Prolon M2000 SERIES Installation instructions

HARDWARE GUIDE
Chiller Controller M2000 Series
Specifications and Operational Guide
REV. 7.3.4
PL-HRDW-CHL-M2000-C/F-EN
www.proloncontrols.com |[e-mail]
17 510, rue Charles, Suite 100, Mirabel, QC, J7J 1X9

2
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Table of Contents
General Information ....................................................................................................................................................... 4
PL-M2000 Chiller Controller............................................................................................................................................................................4
Description............................................................................................................................................................................................................4
General Behavior ................................................................................................................................................................................................4
Operating Sequence ....................................................................................................................................................... 5
Pump.......................................................................................................................................................................................................................5
Water Supply Setpoint......................................................................................................................................................................................5
Chiller Stages........................................................................................................................................................................................................5
Pressure Control..................................................................................................................................................................................................5
Components .................................................................................................................................................................... 6
Component Identication...............................................................................................................................................................................6
LEDs and Switches..............................................................................................................................................................................................7
HAND/OFF/AUTO Switches .............................................................................................................................................................................8
Jumpers..................................................................................................................................................................................................................8
Input and Output Identication....................................................................................................................................................................9
Addressing Dipswitch Conguration for Network Communication............................................................................................. 10
Inputs ..............................................................................................................................................................................11
Temperature Sensors ......................................................................................................................................................................................11
Proof of Pumps ..................................................................................................................................................................................................11
Water Pressure...................................................................................................................................................................................................12
Alarm Contact....................................................................................................................................................................................................12
Outputs .......................................................................................................................................................................... 13
Output Specications .....................................................................................................................................................................................13
Typical Connection of Triac Outputs 1 to 5.............................................................................................................................................14
Typical Connection of Analog Outputs 1 to 3........................................................................................................................................14
Power Source & Network.............................................................................................................................................. 15
Power Source .....................................................................................................................................................................................................15
Network Communication..............................................................................................................................................................................15
Technical Specications ............................................................................................................................................... 16
Compliance .....................................................................................................................................................................17
FCC User Information......................................................................................................................................................................................17
Industry Canada ...............................................................................................................................................................................................17
Overall Dimensions....................................................................................................................................................... 18

3
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Table of Figures
Figure 1 - Component Identication..................................................................................................................................................................6
Figure 2 - LEDs Identication................................................................................................................................................................................7
Figure 3 - Location of the EXTERNAL jumpers...............................................................................................................................................8
Figure 4 - Location of the INTERNAL jumpers.................................................................................................................................................8
Figure 5 - INT and NET jumpers ...........................................................................................................................................................................8
Figure 6 - AI jumpers................................................................................................................................................................................................8
Figure 7 - RJ45 Pinout..............................................................................................................................................................................................9
Figure 8 - Input and Output Identication.......................................................................................................................................................9
Figure 9 - Addressing Dipswitch....................................................................................................................................................................... 10
Figure 10 - Connecting the Temperature Sensors.......................................................................................................................................11
Figure 11 - Connecting the Proof of Pump Contacts to the Controller ...............................................................................................11
Figure 12 - Connecting the Water Pressure Sensor to the Controller...................................................................................................12
Figure 13 - Connecting the Alarm Input Contacts to the Controller ....................................................................................................12
Figure 14 - Wiring Example of Digital Outputs 1 and 2.............................................................................................................................14
Figure 15 - Wiring Example of Analog Output 1..........................................................................................................................................14
Figure 16 - Connecting the 24VAC Power Source........................................................................................................................................15
Figure 17 - Connecting to the Network...........................................................................................................................................................15
Figure 18 - M2000 Size Diagram ........................................................................................................................................................................18

4
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
General Information
Description
The Prolon PL-M2000 Chiller Controller is a microprocessor-based controller designed to operate chiller equipment (AIR
COOLED and WATER COOLED chillers) with up to four stages, as well the associated system pumps. It features a variety
of control strategies, including outside temperature reset scales, lead-lag sequences, pump exercise intervals and more.
General Behavior
The Prolon M2000 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, water pressure 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.
PL-M2000 Chiller Controller

