HARDWARE GUIDE
Hydronics Controller M2000 Series
Specifications and Operational Guide
www.proloncontrols.com | info@proloncontrols.com
17 510, rue Charles, Suite 100, Mirabel, QC, J7J 1X9
REV. 6.1.5
PL-HRDW-HYD-M2000-C/F-EN
Table of Contents
General Information............................................................................................................................. 4
PL-M2000 Hydronics Controller..................................................................................................... 4
Description...................................................................................................................................................................... 4
General Behaviour......................................................................................................................................................... 4
Components......................................................................................................................................... 5
Component Identification........................................................................................................................................... 5
LEDs and Switches......................................................................................................................................................... 6
HAND/OFF/AUTO Switches.......................................................................................................................................... 7
Jumpers............................................................................................................................................................................ 7
Addressing Dipswitch Configuration for Network Communication................................................................ 8
Sequences............................................................................................................................................. 9
Hot and Cold Tank Sequence...................................................................................................................................... 9
Input and Output Identification.............................................................................................................................. 10
Simple Hot Water Tank Sequence with Open Boiler Loop................................................................................ 11
Input and Output Identification.............................................................................................................................. 12
Simple Hot Water Tank Sequence with Closed Boiler Loop............................................................................. 13
Input and Output Identification.............................................................................................................................. 14
Simple Cold Water Tank Sequence.......................................................................................................................... 15
Input and Output Identification.............................................................................................................................. 16
Dual Recovery Sequence........................................................................................................................................... 17
Input and Output Identification.............................................................................................................................. 18
Dual Energy Boilers Sequence.................................................................................................................................. 19
Input and Output Identification..............................................................................................................................20
Typical Wiring............................................................................................................................................................... 21
Inputs.................................................................................................................................................. 21
Temperature Sensors.................................................................................................................................................. 21
Proof of Operation.......................................................................................................................................................22
Output................................................................................................................................................ 23
Output Specifications.................................................................................................................. 23
Triac Outputs 1 to 5..................................................................................................................................................... 24
Analog Outputs 1 to 3................................................................................................................................................ 24
DMUX-4J Connection on Digital Output 2 for 2, 3 or 4 Stage Compressor..................................................25
Power Source...................................................................................................................................... 26
Network Communication................................................................................................................... 26
Technical Specifications..................................................................................................................... 27
Compliance....................................................................................................................................................................28
FCC User Information..................................................................................................................................................28
Industry Canada ..........................................................................................................................................................28
Overall Dimensions............................................................................................................................ 29
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Table of Figures
Figure 1 - Component Identification............................................................................................................................. 5
Figure 2 - LEDs Identification........................................................................................................................................... 6
Figure 3 - Location of the EXTERNAL jumpers........................................................................................................... 7
Figure 4 - Location of the INTERNAL jumpers............................................................................................................. 7
Figure 5 - INT and NET jumpers....................................................................................................................................... 7
Figure 6 - AI jumpers.......................................................................................................................................................... 7
Figure 7 - Addressing Dipswitch..................................................................................................................................... 8
Figure 8 - Hot and Cold Tank Sequence........................................................................................................................ 9
Figure 9 - Input and Output Identification (Hot and Cold Tank Sequence)...................................................... 10
Figure 10 - RJ45 Pinout.................................................................................................................................................... 10
Figure 11 - Simple Hot Water Tank Sequence with Open Boiler Loop................................................................ 11
Figure 12 - Input and Output Identification (Open Boiler Loop).......................................................................... 12
Figure 13 - RJ45 Pinout.................................................................................................................................................... 12
Figure 14 - Simple Hot Water Tank Sequence with Closed Boiler Loop............................................................. 13
Figure 15 - Input and Output Identification (Closed Boiler Loop)....................................................................... 14
Figure 16 - RJ45 Pinout.................................................................................................................................................... 14
Figure 17 - Simple Cold Water Tank Sequence.......................................................................................................... 15
Figure 18 - Input and Output Identification (Simple Cold Water Tank).............................................................. 16
Figure 19 - RJ45 Pinout.................................................................................................................................................... 16
Figure 20 - Dual Recovery Sequence (Dual Compressors Shown)....................................................................... 17
Figure 21 - Input and Output Identification (Dual Recovery)................................................................................ 18
Figure 22 - RJ45 Pinout.................................................................................................................................................... 18
Figure 23 - Dual Energy Boiler Sequence................................................................................................................... 19
Figure 24 - Input and Output Identification (Dual Energy Boilers)......................................................................20
Figure 25 - RJ45 Pinout....................................................................................................................................................20
Figure 26 - Wiring Example of Temperature Sensors.............................................................................................. 21
Figure 27 - Wiring Example of Proof of Operation...................................................................................................22
Figure 28 - Wiring Example of Digital Outputs 1 and 2.......................................................................................... 24
Figure 29 - Wiring Example of Analog Output 1....................................................................................................... 24
Figure 30 - Connecting the DMUX-4J (Powered by M2000)..................................................................................25
Figure 31 - Connecting the 24VAC Power Source.....................................................................................................26
Figure 32 - Connecting to the Network......................................................................................................................26
Figure 33 - M2000 Size Diagram...................................................................................................................................29
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General Information
PL-M2000 Hydronics Controller
Description
The M2000 hydronics controller is designed to control a variety of different water-to-water heatpumps
and hydronic systems. The on-board microcontroller offers precise digital control to maximize performance. The available control sequences are fully configurable, either locally or remotely, using free
software. The M2000 offers a variety of hydronic sequences such as hot and cold tank, dual recovery
system, single hot tank with open or closed boiler loop, dual energy boilers and more.
