Prolon C1050 Series Installation instructions

HARDWARE GUIDE
Boiler Controller C1050 Series
Specifications and Operational Guide
REV. 7.3.1
PL-HRDW-BLR-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 Boiler Controller .....................................................................................................................................................................4
Description..................................................................................................................................................................................................4
General Behaviour....................................................................................................................................................................................4
Operating Sequence................................................................................................................................................. 5
General.........................................................................................................................................................................................................5
Parallel Pump Sequence ........................................................................................................................................................................5
Follower Pump Sequence .....................................................................................................................................................................5
Components.............................................................................................................................................................. 6
Component Identication......................................................................................................................................................................6
LEDs...............................................................................................................................................................................................................7
Address Conguration for Networking .............................................................................................................................................7
Input and Output Identication...........................................................................................................................................................8
Inputs......................................................................................................................................................................... 9
Analog Input...............................................................................................................................................................................................9
Temperature Sensors...............................................................................................................................................................................9
Proof of Pump ..........................................................................................................................................................................................10
Outputs.....................................................................................................................................................................11
Output Specications............................................................................................................................................................................11
Conguration of Digital Outputs.......................................................................................................................................................11
Typical Connection of Digital Outputs ............................................................................................................................................12
Typical Connection of the Analog Output......................................................................................................................................13
Power Source / Network..........................................................................................................................................14
Power Source............................................................................................................................................................................................14
Network Communication.....................................................................................................................................................................14
Technical Specications ..........................................................................................................................................15
Compliance...............................................................................................................................................................16
FCC User Information.............................................................................................................................................................................16
Industry Canada .....................................................................................................................................................................................16
Overall Dimensions .................................................................................................................................................17

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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 (Staged Boiler)................................................................................................................8
Figure 5 - Input and Output Identication (Modulating Boiler).......................................................................................................8
Figure 6 - Analog input .................................................................................................................................................................................9
Figure 7 - Connecting the Temperature Sensors ..................................................................................................................................9
Figure 8 - Connnecting the Proof of Pump Contacts to the Controller.......................................................................................10
Figure 9 - Output in SOURCE mode ........................................................................................................................................................11
Figure 10 - Output in SINK mode .............................................................................................................................................................12
Figure 11 - Connection of Active Outputs 3 and 4 .............................................................................................................................12
Figure 12 - Connection of Passive Output 3 and 4 .............................................................................................................................12
Figure 13 - Connecting the Analog Output (Controller Powered) ................................................................................................13
Figure 14 - Connecting the Analog Output (External Power).........................................................................................................13
Figure 15 - Connecting the 24VAC Power Source ...............................................................................................................................14
Figure 16 - Connecting to the Network .................................................................................................................................................14
Figure 17 - C1050 Size Diagram ................................................................................................................................................................17

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Description
The Prolon PL-C1050 Boiler controller is a microprocessor-based controller designed to operate staged boilers, as well
as the associated pumps and valves. It features a variety of control strategies, including outside temperature reset,
lead-lag sequences, pump exercise intervals and more.
General Behaviour
Although fully congurable, the Prolon C1050 Boiler controller monitors dedicated inputs and uses pre-established
control sequences to drive dedicated outputs to control standard Boiler equipment. These sequences can be fully
optimized to obtain the best results for each type of system. Numerous parameters enable the modication or ne
tuning of the pumps, the boilers, the target supply temperature, the proportional bands, integration times, dierentials,
operational ranges, setpoints and a whole range of limits and safeguards. The various programming options also allow
the user to modify the lead-lag sequences, conditions for pump activity and the inuence of schedules or other data
received over the network. All these parameters can be accessed and modied by using the Prolon Focus software.
General Information
PL-C1050 Boiler Controller

