Acl 5100 User manual

ACL HIGH EFFICIENCY BURNER ASSEMBLY

Installation ManualInstallation Manual

for the for the

ACL 5100ACL 5100

Combustion SafetyCombustion Safety

ControllerController

Installation Manual

for the

ACL 5100

Combustion Safety

Controller

WARNING

This manual must be read in its entirety before installation of this burner.

Installation must be performed by a qualified technician and must adhere

to the standards set by the local regulatory authorities.

ACL is not responsible for the misuse or

incorrect application of this product.

Clear Rush Co.

Box 1898, 5406 Township Road 325B

Sundre, AB T0M 1X0

Canada

www.clearrushco.comwww.clearrushco.comwww.clearrushco.com

1-877-638-5234 (403) 638-52341-877-638-5234 (403) 638-52341-877-638-5234 (403) 638-5234

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

1

SINGLE & THREE TRIALS FOR IGNITION

FLAME MONITORING

INDICATION OF PILOT ON & SYSTEM ON

ALARM INDICATION OF FLAME FAIL, POWER FAIL, &

SHUTDOWN

REMOTE STOP AND START CAPABILITIES

PRE-PROGRAMMED LOGIC

(NO PROGRAMMING NECESSARY)

Power supply 12/24 VDC, 120/240 VAC 50/60 Hz, low power

consumption, suitable for solar applications

Flame out response time of 0.8 seconds

CSA approved for Class I, Div 2 location

CSA approved C22.2 No 199-M89. Combustion safety

controls and solid-state Ignitors for Gas & Oil burning

Equipment

CSA B149.3 - 10 compliant, meets NFPA Standards

Type 4x enclosure, corrosive resistant and weatherproof

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

ACL 5100 ProvidesACL 5100 ProvidesACL 5100 Provides

2

The ACL 5100 combustion safety controller is designed to ignite and prove a

continuous pilot while monitoring and annunciating multiple heater shutdowns for

all types of gas fired heaters and industrial sized burner applications.

The ACL 5100 utilizes a single ignitor/flame rod to provide both flame

acknowledgment and ignition at the pilot tip. When the ACL 5100 starts its

ignition sequence, fuel gas travels to the pilot tip where the ignitor/flame rod is

located and sparking. Once the gas is lit, the flame becomes a current path for

flame acknowledgment and the unit stops sparking. After the pilot has been

proven for 20 seconds (factory set) the ACL 5100 will allow gas to the main

burner.

If the pilot flame is extinguished, the current path is broken and the ignitor/flame

rod starts sparking within 1 second to attempt to re-light the pilot. The main is

shut off during this re-light period. If a flame is not established within the 5

second sparking period, the controller will immediately drop the output to

solenoid #1 pilot gas valve. The controller will attempt to light 2 more times with

15 seconds between each trial when equipped with three trial ignition module. If

the flame is still not lit, the flame fail alarm will be indicated by a continuous

alarm light.

If any of the shutdowns are tripped, the controller will not attempt any re-light,

and solenoid outputs will de-energize immediately. A shutdown will then be

indicated by the flashing alarm light. The shutdown must be cleared before the

controller will allow an ignition cycle.

The controller also has a power fail indicator to determine brownouts or power

disconnection and this is indicated by a flashing system on light after power has

been restored.

APPLICATION

THEORY OF

OPERATION

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

3

ACL 5100 COMES

COMPLETE WITH

MOUNTING

POWER

CONNECTION

SOLENOID

OUTPUTS

The ACL 5100 can be mounted in a Class I, Div 2 area; usually close to the

burner. The 10’ of high voltage lead, (longer lengths are not recommended) must

be run in the non- metallic flex (provided) or free air. If the high voltage lead is

run in the non-metallic flex, a conduit seal (provided) must be installed. Note:

Lead lengths in excess of 10’ or use of metal or metallic sheathed conduit may

result in a diminished ignitor rod voltage. A ground wire (also supplied) must be

connected between the ground lug on the burner assembly and the bonding

ground terminal on the main circuit board. Note: If the controller must be

mounted farther away from the burner assembly, the ignition module, which is

mounted on the main circuit board, may be mounted in or near the burner

housing using the optional, CSA approved, ACL 5000R remote mount kit. Do not

coil excess high voltage lead inside controller enclosure. High voltage magnetic

field may damage sensitive components. Electronic components and cables in

close proximity to the ignition module and ignition cable may be affected by high

voltage noise.