General Behaviour
Although fully configurable, the ProLon M2000 hydronics controller monitors dedicated inputs and uses
pre-established control sequences to drive dedicated outputs that control various types of hydronic
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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Components
Component Identification
Figure 1 - 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 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
24VAC
5VDC
HBEAT
STAT
AO 3
AO 2
AO 1
DO 5
DO 4
NETSND
NETREC
DO 3
DO 2
DO 1
Figure 2 - LEDs Identification
LED Descriptions
• 24 VAC: The M2000 is receiving 24 VAC from the
power source.
• INTSND: Indicates the transmission of data onto
the interface communication bus.
• 5V DC: The microchip and other components
on the M2000 are being powered successfully
by a 5V DC source derived from the 24VAC
source.
• INTREC: Indicates the reception of data from
the interface communication bus.
•
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.
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• 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.
6
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.
Jumpers
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 configuration of various hardware elements.
AI9
AI8
AI7
AI6
AI5
AI4
AI3
AI2
AI1
INT
NET
Figure 3 - Location of the EXTERNAL jumpers
Figure 4 - Location of the INTERNAL jumpers
•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)
0-5 volts
Figure 5 - INT and NET jumpers
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4-20 mA
THERMISTOR
Figure 6 - AI jumpers
7
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 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 7 - Addressing Dipswitch
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Sequences
Hot and Cold Tank Sequence
Figure 8 - Hot and Cold Tank Sequence
A water-to-water heatpump (single compressor or multi stage with lead-lag functionality) is used to heat
or cool a primary water loop. Valves are in place to allow or divert water into hot and cold tanks as
needed. The target setpoint for each tank is calculated based on a configurable outside temperature
reset scale. Priority between tanks is decided based either on outside temperature or on current offset
from the calculated setpoint.
Pumps 1 and 2 ensure water circulation in the primary loop and ground loop. These pumps operate based
on a request for compressor operation. Pumps 3 and 4 circulate water through the building and operate
based on outside temperature.
Auxiliary heat is enabled when the setpoint in the hot tank has not been reached after a configurable
delay (default 60 min) of constant compressor operation has expired. At this point, both auxiliary heat and
the compressor will operate until the setpoint is reached. Once auxiliary heat is enabled, it remains so for
a configurable interval (default 4 hours).
Auxiliary heat can also be activated when the water temperature in the ground loop is too low. In this
situation, only auxiliary heat is allowed and the compressor remains offline. Once auxiliary heat is
enabled, it remains so for a configurable interval (default 4 hours). After the interval expires, and the
ground loop water temperature has risen, the compressor may be used again.
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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.
For incoming communication from a remote computer or network controller, dual RJ45 type connectors
are available 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.