5
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Operating Sequence
Pump
The PL-M2000 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-M2000 Chiller controller can be congured to control up to four chiller stages in various
combinations (ex.: a single chiller with four stages, two dual-stage chillers, etc..). For water cooled chillers, chiller activity
can be interlocked or staged down based on the entering or leaving 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 work-
load.
Pressure Control
The PL-M2000 Chiller controller can maintain a congurable xed water pressure setpoint by modulating analog outputs
that drive a VFD attached to each pump. A PI Loop can be ne-tuned to obtain optimal results. The controller accepts
both negative and positive pressure setpoints and supports a wide variety of input and output signals.

6
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Components
Figure 1 - Component Identication
Component Identification
Legend:
A- Addressing Dipswitch
B- AUTO/OFF/HAND Switches
C- RS485 INT port for interface communication (RJ45 plug and screw connectors are in parallel)
D- Analog outputs (3)
E- Digital outputs (5)
F- Analog inputs (9)
G- RS485 NET port for network communication
H- Terminal block for 24VAC (Class 2 transformer)
I - Jumpers for terminating and bias resistors for the INT port
J - Jumpers for terminating and bias resistors for the NET port

7
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
LEDs and Switches
The M2000 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.
LED Descriptions
•24 VAC: The M2000 is receiving 24 VAC from the power
source.
•5V DC: The microchip and other components on the
M2000 are being powered successfully by a 5 VDC
source derived from the 24VAC source.
•HBEAT: When this LED is blinking, the microchip is
active and the controller’s program is running (normal).
When this LED is ON and steady, the M2000 is inactive
and the microchip is awaiting programming (you must
use Prolon’s Focus software to reprogram the
microchip).
•STAT: Reserved.
•NETSND: Indicates the transmission of data onto the
network communication bus.
•NETREC: Indicates reception of data from the network
communication bus.
•INTSND: Indicates the transmission of data onto the
interface communication bus.
•INTREC: Indicates the reception of data from the inter-
face communication bus.
•AO3: The intensity of the LED represents the voltage
present on analog output 3.
•AO2: The intensity of the LED represents the voltage
present on analog output 2.
•AO1: The intensity of the LED represents the voltage
present on analog output 1.
•DO5: Represents the activity of digital output 5.
•DO4: Represents the activity of digital output 4.
•DO3: Represents the activity of digital output 3.
•DO2: Represents the activity of digital output 2.
•DO1: Represents the activity of digital output 1.
Figure 2 - LEDs Identication
AO 3
AO 2
AO 1
DO 5
DO 4
DO 3
DO 2
DO 1
INTSND
INTREC
NETSND
NETREC
24VAC
5VDC
HBEAT
STAT

8
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
HAND/OFF/AUTO Switches
Jumpers
Each output on the M2000 has a dedicated switch that lets the user manually override the activity of the output. “HAND”
mode (switch at rightmost position) fully activates the output (24 VAC for digital outputs, 10VDC for analog outputs).
“OFF” (switch at center) deactivates the output and “AUTO” (switch at left) returns control of the output to the program
in the M2000’s microchip.
The M2000 has jumpers that are externally accessible (see Figure 3), as well as jumpers that are on the lower internal
board (see Figure 4), that allow for conguration of various hardware elements.
• INT: These are the jumpers for the bias and terminating resistors used for the interface communication bus. See the
Prolon network guide for information about bias and terminating resistors. (See Figure 5)
• NET: These are the jumpers for the bias and terminating resistors used for the network communication bus. See the
Prolon network guide for information about bias and terminating resistors. (See Figure 5)
• AI 1 - 9: These jumpers allow the user to select the signal mode of the associated analog input. (See Figure 6)
Figure 5 - INT and NET jumpers Figure 6 - AI jumpers
0-5 volts 4-20 mA THERMISTOR
Figure 3 - Location of the EXTERNAL jumpers Figure 4 - Location of the INTERNAL jumpers
INT
NET
AI9
AI8
AI7
AI6
AI5
AI4
AI3
AI2
AI1
Jumper AI