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Operating Sequence
General
The Prolon C1050 Boiler controller receives readings from three dierent temperature sensors: outside air, supply
water and return water. In addition to the temperature sensors, it also has an input for proof of operation of the
pumps. It can receive data from Prolon master controllers such as outside temperature, occupancy, or the average
heating request of the building. The controller then analyzes all the data and activates the appropriate outputs to
respond accordingly, within parameters set by the temperature sensors and other safety limits.
Parallel Pump Sequence
This 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. The primary pump is activated based on outside temperature or
upon a call for heating, or both. The secondary pump 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.
The target supply temperature can be a xed setpoint or instead follow a reset based on outside temperature. The target
supply temperature can also be reduced in unoccupied mode or inuenced by a network provided demand, usually
representing an average heating request coming from the zones in the building.
Boiler activity is based on a call for heat (i.e. supply temperature is below the target), which can be interlocked with the
outside temperature. The C1050 boiler controller can be congured to control up to two boiler stages or can control one
modulating boiler with an optional backup stage. Boiler stages can also be set up for various lead-lag sequences that will
cycle through the position of the lead boiler stage.
The C1050 boiler controller can also be used to control a three-way valve when congured for staged control, which it
will modulate to attain the target temperature.
Follower Pump Sequence
This sequence is intended for hydronic systems where there is a primary and secondary loop. The primary pump is
activated based on outside temperature or upon a call for heating, or both. The secondary pump will be activated simply
when there is proof of operation of the primary pump.
The pumps can be exercised after congurable periods of inactivity.
The target supply temperature can be a xed setpoint or instead follow a reset based on outside temperature. The tar-
get supply temperature can also be reduced in unoccupied mode or inuenced by a network provided demand, usually
representing an average heating request coming from the zones in the building.
Boiler activity is based on a call for heat (supply temperature is below the target), which can be interlocked with the
outside temperature. The C1050 boiler controller can be congured to control up to two boiler stages or can control one
modulating boiler with an optional backup stage. Boiler stages can also be set up for various lead-lag sequences that will
cycle through the position of the lead boiler stage.
The C1050 boiler controller can also be used to control a three-way valve when congured for staged control, which it
will modulate to attain the target temperature.

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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 Identication
Components
Component Identification

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DO124V DO2 DO3 DO4 AO HBEAT STAT
NETREC NETSND INTREC INTSND
Blue light: Internal 24VDC power source OK
Status light for analog output 5
(Valve / Modulating Boiler)
Status light for triac output 4 (Boiler 2)
Status light for triac output 3 (Boiler 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 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
Green light: Reception from INT port
Blue pulsing, indicates that
the CPU is online
Red light: Sending to NET port
Green light: Reception from NET port

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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 Boiler 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.
Figure 4 - Input and Output Identication (Staged Boiler)
INT Port: Incoming RS485 network communication (Modbus)
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)
Output 4 - Boiler 2 action (digital - ON/OFF)
Output 3 - Boiler 1 action (digital - ON/OFF)
Output 2 - Pump 2 action (digital - ON/OFF)
Output 1 - Pump 1 action (digital - ON/OFF)
Power source of the controller (24 VAC)
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
Figure 5 - Input and Output Identication (Modulating Boiler)
DO1
DO2
DO3
DO4
AO
DO124V DO2 DO3 DO4 AO HBEAT S TAT
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)
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)
Power source of the controller (24 VAC)
Output 4 - Backup Boiler Stage (digital - ON/OFF)
Output 3 - Modulating Boiler enable signal (digital - ON/OFF)
Output 2 - Pump 2 action (digital - ON/OFF)
Output 1 - Pump 1 action (digital - ON/OFF)

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Inputs
Temperature Sensors
Analog Input
The C1050 Boiler controller has three analog inputs that monitor outside air, supply water and return water temperatures
and will integrate these readings into its control sequence. The sensors used are standard 10k type thermistors that share
a single common connection.
The outside air temperature can be also be provided by an alternate source. 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 7 - Connecting the Temperature Sensors
Figure 6 - 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-BLR 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
Outside air
sensor
Return water
sensor
Supply water
sensor
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