The I/O profile for the Hot and Cold Tank Sequence is as follows:
Incoming communication from
remote computer or network controller
(Dual RJ45 and Terminal Blocks)
Proof of circulator 4 (dry contact)
Proof of circulator 3 (dry contact)
Proof of circs 1 AND 2 (dry contact)
Geothermal supply temperature (10K thermistor)
Cold water return temperature (10K thermistor)
AO 3 - Circulator 4
Hot water return temperature (10K thermistor)
AO 2 - Circulator 3
Water loop supply temperature (10K thermistor)
AO 1 - Auxiliary Heat (ON/OFF)
Outside air temperature sensor (10K thermistor)
DO 5 - Valve 2 (cold tank)
24
VAC
DO 4 - Valve 1 (hot tank)
DO 3 - Rev Valve
Outgoing network communication
(to zones)
DO 2 - Compressor
DO 1 - Circs 1 AND 2
Controller’s power source
Unit’s R&C terminals (24VAC)
Bottom Row:
Common for all outputs
GND
B (-)
A (+)
Figure 9 - Input and Output Identification (Hot and Cold Tank Sequence)
Figure 10 - RJ45 Pinout
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Simple Hot Water Tank Sequence with Open Boiler Loop
The description of the Simple Hot Water Tank sequence with Open Boiler Loop used by the M2000
Hydronics controller is as follows (see Figure 11):
Figure 11 - Simple Hot Water Tank Sequence with Open Boiler Loop
A water-to-water heatpump (single compressor or multi stage with lead-lag functionality) is used to heat
a primary water loop. The target setpoint for the hot tank is calculated based on a configurable outside
temperature reset scale.
Pumps 1 and 2 ensure water circulation in the primary loop and ground loop. These pumps operate based
on a request for compressor operation. Pump 3 circulates water through the building and operates based
on a physical contact input, building demand and outside temperature.
Auxiliary heat is enabled when the setpoint in the hot tank has not been reached after a configurable
delay (default 60 min) of constant compressor operation has expired. At this point, both auxiliary heat
and the compressor will operate until the setpoint is reached. On the next call for heat, the compressor
will activate alone again.
Auxiliary heat can also be activated when the water temperature in the ground loop is too low. In this
situation, only auxiliary heat is allowed and the compressor remains offline. Once the ground loop water
temperature returns to normal, the compressor may be used again.
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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.
For incoming communication from a remote computer or network controller, dual RJ45 type connectors
are available 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.
The I/O profile for the Simple Hot Water Tank sequence with Open Boiler Loop is as follows:
Incoming communication from
remote computer or network controller
(Dual RJ45 and Terminal Blocks)
Proof of circulator 3 (dry contact)
Proof of circs 1 AND 2 (dry contact)
Geothermal supply temperature (10K thermistor)
Circulator 3 (Zones) request (dry contact)
Water return temperature (10K thermistor)
Water loop supply temperature (10K thermistor)
AO 1 - Auxiliary Heat (ON/OFF)
Outside air temperature sensor (10K thermistor)
24
VAC
DO 4 - Circulator 3 (Zones)
DO 3 - Rev Valve
Outgoing network communication
(to zones)
DO 2 - Compressor
DO 1 - Circs 1 AND 2
Controller’s power source
Unit’s R&C terminals (24VAC)
Bottom Row:
Common for all outputs
GND
B (-)
A (+)
Figure 12 - Input and Output Identification (Open Boiler Loop)
Figure 13 - RJ45 Pinout
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Simple Hot Water Tank Sequence with Closed Boiler Loop
The description of the Simple Hot Water Tank sequence with Closed Boiler Loop used by the M2000
Hydronics controller is as follows (see Figure 14):
Figure 14 - Simple Hot Water Tank Sequence with Closed Boiler Loop
A water-to-water heatpump (single compressor or multi stage with lead-lag functionality) is used to heat
a primary water loop. The target setpoint for the hot tank is calculated based on a configurable outside
temperature reset scale.
Pumps 1 and 2 ensure water circulation in the primary loop and ground loop. These pumps operate based
on a request for compressor operation. Pump 3 circulates water through the building and operates based
on a physical contact input, building demand and outside temperature. Pump 4 operates based on a call
for auxiliary heat.
Auxiliary heat is enabled when the setpoint in the hot tank has not been reached after a configurable
delay (default 60 min) of constant compressor operation has expired. At this point, both auxiliary heat
and the compressor will operate until the setpoint is reached. On the next call for heat, the compressor
will activate alone again.
Auxiliary heat can also be activated when the water temperature in the ground loop is too low. In this
situation, only auxiliary heat is allowed and the compressor remains offline. Once the ground loop water
temperature returns to normal, the compressor may be used again.
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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.
For incoming communication from a remote computer or network controller, dual RJ45 type connectors
are available 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.