9
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Input and Output Identification
All the inputs and outputs of the M2000 use pluggable screw type terminal blocks with elevator style clamping, which
make connections easier and more secure.
The M2000 Chiller 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.
The “INT” Port (see below) oers dual RJ45 type connectors in parallel with screw type terminal blocks. The RJ45 con-
nectors allow the use of premade CAT5 cables for simple plug-and-play RS485 communication. These RJ45 connectors
follow the Modbus pinout specication for RS485 communication.
Figure 7 - RJ45 Pinout
Figure 8 - Input and Output Identication
24
VAC
INT Port: Incoming RS485
network communication (modbus)
VFD Pump 1
Chiller 3
Chiller 2
Chiller 1
Pump 2
Pump 1
NET Port: Incoming RS485
network communication (modbus)
Controller’s power source
(24VAC - Class 2)
Bottom row:
common for all outputs
Bottom row:
common for all inputs
VFD Pump 2
Chiller 4
Proof of Pump 2
Condenser Water Temperature Entering
Condenser Water Temperature Leaving
Water Pressure
Alarm
Return Water Temperature
Proof of Pump 1
Supply Water Temperature
Outside Air Temperature

10
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Addressing Dipswitch Configuration for Network Communication
For proper communication, a unique address must be congured on each controller 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, and 64 respectively).
The last switch (#8) is reserved. The value of each switch that is in the ON position is added together to form the nume
rical address of the controller.
The example in Figure 9 shows the switches 1, 2 and 4 in the ON position. Therefore, the corresponding values are 1, 2
and 8, giving an address sum of 11.
The Prolon network allows a maximum of 127 addresses; therefore 127 controllers.
Figure 9 - Addressing Dipswitch

11
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Inputs
Temperature Sensors
Figure 10 - Connecting the Temperature Sensors
The M2000 Chiller Controller has ve analog inputs to monitor various temperature readings, including outside air,
supply water, return water, entering condenser water (ECWT) and leaving condenser water (LCWT) temperatures. The
sensors used are standard 10k type 3 thermistors that share a single common connection (see Figure 10).
Note that 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.
Proof of Pumps
The M2000 has two analog inputs dedicated to the proof of pump signals. Please refer to Figure 11 to see how to correctly
connect them. 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.
Figure 11 - Connecting the Proof of Pump Contacts to the Controller
Return water sensor
Supply water sensor
Outside air sensor
ECWT
LCWT
Proof of Pump 2
(DO2)
Proof of Pump 1
(DO1)

12
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Water Pressure
Alarm Contact
Analog Input 8 on the M2000 Chiller Controller is dedicated to a water pressure sensor. The M2000 accepts various
input signal voltages including 0-5VDC, 1-5VDC and 0.5-4.5VDC. Additionally, it can accept current-based signals as well,
including 4-20mA and 0-20mA, but the internal jumpers rst need to be set in the correct mode for current sensing (see
Jumpers section).
The actual pressure range is congurable in the controller and can span anywhere between -500 to 500 PSI. Please refer
to Figure 12 for correct wiring.
Analog Input 9 on the M2000 Chiller Controller is dedicated to an Alarm Input Signal. This signal can be used to deactivate
the pumps or can be used just for display purposes. Refer to Figure 13 for correct wiring.
Figure 12 - Connecting the Water Pressure Sensor to the Controller
Figure 13 - Connecting the Alarm Input Contacts to the Controller
Water Pressure
Sensor
(+)
(-)
Alarm on
Contact Closure