The ACL 5100 is available in 12/24 VDC and 120/240 VAC. Voltage

requirements must be specified when ordering. The supply voltage of each unit is

clearly marked inside the door on the specification label and on the circuit board

beside its respective terminal. Incorrect polarity on 12/24 VDC units may result in

damage to circuit board components. The terminal marked ground is for supply

or system ground and the terminal marked bonding ground is strictly for the

ground wire to the burner assembly. It is important that a ground wire (supplied)

be connected between the bonding ground terminal and the burner assembly to

provide an uninterrupted path for the flame acknowledgment current.

There are two solenoid output terminals on the main circuit board marked pilot

solenoid and main solenoid. The output voltage at these terminals is always the

same as the controller supply voltage. The pilot solenoid output connects to the

pilot or low fire solenoid and is energized when a start is initiated. Main solenoid,

(main burner) energizes only after the pilot or low fire flame has been proven.

The time delay between proof of flame and energizing of main output is factory

set at 20 seconds. Available in all three voltages).

ACL 5100 controller c/w mounting hardware

ACL M-50A pilot mixer & nozzle

10’ ground wire

10’ high voltage wire complete with connectors

6.5’ non-metallic flex complete with connectors

Ignitor/flame rod complete with mounting hardware

Speed control valve

½”conduit seal

Flame current test leads

Operator’s manual

INSTALLATION

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

4

S/D INPUTS The shutdown input provides a means of connecting other shutdown devices

such as low level, high temperature, low gas and high gas shutdowns for

additional protection. A jumper is installed at the factory and should only be

removed to utilize this feature. Shutdown devices connected (in series) to the

shutdown terminal, and be in a closed state during normal must be dry contacts

operating conditions. If any of the S/D switches go to fault condition, their

contacts will open, de-energizing the solenoid outputs and shutting down fuel to

the pilot and main burners and disabling the re-light sequence. This will be

indicated by the alarm light flashing. Once the fault condition is corrected the

system can be restarted by pressing the stop/reset and then the start buttons.

Note: if a restart is attempted without clearing the fault condition, the controller

will not attempt a re-light. Do not run shutdown loop wire in the same conduit as

solenoid wiring. Induced voltage may damage sensitive circuit board

components.

The remote S/D function is available when the jumper is removed and a

momentary normally closed contact button or remote relay contact (N/C) is

utilized. Note: Must be dry contacts.

The remote start function is available when a momentary normally open contact

button or remote relay contact (N/O) is utilized. When contacts close

momentarily the unit initiates starting sequence. Note: Must be dry contacts.

This feature allows controller to use valves with proof of closure switches for

ensuring main valve is closed before initiating an ignition. When valve switch

contacts are in an open state indicating the valve may be open, the controller will

not start. The contacts must be closed in order for controller to start. Once start

is initiated, the contacts from proof of closure switch can then change state.

The system on light indicates power supplied to the ACL 5100. When it is

flashing it indicates there has been a power failure.

A solid light indicates the pilot has failed to ignite. A flashing light indicates a

shutdown is open.

Alarm status is provided from a set of normally open/normally closed dry

contacts which change state when a pilot flame is detected. If the pilot goes out

due to any of the shutdowns or fails to re-light, the contacts return to normal or

alarm state.

REMOTE S/D

(STOP)

REMOTE START

PROOF OF

CLOSURE

(P.O.C)

SYSTEM ON

LIGHT

ALARM LIGHT

ALARM STATUS

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

5

VOLTAGE

CURRENT

POWER

SOLENOID OUTPUT

RATINGS

OPERATING

TEMPERATURE

FLAME SENSITIVITY

FLAME FAILURE

RESPONSE TIME

SPARK RATE

SPECIFICATIONS DC

ONE BURNER

12 VDC 24VDC

0.204A 0.186A

2.4W 4.5W

5 amp 250 V Per Output

-40 C to 60 C

1 micro amp minimum

0.8 seconds maximum

25 sparks per second

VOLTAGE

CURRENT

POWER

FREQUENCY

SOLENOID OUTPUT

RATINGS

OPERATING

TEMPERATURE

FLAME SENSITIVITY

FLAME FAILURE

RESPONSE TIME

SPARK RATE

SPECIFICATIONS AC

ONE BURNER

120 VAC 240 VAC

0.282A

1 micro amp minimum

0.8 seconds maximum

25 sparks per second

33.84W

50/60 HERTZ

5 amp 250 V Per Output

-40 C to 60 C

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

Specifications DCSpecifications DCSpecifications DC

Specifications ACSpecifications ACSpecifications AC

6

ACL 5100 12/24 VDC

)

To PLC or

RTU for

Remote

Status

Remote Start Button

HT

SD

LL

SD

LG

SD

HG

SD

Note: Must be dry contacts.