The I/O profile for the Simple Hot Water Tank Sequence with Closed Boiler Loop is as follows:
Incoming communication from
remote computer or network controller
(Dual RJ45 and Terminal Blocks)
Proof of circulator 4 (boiler) (dry contact)
Proof of circulator 3 (zones) (dry contact)
Proof of circs 1 AND 2 (dry contact)
Geothermal supply temperature (10K thermistor)
Pump 3 (zones) request (dry contact)
Water return temperature (10K thermistor)
Water loop supply temperature (10K thermistor)
AO 1 - Auxiliary Heat (ON/OFF)
Outside air temperature sensor (10K thermistor)
DO 5 - Circulator 4 (Boiler)
24
VAC
DO 4 - Circulator (Zones)
DO 3 - Rev Valve
Outgoing network communication
(to zones)
DO 2 - Compressor
DO 1 - Circs 1 AND 2
Controller’s power source
Unit’s R&C terminals (24VAC)
Bottom Row:
Common for all outputs
GND
B (-)
A (+)
Figure 15 - Input and Output Identification (Closed Boiler Loop)
Figure 16 - RJ45 Pinout
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Simple Cold Water Tank Sequence
The description of the Simple Cold Water Tank used by the M2000 Hydronics controller is as follows
(see Figure 17):
Figure 17 - Simple Cold Water Tank Sequence
A water-to-water heatpump (single compressor or multi stage with lead-lag functionality) is used to cool
a primary water loop. The target setpoint for the cold tank is calculated based on a configurable outside
temperature reset scale.
Pumps 1 and 2 ensure water circulation in the primary loop and ground loop. These pumps operate based
on a request for compressor operation. Pump 3 circulates water through the building and operates based
on a physical contact input, building demand and outside temperature.
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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.
For incoming communication from a remote computer or network controller, dual RJ45 type connectors
are available 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.
The I/O profile for the Simple Cold Water Tank Sequence is as follows:
Incoming communication from
remote computer or network controller
(Dual RJ45 and Terminal Blocks)
Proof of circulator 3 (zones) (dry contact)
Proof of circs 1 AND 2 (dry contact)
Geothermal supply temperature (10K thermistor)
Circulator 3 (zones) request (dry contact)
Water return temperature (10K thermistor)
Water loop supply temperature (10K thermistor)
Outside air temperature sensor (10K thermistor)
24
VAC
DO 4 - Circulator 3 (Zones)
DO 3 - Rev Valve
Outgoing network communication
(to zones)
DO 2 - Compressor
DO 1 - Circs 1 AND 2
Controller’s power source
Unit’s R&C terminals (24VAC)
Bottom Row:
Common for all outputs
GND
B (-)
A (+)
Figure 18 - Input and Output Identification (Simple Cold Water Tank)
Figure 19 - RJ45 Pinout
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Dual Recovery Sequence
The description of the Dual Recovery sequence used by the M2000 Hydronics controller is as follows
(see Figure 20):
Figure 20 - Dual Recovery Sequence (Dual Compressors Shown)
A water-to-water heatpump (single or dual compressor with lead-lag functionality – dual shown above)
is used to simultaneously provide hot and cold water to hot and cold tanks. Pumps 1A-1B (compressor 1)
and Pumps 2A-2B (compressor 2) operate based on a request from their respective compressors
The target setpoint in each tank changes depending on the season (summer/winter), but remains fixed
within a season (no reset scale).
In the summer sequence, the compressors only operate based on a demand from the cold tank. If the hot
tank temperature should rise too high, Pump 4 brings ground water into the hot tank to reduce its
temperature. The valve is set so as to close the loop from ground to the hot water tank (AB-B).
In the winter sequence, the compressors only operate based on a demand from the hot tank. If the cold
tank temperature should drop too low, Pump 3 brings ground water into the cold tank to increase its
temperature. The valve is set so as to close the loop from ground to the cold water tank (AB-A).
Auxiliary heat is enabled in the winter sequence only, when the setpoint in the hot tank has not been
reached after a configurable delay (default 60 min) of constant compressor operation has expired. At this
point, both auxiliary heat and the compressor will operate until the setpoint is reached. On the next call
for heat, the compressor will activate alone again.
Auxiliary heat will also be used in the winter sequence when no proof of pumps 1 and 2 are obtained
despite a request for compressor.
Pump 5 activates based on a call for auxiliary heat.
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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.
For incoming communication from a remote computer or network controller, dual RJ45 type connectors
are available 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.
