Prolon PL-C1000 Series Quick start guide

Hardware Guide
Boiler Controller
C1000 Series
Specifications and Operational Guide
REV 6.3
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PL-HRDW-C1000BLR-C/F-EN-V63

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Table of Contents
GENERAL INFORMATION............................................................................................................................... 3!
PL-C1000 Boiler Controller ........................................................................................................................... 3!
Description ...................................................................................................................................................................3!
General Behaviour .......................................................................................................................................................3!
Operating Sequence ..................................................................................................................................... 4!
General ........................................................................................................................................................................4!
Parallel Pump Sequence .............................................................................................................................................4!
Follower Pump Sequence............................................................................................................................................5!
COMPONENTS............................................................................................................................................. 6!
Component Identification............................................................................................................................... 6!
LEDs.............................................................................................................................................................. 7!
Address Configuration for Networking........................................................................................................... 8!
Jumper to supply power to the RJ45 plug ..................................................................................................... 8!
Input and Output Identification ...................................................................................................................... 9!
INPUTS............................................................................................................................................................ 10!
Temperature Sensors.................................................................................................................................. 10!
Proof of Pump ............................................................................................................................................. 11!
OUTPUTS........................................................................................................................................................ 12!
Output Specifications .................................................................................................................................. 12!
Configuration of Digital Outputs .................................................................................................................. 13!
Typical Connection of Digital Outputs ......................................................................................................... 14!
Typical connection of the analog output...................................................................................................... 15!
POWER SOURCE / NETWORK ..................................................................................................................... 16!
Power Source.............................................................................................................................................. 16!
Network Communication ............................................................................................................................. 16!
Technical Specifications............................................................................................................................... 17!
Compliance .................................................................................................................................................... 18!
FCC User Information ................................................................................................................................. 18!
Industry Canada .......................................................................................................................................... 18!
OVERALL DIMENSIONS................................................................................................................................ 19!

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3
GENERAL INFORMATION
PL-C1000 Boiler Controller
Description
The ProLon PL-C1000 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 configurable, the ProLon C1000 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 modification or fine tuning of the pumps, the boilers, the target supply
temperature, the proportional bands, integration times, differentials, 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 influence of schedules or other data
received over the network. All these parameters can be accessed and modified by using the ProLon
Focus software.

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Operating Sequence
General
The ProLon C1000 Boiler controller receives readings from three different 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 configurable 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 configurable periods of inactivity.
The target supply temperature can be a fixed setpoint or instead follow a reset based on outside
temperature. The target supply temperature can also be reduced in unoccupied mode or influenced 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 C1000 boiler controller can be configured to control up to
two boiler stages. Boiler stages can also be set up for various lead-lag sequences that will cycle through
the position of the lead boiler stage.
The C1000 boiler controller can also be used to control a three way valve, which it will modulate to attain
the target temperature.

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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 configurable periods of inactivity.
The target supply temperature can be a fixed setpoint or instead follow a reset based on outside
temperature. The target supply temperature can also be reduced in unoccupied mode or influenced 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 C1000 boiler controller can be configured to control up to
two boiler stages. Boiler stages can also be set up for various lead-lag sequences that will cycle through
the position of the lead boiler stage.
The C1000 boiler controller can also be used to control a three way valve, which it will modulate to attain
the target temperature.

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COMPONENTS
Component Identification
1""""2 3""""4 5""""6 7""""8 9"""10 11""12 13""14 15""16 17""18 19
A
B
C
D
BIAS TERM
NET
BIAS TERM
INT
H
I
E
N
M
L
K
J
F
G
Legend:
A= Addressing dipswitch
B= Jumpers for terminating and bias resistors for the NET port (see J)
C= Jumpers for terminating and bias resistors for the INT port (see K)
D= SOURCE/SINK dipswitch for Output 4 (Boiler Stage 2)
E= SOURCE/SINK dipswitch for Output 3 (Boiler Stage 1)
F= SOURCE/SINK dipswitch for Output 2 (Pump 2)
G= SOURCE/SINK dipswitch for Output 1 (Pump 1)
H= Reset Button
I= Jumper to supply voltage to INT port (see J)
J= INT port for RS485 communication (RJ45 jack)
K= NET port for RS485 communication (terminal block)
L= Inputs (4 total)
M= Terminal Blocks for Outputs 1 to 5
N= Terminal Blocks for 24 VAC