Must be in closed state

initially for controller to start

ALARM

STATUS

Remote Stop Button

Valve POC Switch Proof of Closure

Proof of Closure

Remote Start

Remote Stop

Shutdown

NC

COM

NO

(Dry Contacts)

Note: Must be dry

contacts. Must

also be in closed

state for controller

to start

12/24 Positive

12/24 Negative

GROUND

Jumper when not in use

(Changes state when running)

Jumper when not in use

1

2

5

6

7

8

9

10

11

12

13

3

4

14

Ignition

Module

To

Ignitor

Rod

Ground

High

Voltage

Ignition

Wire

To

Ignitor/Flame

Rod

Nema 4 Metal

Box Provided

4 Terminal Plug (provided)

Red

Blue

Brown

Yellow

Optional

Remote Mount

Ignition Module

15

16

17

18

Field Wiring

By Customer Max 50 Ft.

Min. #16 Gauge

Solenoid #2 Positive +

Solenoid #2 Negative -

Solenoid #1 Positive +

Solenoid #1 Negative -

(Main)

(Pilot)

Ignition

Module

To Ignitor/Flame Rod

15

16

17

18

19

Power

Alarm

Valve

Ground

Bonding Ground

20

21

22

23

SV SV

SV

Pilot

1 or 2 Valve System

BURNER

To Ignitor/Flame

Rod Ground Prewired in Control Box

Power supply 12/24 VDC

)

(High voltage ignition wire)

NOTE: If remote mounting of ignition module is

preferred, the ACL 5000R remote mount kit is

available upon request.

Red

Blue

Brown

Yellow

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

7

ACL 5100 120/240 VAC

)

To PLC or

RTU for

Remote

Status

Remote Start Button

HT

SD

LL

SD

LG

SD

HG

SD

Note: Must be dry contacts.

Must be in closed state

initially for controller to start

ALARM

STATUS

Remote Stop Button

Valve POC Switch Proof of Closure

Proof of Closure

Remote Start

Remote Stop

Shutdown

NC

COM

NO

(Dry Contacts)

Note: Must be dry

contacts. Must

also be in closed

state for controller

to start

120 HOT

120 NEU

GROUND

Jumper when not in use

(Changes state when running)

Jumper when not in use

1

2

5

6

7

8

9

10

11

12

13

3

4

14

Ignition

Module

To

Ignitor

Rod

Ground

High

Voltage

Ignition

Wire

To

Ignitor/Flame

Rod

Nema 4 Metal

Box Provided

4 Terminal Plug (provided)

Red

Blue

Brown

Yellow

Optional

Remote Mount

Ignition Module

15

16

17

18

Field Wiring

By Customer Max 50 Ft.

Min. #16 Gauge

Solenoid HOT

Solenoid NEU

Solenoid HOT

Solenoid NEU

Ignition

Module

To Ignitor/Flame Rod

15

16

17

18

19

Power

Alarm

Valve

Ground

Bonding Ground

20

21

22

23

SV SV

SV

Pilot

1 or 2 Valve System

BURNER

To Ignitor/Flame

Rod Ground Prewired in Control Box

120 VAC

)

120 VAC)

)

(Main)

(Pilot)

(High voltage ignition wire)

NOTE: If remote mounting of ignition module is

preferred, the ACL 5000R remote mount kit is

available upon request.

Red

Blue

Brown

Yellow

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

8

Valve Train - Pneumatic Proof of Closure Valve

This drawing is recommended for use with gas appliances that must conform to

CSA B149.3 - 10.

Note A: Auto safety shutdown valve with proof of closure switch- in accordance with CSA

standard 6.5-2005/ANSI Z21.21 and marked C/I Class I Div 1.

Note B: 1/4” x 1/4” Speed Control Valve supplied.

Note C: CSA standard 6.5-2005 C/I Class I Div 1 1/4” solenoid valve.