The I/O profile for the Dual Recovery Sequence is as follows:
Proof of pump 4 (dry contact)
Incoming communication from
remote computer or network controller
(Dual RJ45 and Terminal Blocks)
Proof of pump 3 (dry contact)
Proof of pumps 2A-2B (dry contact)
Proof of pumps 1A-1B (dry contact)
Geo return temperature (10K thermistor)
Geo supply temperature (10K thermistor)
AO 3 Diverting Valve (3 way)
Cold water tank temperature (10K thermistor)
AO 2 - Compressor 2
Hot water tank temperature (10K thermistor)
AO 1 - Compressor 1
Outside air temperature sensor (10K thermistor)
DO 5 - Pump 5 (Aux heat)
24
VAC
DO 4 - Pump 4 (Hot tank)
DO 3 - Pump 3 (Cold tank)
Outgoing network communication
(to zones)
DO 2 - Pump 2A-2B
DO 1 - Pump 1A-1B
Controller’s power source
Unit’s R&C terminals (24VAC)
Bottom Row:
Common for all outputs
GND
B (-)
A (+)
Figure 21 - Input and Output Identification (Dual Recovery)
Figure 22 - RJ45 Pinout
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Dual Energy Boilers Sequence
The description of the Dual Energy Boiler sequence used by the M2000 Hydronics controller is as follows
(see Figure 23):
Figure 23 - Dual Energy Boiler Sequence
This system is comprised of two hot water tanks: one that stores the domestic hot water for everyday
use, while the other is a buffer tank used for building heating purposes. The domestic hot water tank
is maintained at a fixed temperature year-round, while the buffer tank’s setpoint follows an outdoor
temperature reset scale. The buffer tank will not request heating in the summer season.
Heating action comes in the form of two boilers, one that is combustion based (Boiler 1) and one that
is electric (Boiler 2). The boiler to be used is determined by an external contact (Bi-Energy or other
connected to the M2000, which is used to obtain a preferential rate on the electrical bill. When the
contact is closed, the electric boiler is used. Otherwise the combustion boiler is used.
Pump 1 is activated on a call for heat from either boiler. Pump 2 is activated based on an external contact
closing which, when connected to the M2000, represents a call for heat coming from the building.
The Valves 1 and 2 will direct hot water to where it is needed, either into a single tank, or to both tanks.
Both boilers will be activated on a call for auxiliary heat. Auxiliary heat is requested when the setpoint
in either tank is not reached after a configurable delay, or if the demand from the building (zones) is too
high for a configurable interval of time.
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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.
For incoming communication from a remote computer or network controller, dual RJ45 type connectors
are available 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.
The I/O profile for the Dual Energy Boilers Sequence is as follows:
Proof of boiler 2 (dry contact)
Incoming communication from
remote computer or network controller
(Dual RJ45 and Terminal Blocks)
Proof of boiler 1 (dry contact)
Proof of pump C2 (dry contact)
Proof of pump C1 (dry contact)
Zone Demand (dry contact)
Dual-Energy Input (dry contact)
AO 1 - Boiler 1
1 Stage: (0V=OFF / 10V=ON)
2 Stages: (0V=OFF / 5V=1 stage / 10V=2 stages)
Domestic water tank temperature (10K thermistor)
Buffer water tank temperature (10K thermistor)
Outside air temperature sensor (10K thermistor)
DO 5 - Boiler 2
24
VAC
DO 4 - Valve 2
DO 3 - Valve 1
Outgoing network communication
(to zones)
DO 2 - Pump 2
DO 1 - Pump 1
Controller’s power source
Unit’s R&C terminals (24VAC)
Bottom Row:
Common for all outputs
GND
B (-)
A (+)
Figure 24 - Input and Output Identification (Dual Energy Boilers)
Figure 25 - RJ45 Pinout
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Typical Wiring
Inputs
Temperature Sensors
The M2000 Hydronics controller has various analog inputs that can monitor air and water temperatures
depending on the sequence, and will integrate these readings into its control sequence. The sensors used
are standard 10k type 3 thermistors that share a single common connection. See Figure 26 for typical
wiring of thermistors (NOTE: the input and function used by each thermistor will vary depending on the
sequence).
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.
Thermistor C
Thermistor B
Thermistor A
Figure 26 - Wiring Example of Temperature Sensors
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Proof of Operation
The M2000 Hydronics controller has various analog inputs that can monitor the proof of operation
signals (pump, boiler, etc…) depending on the sequence, and will integrate these readings into its control
sequence. To indicate proof of operation, the contact must be closed. See Figure 27 for typical wiring of
proof of operation signals
(Note: the input and function used by each proof of operation will vary depending on the sequence).
