Prolon M2000 SERIES Installation instructions

HARDWARE GUIDE
Boiler Controller M2000 Series
Specifications and Operational Guide
REV. 7.2.0
PL-HRDW-BLR-M2000-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-M2000 Boiler Controller .............................................................................................................................................................................4
Description............................................................................................................................................................................................................4
General Behavior ................................................................................................................................................................................................4
Operating Sequence .........................................................................................................................................................................................5
General...................................................................................................................................................................................................................5
Parallel Pump Sequence ..................................................................................................................................................................................5
Follower Pump Sequence................................................................................................................................................................................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
Max Heat Setpoint............................................................................................................................................................................................12
Disable Boiler Call.............................................................................................................................................................................................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

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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 (Staged Boiler) ........................................................................................................................9
Figure 9 - Input and Output Identication (Modulating Boiler)............................................................................................................ 10
Figure 10 - Addressing Dipswitch..................................................................................................................................................................... 10
Figure 11 - Connecting the Temperature Sensors.......................................................................................................................................11
Figure 12 - Connecting the Proof of Pump Contacts to the Controller ...............................................................................................11
Figure 13 - Connecting Max Heat Setpoint Contact to the Controller.................................................................................................12
Figure 14 - Connecting Disable Boiler Call Contacts to the Controller................................................................................................12
Figure 15 - Wiring Example of Digital Outputs 1 and 2.............................................................................................................................14
Figure 16 - Wiring Example of Analog Output 1..........................................................................................................................................14
Figure 17 - Connecting the 24VAC Power Source........................................................................................................................................15
Figure 18 - Connecting to the Network...........................................................................................................................................................15
Figure 19 - M2000 Size Diagram ........................................................................................................................................................................18

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General Information
Description
The Prolon PL-M2000 Boiler controller is a microprocessor-based controller designed to operate staged or modulating
boilers, as well as the associated pumps and valves. It features a variety of control strategies, including outside tempera-
ture reset scales, lead-lag sequences, pump exercise intervals and more.
General Behavior
Although fully congurable, the Prolon M2000 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.
PL-M2000 Boiler Controller

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Operating Sequence
General
The Prolon M2000 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 inputs 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 scale 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 (supply temperature is below the target), which can be interlocked with the
outside temperature. The M2000 boiler controller can be congured to control up to four boiler stages, whether it be
a single boiler with four stages or four single stage boilers, or a combination thereof. The M2000 boiler controller can
alternately control up to two modulating boilers with an optional backup stage, in which these boilers will modulate to
attain target temperature. Boiler outputs (staged or modulating) can also be set up for various lead-lag sequences that
will cycle through the position of the lead boiler stage.
The M2000 boiler controller can also be used to control a three-way valve when congured for staged control.
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 scale 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 (supply temperature is below the target), which can be interlocked with the outside temperature. The M2000
boiler controller can be congured to control up to four boiler stages, whether it be a single boiler with four stages or
four single stage boilers, or a combination thereof. Boiler stages can also be set up for various lead-lag sequences that
will cycle through the position of the lead boiler stage.
The M2000 boiler controller can also be used to control a three-way valve.

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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

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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

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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

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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 Boiler 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
24
VAC
Controller’s Power Source
(24VAC - Class 2)
AO1 Pump 2 (ON/OFF) (0-10 VDC)
DO5 Pump 1
DO4 Boiler Stage 4
DO3 Boiler Stage 3
DO2 Boiler Stage 2
DO1 Boiler Stage 1
Proof of Pump 2 (AO1) (Dry Contact)
Use Max Heat Setpoint (Dry Contact)
Disable Boiler Call (Dry Contact)
Return Water temp sensor (10K thermistor)
Proof of Pump 1 (DO5) (Dry Contact)
Supply Water temp sensor (10K thermistor)
Outside air temperature sensor (10K thermistor)
INT Port: Incoming RS485
Network communication (Modbus)
NET Port: Incoming RS485 Network
communication (Modbus)
AO3 Valve (0-10 / 2-10 / 0-5 VDC)
Figure 8 - Input and Output Identication (Staged Boiler)

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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 numer-
ical 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 10 - Addressing Dipswitch
24
VAC
Controller’s Power Source
(24VAC - Class 2)
AO3 - Modulating Boiler Stage 2
(0-10 / 2-10 / 0-5 VDC)
AO2 - Modulating Boiler Stage 1
(0-10 / 2-10 / 0-5 VDC)
AO1 - Pump 2 (ON/OFF) (0-10 VDC)
DO5 - Pump 1
DO4 - Boiler Backup Stage
DO3 - N/A
DO2 - Boiler Stage 2 Enable
DO1 - Boiler Stage 1 Enable
Proof of Pump 2 (AO1) (Dry Contact)
Use Max Heat Setpoint (Dry Contact)
Disable Boiler Call (Dry Contact)
Return Water temp sensor (10K thermistor)
Proof of Pump 1 (DO5) (Dry Contact)
Supply Water temp sensor (10K thermistor)
Outside air temperature sensor (10K thermistor)
INT Port: Incoming RS485
Network communication (Modbus)
NET Port: Incoming RS485 Network
communication (Modbus)
Figure 9 - Input and Output Identication (Modulating Boiler)