Note: If using separate fuel gas supply for Pilot, a Low Gas Pressure Switch is

recommended in the pilot line.

1/4" Solenoid

Valve

P1

LG

Supply 12-24 VDC

120 VAC 50/60 Hz

HG

Pilot

Main

PRV

High Voltage

Ignition Wire

Provides Flame

Fail / S/D & Ignition

P1

PSV

P1

Fuel

Supply Pressure

Safety

Valve

Main Burner

Gas Pressure

Regulator

High Gas

Pressure

Switch

Temp

Control

Valve

Manual

Shutoff

Valve

Low Gas

Pressure

Switch

Pilot

Regulator

Gauge

Manual

Shutoff

Valve

See

Note C

Gauge

A/S

A

3-Way

Solenoid

Automatic Safety

Shut Down Valve

Proof of

Closure

Speed Control

(Note B)

See Note A

SC

A

ACL 5100

Ignition Control System

6.5

C/I

6.5

C/I

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

9

Valve Train - Electric Solenoid Valves

This drawing is recommended for use with gas appliances that must conform to

CSA B149.3 - 10.

Note A: Solenoid CSA certified 6.5-2005 C/I Class I Div 1 1/4” solenoid valve or

equivalent.

Note B: Solenoid CSA certified 6.5-2005 C/I Class I Div 1 1” solenoid valve or

equivalent.

Note: If using separate fuel gas supply for Pilot, a Low Gas Pressure Switch is

recommended in the pilot line.

P1

LG

ACL 5100

Ignition Control System

Supply 12-24 VDC

120 VAC 50/60 Hz

HG

Pilot

Main

PRV

High Voltage

Ignition Wire

Provides Flame

Fail / S/D & Ignition

P1

PSV

P1

Fuel

Supply

Pressure

Safety

Valve

Main Burner

Gas Pressure

Regulator

High Gas

Pressure

Switch

Temp

Control

Valve

Manual

Shutoff

Valve

1/4" Solenoid

Valve

Low Gas

Pressure

Switch

Pilot

Regulator

Gauge

Manual

Shutoff

Valve

See

Note A

Gauge

A

ASee

Note B

1" Solenoid

Valve

See

Note B

A

1" Solenoid

Valve

6.5

C/I

6.5

C/I

6.5

C/I

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

4

6

10

CAUTION

HI-VOLTAGE

Ground

Valve

Alarm

ACL Manufacturing

Ignition Module

12 vdc +

ignition wire

Meter

Leads Red

Black

2.0mA DC

High Voltage

Ignition Wire

Meter

Ceramic

Insulator

Metal Strain

Relief

Adjustable

Bracket

sst Pilot

Nozzle

1/8 " Gap Setting

to inside edge

of Nozzle

Ignitor/Flame Rod

Ground Lug. ACL M50

Mixer

1/8" Gas

Connection

Air Shutter

Test

Harness

Flame Signal Test Procedure

1. Turn power off to ACL controller

2. Remove High-Voltage Ignition wire from Ignition Module and

insert meter leads with test harness as shown

3. Turn on power and initiate start sequence

4. Meter will give erratic readings during ignition period but

should settle down between 1-2µA reading on meter

5. Adjust air shutter on pilot mixer and adjust pressure on

regulator to achieve a flame signal close to 2µA or greater which is

optimum

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

11

ACL HE-ON BURNER

Note: This pilot assembly can be used as a stand alone

unit using adjustable bracket or incorporated with our

ACL-HE-ON Burner assembly as shown. Simply un-

screw 3/4” bulkhead located on ACL-HE-ON Burner.

Pilot Assembly

Ignitor/Flame Rod

gap should be 1/8"

to inside edge of

nozzle

ACL-I-ON

Ignitor/Flame Rod

3/4" NPT Bulkhead

(For pilot)

ACL HE-ON Burner Front View

Detail of Flame Rod

Positioning

Air dampening

& Deflector blades

(factory adjusted to 30 )

Field adjustable

Pilot Nozzle

Ignitor/flame rod gap

should be 1/8" to inside

edge of nozzle

ACL-I-ON

(Ignitor/flame rod)

Pilot sight port

Auxiliary

air inlet

Air Shutter

ACL-M Series

(Air fuel mixer)

Fuel

Connection

Venturi

Burner

Barrel

ACL-I-ON

(Ignitor/Flame rod)