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LEDs
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.
Green pulsing,
indicates that the
CPU is online
Green light: Internal 5 VDC
power source OK
Status light for triac output 4
(Boiler 2)
Status light for analog output 5
(Valve / Modulating Boiler)
Green light: Reception
from NET port
Red light: Sending to
NET port
Green light: Reception
from INT port
Green light: Internal
24VDC power source
OK
Red light: Sending
to INT port
OUT4 OUT5 STATHBEAT
Status light for triac output 3
(Boiler 1)
OUT3
Status light for triac output 2
(Pump 2)
OUT2
Status light for triac output 1
(Pump 1)
OUT1

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Address Configuration for Networking
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 1 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.
Jumper to supply power to the RJ45 plug
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 a 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:
No power 24 VAC 24 VDC
12 3 4 5 6 7
Figure 1: Addressing
Dipswitches

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Input and Output Identification
All the inputs and outputs of the C1000 use pluggable screw type terminal blocks with elevator style
clamping, which make connections easier and more secure.
The C1000 Boiler Controller has two 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.
Power&source&of&the&controller
24&VAC
NET&Port:&Incoming&RS485&Network&
communication&(Modbus)
OUT5
OUT4
24VACCOM
Outputs Inputs Net
INTERFACE
Supply
Common&for&all&the&inputs
Outside&air&temperature&sensor&(10K&thermistor)
Return&water&temperature&sensor&(10K&thermistor)
Supply&water&temperature&sensor&(10K&thermistor)
External&dry&contact&for&proof&of&pump
Output&5&– Valve&/&Modulating&Boiler
(Analog&0-10&/&2-10&/&0-5&VDC)
Output&4&– Boiler&2&Action
(Digital&- ON/OFF)
INT&Port:&Incoming&RS485&Network&
communication&(Modbus)
PL-C1000-BLR
HBEAT
1&&&&2 9&&&&&10 11&&&12 13&&&&14 15&&16 17&&18 19
NETREC NETSND STAT INTSNDINTREC
COM
+
24VAC
COM
ROOM
SETPT
GND
SUPPLY
OCC
A
B
NET
RESET
Output&3&– Boiler&1&Action&
(Digital&- ON/OFF)
OUT3
24VAC
COM
7&&&&&8
OUT2
24VAC
COM
5&&&&&6
OUT1
24VAC
COM
3&&&&&4
Output&2&– Pump&2&Action
(Digital&- ON/OFF)
Output&1&– Pump&1&Action
(Digital&- ON/OFF)
RJ45 Pinout
1"""2"""3"""4"""5"""6"""7"""8
AB GND
(+)(-)

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INPUTS
Temperature Sensors
The C1000 Boiler controller has three analog inputs that monitor outside air, supply water and return
water temperatures (see Figure 2) 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 2: Connecting the temperature sensors

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Proof of Pump
The C1000 has one digital inputs dedicated to the proof of pump signals. Please refer to Figure 3 see
how to correctly connect it. To indicate proof of pump, the contact must be closed. If no proof of pump
signal is available, you must short the corresponding input, or else the controller will interpret the
absence of signal as a pump malfunction and no heating action will be taken.
Proof%of%
pump
17%%%18 19
A
B
GND
SUPPLY
NET
13%%%%%14 15%%%%%16
ROOM
SETPT
OCC
Figure 3: Connecting the proof of pump contacts to the controller