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Inputs
Temperature Sensors
Figure 11 - Connecting the Temperature Sensors
Outside air sensor
Supply water sensor
Return water sensor
The M2000 Boiler controller has three analog inputs that monitor supply, outside and zone air temperatures (see Figure
10) and will integrate these readings into its control sequence. The sensors used are standard 10k type 3 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.
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 correct-
ly 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
heating action will be taken.
Figure 12 - Connecting the Proof of Pump Contacts to the Controller
Proof of Pump 2
(AO1)
Proof of Pump 1
(DO5)

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Max Heat Setpoint
Disable Boiler Call
The M2000 has one analog input dedicated to enabling the maximum heating setpoint. By shorting the input to ground,
the M2000 Boiler controller will use its highest hot water setpoint when using the setpoint reset feature. If the M2000
Boiler controller is using a xed setpoint, then this input has no eect on the operation of the controller.
The M2000 has one analog input dedicated to disabling the boiler outputs. By shorting the input to ground, the M2000
Boiler controller will disable all boiler outputs (digital and analog). Note that the pump operation is not aected by this
input.
Figure 13 - Connecting Max Heat Setpoint Contact to the Controller
Figure 14 - Connecting Disable Boiler Call Contacts to the Controller
Max Heat Setpoint
Disable Boiler Call

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Outputs
Output Specifications
The M2000 Boiler 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-co-
loured 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 Boiler Stage 1
DO 2 Triac source 24VAC,
Max Current: 300 mA On-or-O Boiler Stage 2
DO 3 Triac source 24VAC,
Max Current: 300 mA On-or-O Boiler Stage 3
DO 4 Triac source 24VAC,
Max Current: 300 mA On-or-O Boiler Stage 4
DO 5 Triac source 24VAC,
Max Current: 300 mA On-or-O Pump 1
AO 1
Congurable Analog Output:
- 0 to 10 VDC
Max Current: 40 mA
On-or-O Pump 2
AO 2
Congurable Analog Output:
- 0 to 10 VDC
- 2 to 10 VDC
- 0 to 5 VDC
Max Current: 40 mA
Modulating Proportional Modulating Boiler
AO 3
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 /
Modulating Boiler
(Backup)

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Typical Connection of Triac Outputs 1 to 5
Typical Connection of Analog Outputs 1 to 3v
On the M2000 Boiler 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 12). 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 13). Analog output 1 is congured to control a 10 VDC On/O relay. Analog outputs 2
and 3 can only modulate a DC load (0-10 VDC, 2-10 VDC, 0-5 VDC).
Figure 16 - Wiring Example of Analog Output 1
Figure 15 - Wiring Example of Digital Outputs 1 and 2
(+)
(-)
External Load
Pump 2
(Boiler Stage 2)
Equipment Terminal Board
(Boiler Stage 1)

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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 14). 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 Boiler 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 15).
Figure 17 - Connecting the 24VAC Power Source
Figure 18 - Connecting to the Network
( A )
( B )
Towards
RS485
Network
( R )
( C )
To transformer (class 2)
24VAC

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Technical Specifications
Supply: 24 VAC ±10%, 50/60 Hz, Class 2
Power: 5 VA (consumption), 40 VA (input)
Inputs: 7 configurable analog inputs (outside temp / supply temp / return temp / dry contacts for proof of pumps,
max heat request and boiler disable). Input signals (thermistor / dry contact / 4-20mA / 0-5 VDC) individually
configurable for each inputt
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: 32-122 ºF (0-50 ºC) Non-Condensing
Certication: UL916 Energy Management Equipment, CAN/CSA-C22.2, RoHS
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.

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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 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.

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Overall Dimensions
REV. 7.2.0
PL-HRDW-BLR-M2000-C/F-EN
4.41"
(112 mm)
5.39"
(137 mm)
2.29"
(58 mm)
Figure 19 - M2000 Size Diagram
AUTO/OFF/HAND
INTSND
INTREC
INT
OUTPUTS
NETSND
NETREC
24VAC
5VDC
proloncontrols.com
1-877-9PROLON
ON
OFF
HBEAT
STAT
PL-M2000-XXX VER: X.X.X
ADDRESS PROJECT
NET
12345678
1248 16 32 64 B
RS485 NET
M2000
© Copyright 2019 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.