Prolon PL-M2000 Series Installation instructions

Hardware Guide
Boiler Controller
M2000 Series
Specifications and Operational Guide
REV 6.3
www.proloncontrols.com
[email protected]
PL-HRDW-M2000BLR-C/F-EN-V63

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Table of Contents
GENERAL INFORMATION............................................................................................................ 3!
PL-M2000 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 and Switches ....................................................................................................................................... 7!
HAND/OFF/AUTO Switches.......................................................................................................................... 8!
Jumpers......................................................................................................................................................... 9!
Input and Output Identification .................................................................................................................... 10!
Addressing Dipswitch Configuration for Network Communication .............................................................. 11!
INPUTS ............................................................................................................................................. 12!
Temperature Sensors.................................................................................................................................. 12!
Proof of Pumps............................................................................................................................................ 13!
OUTPUTS ......................................................................................................................................... 14!
Output Specifications .................................................................................................................................. 14!
Typical Connection of Triac Outputs 1 to 5 ................................................................................................. 15!
Typical Connection of Analog Outputs 1 to 3 .............................................................................................. 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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GENERAL INFORMATION
PL-M2000 Boiler Controller
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 temperature reset scales, lead-lag
sequences, pump exercise intervals and more.
General Behaviour
Although fully configurable, 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 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 M2000 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 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 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 scale 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 M2000 boiler controller can be configured 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 or an analog boiler, in 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 scale 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 M2000 boiler controller can be configured 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 or an analog boiler, in which it
will modulate to attain the target temperature.

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COMPONENTS
Component Identification
A
B
C
D
E
F
I
J
G
H
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 (powered by 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 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.
INTSND
INTREC
AO 3
AO 2
AO 1
DO 5
DO 4
DO 3
DO 2
DO 1
24 VAC
5 VDC
HBEAT
STAT
NETSND
NETREC
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 5V DC 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 interface 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.

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•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.
HAND/OFF/AUTO Switches
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.

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BIAS1
BIAS2
TERM
AI9
AI8
AI7
AI6
AI5
AI4
AI3
AI2
AI1
Jumpers
The M2000 has jumpers that are externally accessible (see Figure 1), as well as jumpers that are on the
lower internal board (see Figure 2), that allow for configuration 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.
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.
AI 1 - 9: These jumpers allow the user to select the signal mode of the associated analog input.
0-5 volts 4-20 mA THERMISTOR
INT
NET
Figure 1: Location of the EXTERNAL jumpers
Figure 2: Location of the INTERNAL jumpers

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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 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) offers dual RJ45 type connectors in parallel with screw type terminal blocks.
The RJ45 connectors allow the use of premade CAT5 cables for simple plug-and-play RS485
communication. These RJ45 connectors follow the Modbus pinout specification for RS485
communication.
Controller’s power source
24VAC – Class 2
NET$Port:$Incoming$RS485$Network$
communication$(Modbus)
Bottom Row:
Common for all outputs
DO1 Boiler Stage 1
DO2 Boiler Stage 2
DO3 Boiler Stage 3
DO4 Boiler Stage 4
AO1 Pump 2 (ON/OFF) (0/10 VDC)
AO2 Modulating Boiler
(0-10 / 2-10 / 0-5 VDC)
AO3 Valve (0-10 / 2-10 / 0-5 VDC)
or Backup Modulating Boiler
INT$Port:$Incoming$RS485$
Network$communication$
(Modbus)
2$$$$1
32$$$$1
4$$$$35
3$$$$4 5$$$$6 7$$$$8 9
1$$$$2
A
B
A
B
24
VAC
Bottom Row:
Common for all inputs
Outside air temperature sensor (10K thermistor)
Proof of Pump 1 (DO5) (Dry Contact)
DO5 Pump 1
Supply water temp sensor (10K thermistor)
Return Water temp sensor (10K thermistor)
Proof of Pump 2 (AO1) (Dry Contact)
RJ45 Pinout
1"""2"""3"""4"""5"""6"""7"""8
AB GND
(+)(-)