Proof of
Operation 1
Proof of
Operation 2
Figure 27 - Wiring Example of Proof of Operation
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Output
The M2000 Hydronics controller has 8 customizable outputs; five triac ON/OFF outputs (24VAC) and
three analog outputs (0-10VDC). Output configuration is performed via the ProLon Focus software and
is dependent on the sequence chosen.
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
Output
Type
Action
DO 1
Triac source 24VAC,
Max Current: 300 mA
On-or-Off
DO 2
Triac source 24VAC,
Max Current: 300 mA
On-or-Off
DO 3
Triac source 24VAC,
Max Current: 300 mA
On-or-Off
DO 4
Triac source 24VAC,
Max Current: 300 mA
On-or-Off
DO 5
Triac source 24VAC,
Max Current: 300 mA
On-or-Off
AO 1
0 to 10 VDC
Max Current: 40 mA
On-or-Off
AO 2
0 to 10 VDC
Max Current: 40 mA
On-or-Off
AO 3
0 to 10 VDC
Max Current: 40 mA
On-or-Off
REV. 6.1.5 / PL-HRDW-HYD-M2000-C/F-EN
23
Triac Outputs 1 to 5
On the M2000 hydronics 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. Consquentially, only the live side of the output connections are usually needed; these are on the top row (see
Figure 28). The bottom row is the common (GND).
Equipment Terminal Board
(Pump 2)
(Pump 1)
Figure 28 - Wiring Example of Digital Outputs 1 and 2
Analog Outputs 1 to 3
For all analog outputs, the common is found on the bottom row terminal blocks, and the active signals
are found on the top row terminal blocks (see Figure 29). 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).
External Load
(+)
Pump 2
(-)
Figure 29 - Wiring Example of Analog Output 1
REV. 6.1.5 / PL-HRDW-HYD-M2000-C/F-EN
24
DMUX-4J Connection on Digital Output 2 for 2, 3 or 4 Stage Compressor
When 2, 3 or 4 stages of compressor are required (Hot and Cold Tank sequence only), the M2000
Hydronics controller must be equipped with a DMUX-4J. The DMUX-4J input is only connected to
Digital Output 2 on the M2000 Hydronics controller. The DMUX-4J must be configured to “Individual
Relay Control” with a 0.5 second pulse resolution. The “Triac Input Selection” jumper must be set to
normal signal input and the “Power Type Selection” jumper must be set to AC power. The DMUX-4J output
are then connected to the equipment (see figure 10). Each of the DMUX-4J outputs have connections for
“Normally Closed” and “Normally Open” operation, so use the connection that is compatible with your
equipment. For more information on the DMUX-4J, consult the Specification Sheet and the Installation
Guide for the DMUX-4J.
DMUX-4J
4
Y4
24V
3
Y3
COM
2
Y2
IN
1
Y1
24
VAC
24 VAC
COM
G
R
C
Figure 30 - Connecting the DMUX-4J (Powered by M2000)
REV. 6.1.5 / PL-HRDW-HYD-M2000-C/F-EN
25
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 15). 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.
24VAC
(R)
To transformer (class 2)
(C)
Figure 31 - Connecting the 24VAC 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 15). 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.
(A)
(B)
Towards
RS485
Network
Figure 32 - Connecting to the Network
REV. 6.1.5 / PL-HRDW-HYD-M2000-C/F-EN
26
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.
REV. 6.1.5 / PL-HRDW-HYD-M2000-C/F-EN
27
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.
REV. 6.1.5 / PL-HRDW-HYD-M2000-C/F-EN
28
Overall Dimensions
INT
ON
PL-M2000 RTU
VER: X.X.X
AO 2
AO 1
DO 5
DO 3
DO 2
DO 1
OUTPUTS
DO 4
M2000
RS485 NET
AO 3
24VAC
5VDC
HBEAT
STAT
PROJECT
AUTO/OFF/HAND
proloncontrols.com
1-877-9PROLON
OFF
ADDRESS
INTSND
INTREC
1 2 3 4 5 6 7 8
1 2 4 8 16 32 64 B
112 mm
4.41"
NETSND
NETREC
NET
137 mm
5.39"
58 mm
2.29"
Figure 33 - M2000 Size Diagram
REV. 6.1.5
PL-HRDW-HYD-M2000-C/F-EN
© Copyright 2017 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.
REV. 6.1.5 / PL-HRDW-HYD-M2000-C/F-EN
29