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Proof of Pump
Figure 8 - Connnecting the Proof of Pump Contacts to the Controller
The C1050 has one digital input dedicated to the proof of pump signal. Please refer to Figure 9 see how to correctly con-
nect 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 heating
action will be taken.
HBEAT S TAT
NETREC NETSND INTREC INTSND
UI1
UI2
COM
UI3
DI
-
24VAC
COM
INT
+
B
NET
A
RS485
NET RS485
INT
Proof of pump

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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 1
DO 3 Triac Source 24VAC
Max Current: 300 mA On-or-O Boiler Stage 1
DO 4 Triac Source 24VAC
Max Current: 300 mA On-or-O Boiler Stage 2
AO 1
Congurable Analog Output:
- 0 to 10 VDC
- 2 to 10 VDC
- 0 to 5 VDC
Max Current: 40 mA
Modulating Proportional Three Way Valve or
Modulating Boiler
The C1050 Boiler 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 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 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 9 - Output in SOURCE mode
Switch for
Output 4
24 VAC Output (ON/O)
Output 4 Common
DO3
DO4
AO
DO3 DO4 AO

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Two types of congurations are possible:
1) Active output (SOURCE). The C1050 is actively powering the load:
2) Passive output (SINK). The C1050 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 10 - Output in SINK mode
Figure 11 - Connection of Active Outputs 3 and 4
Figure 12 - Connection of Passive Output 3 and 4
Switch for
Output 4
Isolated dry contact
(On/O)
DO3
DO4
AO
DO3 DO4 AO
External Load
DO3
DO4
AO
DO3 DO4 AO
External 24 V
External Load
24 N
DO3
DO4
AO
DO3 DO4 AO

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REV. 7.3.1 / PL-HRDW-BLR-C1050-C/F-EN
Typical Connection of the Analog Output
Two types of conguration are possible:
1) The C1050 powers the load and provides a control signal:
2) The C1050 only provides the control signal to the load, which is powered by an external source:
Figure 13 - Connecting the Analog Output (Controller Powered)
Figure 14 - Connecting the Analog Output (External Power)
Controlled
Load
24 VAC power
(From terminal block
#2 of the controller)
24v
0-10v
COM
DO3
DO4
AO
DO3 DO4 AO
Controlled
Load
External
24 VAC
source
N
24v
0-10v
COM
DO3
DO4
AO
DO3 DO4 AO

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Power Source / Network
Power Source
Network Communication
The Prolon C1050 controller is powered by a 24 VAC power source connected using the "COM" terminal and the "24 VAC"
terminal (see Figure 15). 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 out-
put power sources also originate from the controller’s power source.
Figure 15 - Connecting the 24VAC Power Source
Figure 16 - Connecting to the Network
The Prolon C1050 controller works autonomously or networked. When networked, it will communicate in real-time with
other controllers. The C1050 controller’s default communication protocol is Modbus RTU over RS485. The addressing is
done with the addressing dipswitch located on the C1050 card (see Figure 3). The network connections are made using
the NET terminal block located on the Prolon C1050 controller (see Figure 16).
HBEAT STAT
NETREC NETSND INTREC INTSND
UI1
UI2
COM
UI3
DI
-
24VAC
COM
INT
+
B
NET
A
RS485
NET
RS485
INT
Tow ard
network
A
B
NL
120VAC24VAC
DO1
DO124V

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REV. 7.3.1 / PL-HRDW-BLR-C1050-C/F-EN
Supply: 24 VAC ±10%, 50/60 Hz, Class 2
Consumption: 2 VA (Consumption), 32 VA (Input)
Inputs: Outside air – 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)
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: -4 to 122 ºF (-20 to 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 resi-
dential 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-BLR-C1050-C/F-EN
5.3"
(135 mm)
6.5"
(165 mm)
2.2"
(55 mm)
Figure 17 - C1050 Size Diagram
Overall Dimensions
© Copyright 2021 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.
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
COM
COM
COM
COM
COM