ACL-ON-Nozzle

(Optimizer nozzle)

Ignitor/flame rod

Gap should be 1/8"

to inside edge of

nozzle

1/2" NPT Bulkhead

1/2 " nipple

By Customer M50 Pilot Mixer

Low pressure ring

------------

nozzle

insert

(Recommended SCH 40/Reamed)

ACL 2 piece

nozzle supplied

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

M50A PILOT ASSEMBLY

FUEL

LOCKNUT

ACL V-SERIES

ACL M-SERIES

AIR SHUTTER

BURNER BARREL

12

10"

8"

6"

11"

6"

11" 10"

6"

Control Box Dimensions

Outside Dimensions Side View Mounting Dimensions

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

ACL 1500 Pilot Assembly

ACL-P1500

PILOT NOZZLE

ACL

Manufacturing

AIR/FUEL MIXER

VENTURI

GROUND

LUG

3/4" PIPE

BARREL

FUEL

CONNECTION

M50A PILOT ASSEMBLY

ACL-IR-ASSY-3/16

(IGNITOR FLAME ROD)

ACL-M50A

PILOT NOZZLE NOZZLE INSERT

LOCKNUT

1/8"

ACL M50A Pilot Assembly

Ignition cable defective or insulation

worn

Ensure 12 volts on both terminals

Attempts ignition but doesn't light

Supply voltage too low

Poor power connections

Fuel gas supply to pilot may be too

high or too low

Gap setting on ignitor/flame rod not

correct

Ensure ground connections are good in BMS and at pilot/burner

BMS Trouble Shooting Guide

Fails to attempt ignition

Replace Cable

Check ground at both ends (BMS & ignitor tip)

Remove pilot assembly clean rod and nozzle and re install

Contaminated Ignitor rod or pilot

nozzle

POC terminal not closed (5100 Only)

Remote stop not closed (5100 Only)

Check connections on terminal strips

Ensure 12 volts on both terminals

Ignition cable defective or insulation

worn

Poor ground

Replace fuse 4 amp max for 5100 and 5500 6.4 amp max for

CSC 200

Blown fuse

Pilot fuel gas supply should be set at 5 pounds

Gap should be approx 1/8" and rod tip needs to be cut to a sharp

point

Check continutiy through the igniton cable, should read (0 Ohms)

if not you will need to replace cable

Ensure 11.5 volts minimum supply power for 12/24 or 119 VAC

for 120/240

Check supply power to solenoid, and check gas flow through

solenoid

Shorten gap setting to approx 1/8" and re cut the igntior rod tip.

Plugged orifice on pilot Clean out pilot orifice (Do not redrill)

Poor ground

Pilot solenoid failure

Gap seting too wide or rod not cut to a

point

Weak or erratic spark

13

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

Fails to Attempt IgnitionFails to Attempt IgnitionFails to Attempt Ignition

Attempt Ignition But Doesn’t LightAttempt Ignition But Doesn’t LightAttempt Ignition But Doesn’t Light

Weak or Erratic SparkWeak or Erratic SparkWeak or Erratic Spark

BMS Troubleshooting GuideBMS Troubleshooting GuideBMS Troubleshooting Guide

setting

NOTES

_____________________________________________________________________

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

14

NOTES

_____________________________________________________________________

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

15

NOTES

_____________________________________________________________________

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

16

NOTES

_____________________________________________________________________

ACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety ControllerACL 5100 Combustion Safety Controller

17

E-mail: [email protected]

Website: www.aclmfg.com

Limited Warranty

Seller warrants that the product hereby purchased is, upon delivery, free from defects

in material and workmanship and that any product which is found to be defective in

such workmanship or material will be repaired or replaced by Seller for a period of one

year from purchase date. Warranty of such items do not include shipping, installation

or set-up.

Liability Statement

ACL Manufacturing Inc. Shall not be liable for any special, indirect, consequential or

other damages of a like general nature, including, without limitation, loss of profits or

production, or loss of expenses of any nature incurred by the buyer or any third party.

Clear Rush Co.

Box 1898, 5406 Township Road 325B

Sundre, AB T0M 1X0

Canada

www.clearrushco.comwww.clearrushco.comwww.clearrushco.com

1-877-638-5234 (403) 638-52341-877-638-5234 (403) 638-52341-877-638-5234 (403) 638-5234

ACL 5100 User manual

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