13
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Outputs
Output Specifications
The M2000 Chiller controller contains 8 customizable outputs; ve triac ON/OFF outputs (24VAC) and three analog
outputs (0-10VDC). Output conguration is performed via the Prolon Focus software.
An integrated resettable fuse protects each of the outputs of the M2000 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 a round, yellow-
coloured PTC that will change to orange and heat up on an overload condition. Once power has been removed from the
M2000, the fuse will cool down and automatically reset. Fix the faulty wiring and you will be able to activate the output
once again.
Output Type Action Application
DO 1 Triac source 24VAC,
Max Current: 300 mA On-or-O Pump 1
DO 2 Triac source 24VAC,
Max Current: 300 mA On-or-O Pump 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
DO 5 Triac source 24VAC,
Max Current: 300 mA On-or-O Chiller Stage 3
AO 1
Congurable Analog Output:
- 0 to 10 VDC
- 2 to 10 VDC
- 0 to 5 VDC
Max Current: 40 mA
Modulating Proportional Variable Frequency
Drive 1
AO 2
Congurable Analog Output:
- 0 to 10 VDC
- 2 to 10 VDC
- 0 to 5 VDC
Max Current: 40 mA
Modulating Proportional Variable Frequency
Drive 2
AO 3
Congurable Analog Output:
- 0 to 10 VDC
Max Current: 40 mA
On-or-O Chiller Stage 4

14
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Typical Connection of Triac Outputs 1 to 5
Typical Connection of Analog Outputs 1 to 3
On the M2000 Chiller controller, all triac outputs produce a 24 VAC live voltage when activated. Note that all output
voltages originate from a single voltage supply: the equipment’s transformer. Consequentially, only the live side of the
output connections are usually needed; these are on the top row (see Figure 14). The bottom row is the common (GND).
For all analog outputs, the common is found on the bottom row terminal block, and the active signals are found on the
top row terminal block (see Figure 15).
Analog Outputs 1 and 2 are set to modulate the VFD for each pump (DC load using 0-10 VDC, 2-10 VDC or 0-5 VDC).
Analog Output 3 is congured to control a 10 VDC On/O relay that will drive Chiller Stage #4 (if applicable).
Figure 15 - Wiring Example of Analog Output 1
Figure 14 - Wiring Example of Digital Outputs 1 and 2
(Pump 2)
Equipment Terminal Board
(Pump 1)
(+)
(-)
External Load
VFD 1

15
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Power Source & Network
Power Source
Network Communication
The M2000 controller is powered by a 24 VAC power supply (class 2) by connecting the common (’’C’’ wire) to the "COM"
terminal and the live (‘’R’’ wire) to the "24 VAC" terminal (see Figure 16). The common for all inputs and outputs is the
same as the power source’s common. All output power sources also originate from the source transformer (class 2).
The Prolon M2000 Chiller controller is designed to work standalone or networked with Prolon master controllers.
When networked, the master transmits the occupancy status, outside temperature and math demand in real-time. The
network connections are made using the network terminal block located on the M2000 controller (see Figure 17).
Figure 16 - Connecting the 24VAC Power Source
Figure 17 - Connecting to the Network
( A )
( B )
Towards
RS485
Network
( R )
( C )
To transformer (class 2)
24VAC

16
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Technical Specifications
Supply: 24 VAC ±10%, 50/60 Hz, Class 2
Power: 5 VA (consumption), 40 VA (input)
Inputs: 9 analog inputs (outside temp / supply water temp / return water temp / dry contacts for proof of pumps,
entering condenser water temp, leaving condenser water temp, water pressure and alarm). Input signals (thermistor
/ dry contact / 4-20mA / 0-5 VDC) individually configurable for each input.
Digital Outputs: 5 triac outputs, 10-30 VAC source, 300 mA max (resettable fuse)
Analog Outputs: 3 x 0-10 VDC outputs, 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 Rates: 9600, 19200, 38400, 57600, 76800, 115200
Connection: Removable screw-type terminal blocks (max 16 AWG) and RJ45 modular jacks
Dimensions: 5.39" x 4.41" x 2.25" (137 mm x 112 mm x 57 mm)
Weights: 1.05 lbs (0.48 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.

17
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Compliance
• cULus Listed; UL 916 Energy Management Equipment, File E364757, Vol.1
• CAN/CSA-C22.2 No. 2015-12, Signal Equipment
• 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.

18
REV. 7.3.4 / PL-HRDW-CHL-M2000-C/F-EN
Overall Dimensions
REV. 7.3.4
PL-HRDW-CHL-M2000-C/F-EN
4.41"
(112 m m)
5.39"
(137 mm)
2.29"
(58 mm)
Figure 18 - M2000 Size Diagram
12345678
© 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.