Prolon C1000 Series Installation instructions

HARDWARE GUIDE
Water Loop Controller C1000 Series
Specifications and Operational Guide
REV. 7.1.0
PL-HRDW-WLC-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 Water Loop Controller............................................................................................................................... 4
Description ..................................................................................................................................................................... 4
General Behaviour ........................................................................................................................................................ 4
Components ........................................................................................................................................5
Component Identification.......................................................................................................................................... 5
LEDs .................................................................................................................................................................................. 6
Address Configuration for Networking................................................................................................................... 6
Jumper to Supply Power to the RJ45 Plug ............................................................................................................. 7
Input and Output Identification ............................................................................................................................... 7
Inputs...................................................................................................................................................8
Temperature Sensors ................................................................................................................................................... 8
Auxiliary Digital Input.................................................................................................................................................. 8
Outputs................................................................................................................................................ 9
Output Specifications .................................................................................................................................................. 9
Configuration of Digital Outputs 1 to 4.................................................................................................................. 9
Typical Connection of Digital Outputs 1 to 4......................................................................................................10
Typical Connection of Analog Output .................................................................................................................. 11
Power Source / Network.................................................................................................................... 12
Power Source ............................................................................................................................................................... 12
Network Communication ......................................................................................................................................... 12
Technical Specifications.................................................................................................................... 13
Compliance ........................................................................................................................................ 14
FCC User Information................................................................................................................................................. 14
Industry Canada .........................................................................................................................................................14
Overall Dimensions ........................................................................................................................... 15

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Table of Figures
Figure 1 - Component Identification ............................................................................................................................ 5
Figure 2 - LEDs Identification.......................................................................................................................................... 6
Figure 3 - Addressing Dipswitches ................................................................................................................................ 6
Figure 4 - Jumpers ............................................................................................................................................................. 7
Figure 5 - Input and Output Identification.................................................................................................................. 7
Figure 6 - Connecting the Water Temperature Sensors........................................................................................... 8
Figure 7 - Connecting the Auxiliary Digital Input ..................................................................................................... 8
Figure 8 - Output in SOURCE mode .............................................................................................................................. 9
Figure 9 - Output in SINK mode ...................................................................................................................................10
Figure 10 - Connection of Active Outputs 3 and 4..................................................................................................10
Figure 11 - Connection of Passive Output 3 and 4..................................................................................................10
Figure 12 - Connecting the Analog Output (Controller Powered) ...................................................................... 11
Figure 13 - Connecting the Analog Output (External Power) .............................................................................. 11
Figure 14 - Connecting the 24VAC Power Source.................................................................................................... 12
Figure 15 - Connecting to the Network...................................................................................................................... 12
Figure 16 - C1000 Size Diagram.................................................................................................................................... 15

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Description
The PL-C1000 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 offers precise digital control to maxi-
mize performance. The available control sequences are fully configurable, either locally or remotely with
free software. The C1000 offers a variety of functions such as bypass valve control, cooling tower damper
control and more.
General Behaviour
The C1000 Water Loop controller has a single output dedicated to heating, while the remaining four
outputs are all dedicated to various cooling actions.
When the supply water temperature drops below a configurable setpoint, the heating output (Output 1),
which is connected to a boiler, activates.
When the supply water temperature rises too high, the following actions can take place, in any configu-
rable order: a damper at the top of the water tower opens (Output 2), a spray pump activates (Output 3),
the cooling tower’s first stage (or permission) activates (Output 4), and finally the cooling tower’s second
stage activates (Output 5). Output 5 can either be ON-OFF or modulating proportional. The setpoints and
differential bands for each output are configurable, 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 temperature.
General Information
PL-C1000 Water Loop Controller

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Legend:
A - Addressing Dipswitch
B - Output 1 Dipswitch
C - Output 2 Dipswitch
D - Output 3 Dipswitch
E - Output 4 Dipswitch
F - Master reset button
G - Terminal Blocks for Inputs and Outputs
H - LEDs
I - Jumpers for terminating and bias resistors for the NET port
J - Jumpers for terminating and bias resistors for the INT port
K - Jumper to supply voltage to INT port (RJ45 jack)
Figure 1 - Component Identification
Components
Component Identification
NET
BIAS TERM
INT
BIAS TERM

