication
LEDs
Address Configuration for Networking
The C1000 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

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Figure 5 - RJ45 Pinout
Input and Output Identification
All the inputs and outputs of the C1000 use pluggable screw type terminal blocks with elevator style clamping, which
make connections easier and more secure.
The C1000 Chiller Controller has two 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.
The “INT” Port (see below) uses an RJ45 type connector. The RJ45 connector allows the use of premade CAT5 cables for
simple plug-and-play RS485 communication. This RJ45 connector follows the Modbus pinout specication for RS485
communication.
GND
B (-)
A (+)
Figure 4 - Input and Output Identication
STAT
NETSNDNETREC INTSND
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM
+
COM
24VAC
COM
24VAC
COM
24VAC
COM
24VAC
COM
24VACCOM
INTREC
HBEATOUT5OUT4OUT3OUT2OUT1
RESET
INTERFACE
INT Port: Incoming RS485
Network communication (Modbus)
NET Port: Incoming RS485
Network communication (Modbus)
Proof of Pump
Supply water temperature
Common for all the inputs
Return water temperature
Chiller 3
Chiller 2
Chiller 1
Pump 2
Pump 1
Condenser water temp entering (Water Cooled Chiller) /
Outside air temp (Air Cooled Chiller)
Power source of the controller
24 VAC

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Inputs
Temperature Sensors
Proof of Pump
The C1000 Chiller Controller has three analog inputs to monitor various temperature readings, including supply water,
return water and entering condenser water (ECWT) or outside air temperature (OAT), whether the chiller is water cooled
or air cooled. The sensors used are standard 10k type 3 thermistors that share a single common connection (see Figure 6).
Note that the outside air temperature can be provided by an alternate source on the network. If a network controller is
present on the network, it can retrieve the outside temperature reading from one controller and distribute it to any other
controllers on the network.
Figure 6 - Connecting the Temperature Sensors
Figure 7 - Connnecting the Proof of Pump Contacts to the Controller
The C1000 has one digital input dedicated to the proof of pump signals. Please refer to Figure 7 see how to correctly
connect it. To indicate proof of pump, the contact must be closed. If no proof of pump signal is available, you must short
the corresponding input, or else the controller will interpret the absence of signal as a pump malfunction and no cooling
action will be taken.
Proof of
pump
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM
ECWT / OAT
Return water
sensor
Supply water
sensor
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM

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Outputs
Configuration of Digital Outputs
Output Specifications
Output Type Action Applications
DO 1 Triac Source 24VAC
Max Current: 300 mA On-or-O Pump Stage 1
DO 2 Triac Source 24VAC
Max Current: 300 mA On-or-O Pump Stage 2
DO 3 Triac Source 24VAC
Max Current: 300 mA On-or-O Chiller Stage 1
DO 4 Triac Source 24VAC
Max Current: 300 mA On-or-O Chiller Stage 2
AO 1
Congurable Analog Output:
- 0 to 10 VDC
Max Current: 40 mA
On-or-O Chiller Stage 3
The C1000 Chiller controller contains 5 customizable outputs; four triac ON/OFF outputs (24VAC) and one analog output
(0-10VDC). Output conguration is 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 round and
yellow-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:
Figure 8 - Output in SOURCE mode
24VAC
COM
OUT5OUT4
Switch for
Output 4
24 VAC Output (ON/O)
Output 4 Common

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Two types of congurations are possible:
1) Active output (SOURCE). The C1000 is actively powering the load:
2) Passive output (SINK). The C1000 opens and closes a contact to allow an external source to power the load:
Typical Connection of Digital Outputs
2) Switch position to obtain a SINK passive output:
Figure 9 - Output in SINK mode
Figure 10 - Connection of Active Outputs 3 and 4
Figure 11 - Connection of Passive Output 3 and 4
OUT5OUT4
Switch for
Output 4
Isolated dry contact
(On/O)
OUT5OUT4
24V
COM
External Load
OUT5OUT4
External 24 V
External Load
24 N

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Typical Connection of the Analog Output
Two types of conguration are possible:
1) The C1000 powers the load and provides a control signal:
2) The C1000 only provides the control signal to the load, which is powered by an external source:
Figure 12 - Connecting the Analog Output (Controller Powered)
Figure 13 - Connecting the Analog Output (External Power)
OUT5OUT4
0-10v
COM
Controlled
Load
24 VAC power
(From terminal block
#2 of the controller)
24v
0-10v
COM
OUT5OUT4
0-10v
COM
Controlled
Load
External
24 VAC
source
N
24v
0-10v
COM

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Power Source / Network
Power Source
Network Communication
The Prolon C1000 controller is powered by a 24 VAC power source connected using the "COM" terminal and the "24 VAC"
terminal (see Figure 14). The common for all inputs and outputs are the same as the power source’s common (exception:
when an output is set to passive, the common for this output will not correspond to the power source common). All
output power sources also originate from the controller’s power source.
Figure 14 - Connecting the 24VAC Power Source
Figure 15 - Connecting to the Network
OUT1
COM 24VAC
Supply
NL
120VAC24VAC
The Prolon C1000 controller works autonomously or networked. When networked, it will communicate in real-time with
other controllers. The C1000 controller’s default communication protocol is Modbus RTU over RS485. The addressing is
done with the addressing dipswitch located on the C1000 card (see Figure 5). The network connections are made using
the NET terminal block located on the Prolon C1000 controller (see Figure 15).
Tow a r d
network

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Supply: 24 VAC ±10%, 50/60 Hz, Class 2
Consumption: 2 VA (Consumption), 32 VA (Input)
Inputs: Entering Condenser Water – 10K thermistor
Return Water – 10 K thermistor
Supply Water – 10 K thermistor
Proof of pump – 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) for the valve
Indication lights (LED): State of each output / Communication / Supply / 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: 6.2” x 5.2” x 2.5” (157 mm x 132 mm x 64 mm)
Weight: 0.85 lbs (0.39 kg)
Environment: 32-122 ºF (0-50 ºC) Non-Condensing
Certication: UL916 Energy Management Equipment, CAN/CSA-C22.2, RoHS, FCC part 15: 2012 class B
The performance specications are nominal and conform to acceptable industry standards. Prolon Inc. will not be liable for
damages resulting from misapplication or misuse of its products.
Technical Specifications

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• FCC Compliant to CFR47, Part 15, Subpart B, Class B
• Industry Canada (IC) Compliant to ICES-003, Issue 5: CAN ICES-3 (B)/NMB-3(B)
• RoHS Directive (2002/95/EC)
FCC User Information
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device
may not cause harmful interference, and (2) this device must accept any interference received, including interference
that may cause undesired operation.
Caution: Any changes or modications 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 res-
idential 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 o 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 dierent 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.
Compliance

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REV. 7.3.1
PL-HRDW-CHL-C1000-C/F-EN
5.3"
(135 mm)
6.5"
(165 mm)
2.2"
(55 mm)
Figure 16 - C1000 Size Diagram
Overall Dimensions
© Copyright 2020 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.