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OUTPUTS
The C1000 Boiler controller contains 5 customizable outputs; four triac ON/OFF outputs (24VAC) and
one analog output (0-10VDC). Output configuration is performed via the ProLon Focus software.
An integrated resettable fuse protects each of the outputs of the C1000 against current surges and short
circuits. This protection will cut the current to the output as soon as an overload condition is detected.
The fuse is round and yellow-colored which, upon a short circuit condition, will heat up and change to
orange. When the faulty wiring or circuit is fixed, the fuse will automatically reset and allow current to
flow through the output again.
Output Specifications
Output Type Action Application
DO 1
Triac source 24VAC
Max Current:300 mA
On-or-Off Pump Stage 1
DO 2
Triac source 24VAC
Max Current:300 mA
On-or-Off Pump Stage 1
DO 3
Triac source 24VAC
Max Current:300 mA
On-or-Off Boiler Stage 1
DO 4
Triac source 24VAC
Max Current:300 mA
On-or-Off Boiler Stage 2
AO 1
Configurable Analog Output:
- 0 to 10 VDC
- 2 to 10 VDC
- 0 to 5 VDC
Max Current: 40 mA
Modulating proportional
Three W ay Valve or
Modulating Boiler

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Configuration of Digital Outputs
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 4):
24 VAC Output (On/Off)
Output 4 Common
Out 5Out 4
Output
7 8 9 10 11 12
Switch for
Output 4
24 VAC
Com
Figure 4: Output in SOURCE mode
2) Switch position to obtain a SINK passive output (see Figure 5):
Out 5Out 4
Output
7 8 9 10 11 12
Isolated dry contact
(On/Off)
Switch for
Output 4
Figure 5: Output in SINK mode

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Typical Connection of Digital Outputs
Two types of configurations are possible:
1) Active output (SOURCE). The C1000 is actively powering the load. (see Figure 6)
Out 5Out 4
Outputs
R
External Load
Com
24 v
7 8 9 10 11 12
Figure 6: Connection of active outputs 3 and 4
2) Passive output (SINK). The C1000 opens and closes a contact to allow an external source to
power the load (see Figure 7).
Out 5Out 4
Outputs
R
External Load
24 N
External 24 V
7 8 9 10 11 12
Figure 7: Connection of passive outputs 3 and 4

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Typical connection of the analog output
Two types of configuration are possible:
1) The C1000 powers the load and provides a control signal (see Figure 8)
Out$5
Out$4
Outputs
Com
0-10v
Com
24$v
0-10v Controlled$
Load
24$VAC$power$
(From$terminal$block$
#2$of$the$controller)
7$$$$$$8 9$$$$10 11$$$$12
Figure 8: Connecting the analog output (controller powered)
2) The C1000 only provides the control signal to the load, which is powered by an external source (see
Figure 9)
Out$5Out$4
Outputs
Com
0-10v
Com
24$v
0-10vControlled$
Load
External$
24$VAC$
source
7$$$$$$8 9$$$$10 11$$$$12
N
Figure 9: Connecting the analog output (external power)

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POWER SOURCE / NETWORK
Power Source
The ProLon C1000 controller is powered by a 24 VAC
power source connected using the "COM" terminal and
the "24 VAC" terminal (see Figure 10). 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.
Network Communication
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 1). The network connections are made using the NET terminal block located on the ProLon
C1000 controller (see Figure 11).
Towards
network
13 14 15 16 17 18 19
ROOM
SETPT
A
B
GND
SUPPLY
OCC
NET
Figure 11: Connecting to the network
N
L
120Vac24Vac
Out 1
24VAC
COM
Supply
1 2 3 4
Figure 10: Connecting the 24VAC power
source

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Technical Specifications
Supply: 24 VAC ±10%, 50/60 Hz, Class 2
Consumption: 5 VA
Inputs: Outside air – thermistor 10K
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 dry contact, 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
Communication: Modbus RTU (RS485), up to 127 nodes
Baud rate: 9600, 19200, 38400, 57600, 76800, 115200
Wiring: Removable screw-type terminal blocks (16 AWG max) and RJ45 modular jack
Dimensions: 157 mm x 133 mm (6.2" x 5.2" )
Environment: 0-50 ºC (32-122 ºF) Non-Condensing
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.

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Compliance
•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 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.

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19
OVERALL DIMENSIONS
165$mm
6.5"
135$mm
5.3"
1$$$$2 3$$$$4 5$$$$6 7$$$$8 9$$$10 11$$12 13$$14 15$$16 17$$18 19
55$mm
2.2"
© Copyright 2016 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 specifications 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.