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STATHBEATOUT5OUT4OUT3OUT2OUT1
Green light: Reception
from interface
Green pulsing, indicates
that the CPU is online
Green light: Internal
24VDC power source OK
Green light: Internal 5
VDC power source OK
Red light: Sending to network bus
Green light: Reception from network bus
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 interface
Figure 2 - LEDs Identification
LEDs
Address Configuration for Networking
The C1000 has various LEDs which are linked to different functions and outputs of the controller. Each
LED is individually identified to help the user make a quick visual diagnostic of the controller’s activity
and status.
A unique address on each controller must be configured by setting the first 7 switches on the addressing
dipswitch to the desired value.
These switches are numbered from 1 to 7 and represent a binary value from 1 to 64 (1, 2, 4, 8, 16, 32, 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 4 - Jumpers
Jumper to Supply Power to the RJ45 Plug
Input and Output Identification
No power 24 VAC 24 VDC
The RJ45 jumper lets the user select the voltage that will appear on pin #7 of the RJ45 plug. This can be
used to power a device attached to the RJ45 plug, such as the digital sensor or interface. NOTE: If multiple
C1000 controllers are connected together through the RJ45 plug, only one C1000 should be supplying
power onto the RJ45, otherwise you will be mixing your supply sources and possibly cause damage. The
jumper setups are as follows:
All the inputs and outputs of the C1000 use pluggable screw type terminal blocks with elevator style
clamping, which make connections easier and more secure.
The C1000 Water Loop Controller has 2 separate communication ports offering 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 specification for RS485 communication.
Figure 5 - Input and Output Identification
STAT
NETSNDNETREC INTSND
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM
+
COM
24VAC
COM
24VAC
COM
24VAC
COM
24VAC
COM
24VACCOM
INTREC
HBEATOUT5OUT4OUT3OUT2OUT1
RESET
PL-C1000-WLC
INTERFACE
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 - 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
Auxiliary Digital Input
Figure 6 - Connecting the Water Temperature Sensors
Figure 7 - Connecting the Auxiliary Digital Input
The C1000 Water Loop controller has an analog inputs dedicated to monitoring the supply and return
water temperatures and will integrate these reading into its control sequence. An auxiliary temperature
sensor input in also available (for visualisation purposes only) and will not affect the sequence. The
sensors used are standard 10k type 3 thermistors.
The C1000 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 affect the sequence in any way.
Contact
A
NET
B
OCC
SUPPLY
GND
SETPT
ROOM
Return Water Sensor
Supply Water Sensor
A
NET
B
OCC
SUPPLY
GND
RA
OA

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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-Off Boiler
2Triac Source: 24VAC
Max Current: 300 mA On-or-Off
Bypass /
Damper /
Cooling
3Triac Source: 24VAC
Max Current: 300 mA On-or-Off Pump
4Triac Source: 24VAC
Max Current: 300 mA On-or-Off Cooling Tower Stage 1
5
Analog Output
0 to 10VDC
Max Current: 40 mA
Modulating Proportional /
On-or-Off Cooling Tower Stage 1
Figure 8 - Output in SOURCE mode
24VAC
COM
OUT5OUT4
Switch for
Output 4
24 VAC Output (ON/O )
Output 4 Common
The C1000 Water Loop controller contains 5 configurable outputs. The first 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 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 fixed, the fuse will automatically reset and allow current to
flow through the output again.
The digital triac outputs are configurable (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 (see Figure 8):

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Two types of configurations are possible:
1) Active output (SOURCE). The C1000 is actively powering the load (see Figure 10).
2) Passive output (SINK). The C1000 opens and closes a contact to allow an external source to power
the load (see Figure 11).
Typical Connection of Digital Outputs 1 to 4
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
2) Switch position to obtain a SINK passive output (see Figure 9):

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Two types of configuration are possible:
1) The C1000 powers the load and provides a control signal (see Figure 12).
2) The C1000 only provides the control signal to the load, which is powered by an external source (see
Figure 13).
Typical Connection of Analog Output
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
Figure 14 - Connecting the 24VAC Power Source
Figure 15 - Connecting to the Network
OUT1
COM 24VAC
Supply
NL
120VAC24VAC
Tow ard
network
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.
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 3). The network connections are made using the NET terminal block located on the ProLon C1000
controller (see Figure 15).

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Supply: 24 VAC ±10%, 50/60 Hz, Class 2
Consumption: 2 VA (Consumption), 5 VA (Input)
Inputs: • Supply water temp – thermistor 10K
• Return water temp – thermistor 10K
• Auxiliary temp – thermistor 10K
• Auxiliary digital input – dry contact
Digital outputs: 4 triac outputs, 10-30 VAC source or dry contact, 300 mA max (resettable fuse)
Analog output: 1 output 0-10 VDC, 40 mA max (resettable fuse)
Indication lights (LED): State of each output / Communication / Power / State of microprocessor
Microprocessor: PIC18F6722, 8 bits, 40 MHz, 128KB FLASH memory
Casing: Molded ABS, UL94-HB
Communication: Modbus RTU (RS485), up to 127 nodes
Baud rate: 9600, 19200, 38400, 57600, 76800, 115200
Connection: Removable screw-type terminal blocks (16 AWG max) and RJ45 modular jack
Dimensions: 6.5" x 5.3" (165mm x 135mm)
Weight: 0.85 lbs
Environment: 32-122 ºF (0-50 ºC) Non-Condensing
Certification: RoHS, FCC part 15: 2012 class B
The performance specifications are nominal and conform to acceptable industry standards. ProLon Inc. will
not be liable for damages resulting from misapplication or misuse of its products.
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 re-
ceived, including interference that may cause undesired operation.
Caution: Any changes or modifications not approved by ProLon can void the user’s authority to operate
the equipment.
Note: This equipment has been tested and found to comply with the limits for a Class B digital device,
pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against
harmful interference in a residential installation. This equipment generates, uses and can radiate radio
frequency energy and, if not installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or television reception,
which can be determined by turning the equipment off and on, the user is encouraged to try to correct
the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the receiver
is connected.
• Consult the dealer or an experienced radio/TV technician for help.
Industry Canada
This Class (B) digital apparatus meets all the requirements of the Canadian Interference-Causing
Equipment regulations.
Cet appareil numérique de la Classe (B) respecte toutes les exigences du Réglement sur le matériel
brouilleur du Canada.
Compliance

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REV. 7.1.0
PL-HRDW-WLC-C1000-C/F-EN
5.3"
(135 mm)
6.5"
(165 mm)
2.2"
(55 mm)
Figure 16 - C1000 Size Diagram
Overall Dimensions
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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.