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Addressing Dipswitch Configuration for Network
Communication
For proper communication, a unique address must be configured on each controller 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, 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 numerical address of the controller.
The example in Figure 3 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.
12 3 4 5 6 7
Figure 3: Addressing Dipswitch

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INPUTS
Temperature Sensors
The M2000 Boiler controller has three analog inputs that monitor outside air, supply water and return
water temperatures (see Figure 4) 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 4: Connecting the temperature sensors

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Proof of Pumps
The M2000 has two analog inputs dedicated to the proof of pump signals. Please refer to Figure 5 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 heating action will be taken.
Proof%of%
Pump%1%
(DO5)
3%%%%4 5%%%%6 7%%%%8 91%%%%2
Proof%of%
Pump%2%
(AO1)
Figure 5: Connecting the proof of pump contacts to the controller

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OUTPUTS
The M2000 Boiler controller contains 8 customizable outputs; five triac ON/OFF outputs (24VAC) and
three analog outputs (0-10VDC). Output configuration 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 Specifications
DO 1
Triac s ourc e 24VAC
Max Current:300 mA
On-or-Off Boiler Stage 1
DO 2
Triac s ourc e 24VAC
Max Current:300 mA
On-or-Off Boiler Stage 2
DO 3
Triac s ourc e 24VAC
Max Current:300 mA
On-or-Off Boiler Stage 3
DO 4
Triac s ourc e 24VAC
Max Current:300 mA
On-or-Off Boiler Stage 4
DO 5
Triac s ourc e 24VAC
Max Current:300 mA
On-or-Off Pump 1
AO 1
0 or 10 VDC
Max Current: 40 mA
On-or-Off Pump 2
AO 2
Configurable Analog Output:
- 0 to 10 VDC
- 2 to 10 VDC
- 0 to 5 VDC
Max Current: 40 mA
Modulating proportional Modulating Boiler
AO 3
Configurable 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
(Backup)

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Typical Connection of Triac Outputs 1 to 5
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 6).
The bottom row is the common (GND).
2""""1
4""""35
Equipment"terminal"board
!"#$%&'()*+,&(-.
!"#$%&'()*+,&(/.
Figure 6: Wiring example of digital outputs 1 and 2
Typical Connection of Analog Outputs 1 to 3
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 7). Analog output 1 is configured to control a 10 VDC
On/Off relay. Analog outputs 2 and 3 can only modulate a DC load (0-10 VDC, 2-10 VDC, 0-5 VDC).
2""""1
3
(+)
(-)
External"
Load
Pump"2
Figure 7: Wiring example of analog output 1

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POWER SOURCE & NETWORK
Power Source
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 8). 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).
("R")
("C")
To"transformer"(class"2)
24VAC
+
-
Figure 8: Connecting the 24VAC power source
Network Communication
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 9).
Towards
RS485-
network
+
-
(A)
(B)
Figure 9: Connecting to the network

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Technical Specifications
Supply: 24 VAC ±10%, 50/60 Hz, Class 2
Power: 5 VA (consumption), 40 VA (Input)
Inputs: 9 configurable analog inputs (thermistor / dry contact / 4-20mA / 0-5 VDC)
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
Indication lights (LED): State of each output / Communication / Power / State of microprocessor
Microprocessor: PIC18F6722, 8 bits, 40 MHz, 128KB FLASH memory
Communication: Modbus RTU (RS485) up to 127 nodes
Baud Rates: 9600, 19200, 38400, 57600, 76800, 115200
Wiring: Removable screw-type terminal blocks (max 16 AWG) and RJ45 modular jacks
Dimensions: 137 mm x 112 mm ( 5.39" x 4.41" )
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
•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 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
137 mm
(5.39")
112 mm
(4.41")
58 mm
(2.29")
© 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 other trademarks are the property of their respective owners.