ACL 5100 User manual

805 Main Ave. West - Box 2002 Sundre, Alberta T0M 1X0 - Phone: [phone] - Fax: [phone] - Email: [email protected]
Website: www.aclmfg.com
Manufacturing Inc.
ACL ACL 5100 COMBUSTION SAFETY CONTROL
WARNING
ACL is not responsible for the misuse or incorrect application of this product.
This manual must be read in its entirety before installation of this controller.
Installation must be performed by a qualified technician and must adhere to the
standards set by the local regulatory authorities.
INSTALLATION
MANUAL
ACL 5100
COMBUSTION SAFETY
CONTROLLER
FOR

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ACL
ACL 5100 COMBUSTION SAFETY CONTROL

ACL 5100 SAFETY COMBUSTION CONTROL
1Manufacturing Inc.
ACL
ACL 5100 PROVIDES
•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)
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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 , 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 compatible
Type 4x enclosure, corrosive resistant and weatherproof
I

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ACL
ACL 5100 COMBUSTION SAFETY CONTROL
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 SAFETY COMBUSTION CONTROL
3Manufacturing Inc.
ACL
ACL 5100 COMES
COMPLETE WITH
MOUNTING
POWER
CONNECTION
SOLENOID
OUTPUTS
The ACL 5100 can be mounted in a Class , 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.
I
Note:
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.
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.
Incorrect polarity on 12/24 VDC units may result in
damage to circuit board components.
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.
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).
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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

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ACL
ACL 5100 COMBUSTION SAFETY CONTROL
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
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.
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.
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.
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
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.
must be dry contacts
Note:
as
solenoid wiring. Induced voltage may damage sensitive circuit board
components.
Note: Must be dry contacts.
Note: Must be dry contacts.
dry
contacts
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
REMOTE S/D
(STOP)
REMOTE START
PROOF OF
CLOSURE
(P.O.C)
SYSTEM ON
LIGHT
ALARM LIGHT
ALARM STATUS

ACL 5100 SAFETY COMBUSTION CONTROL
5Manufacturing Inc.
ACL
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

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ACL
ACL 5100 COMBUSTION SAFETY CONTROL
ACL 5100 12/24 VDC
)
)
To PLC or
RTUfor
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 POCSwitch Proof of Closure
Proof of Closure
Remote Start
Remote Start
Remote Stop
Remote Stop
Shutdown
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
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, theACL5000R remote mount kit is
available upon request.
Red
Blue
Brown
Yellow

ACL 5100 SAFETY COMBUSTION CONTROL
7Manufacturing Inc.
ACL
ACL 5100 120/240 VAC
)
To PLC or
RTUfor
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 Start
Remote Stop
Remote Stop
Shutdown
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
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, theACL5000R remote mount kit is
available upon request.
Red
Blue
Brown
Yellow

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Manufacturing Inc.
ACL
ACL 5100 COMBUSTION SAFETY CONTROL
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 Div 1.
Note B: 1/4”x 1/4”Speed Control Valve supplied.
Note C: CSA standard 6.5-2005 C/I Class 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.
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I
1/4" Solenoid
Valve
P1
LG
Supply12-24VDC
120 VAC50/60Hz
HG
Pilot
Main
PRV
PRV
HighVoltage
Ignition Wire
ProvidesFlame
Fail / S/D&Ignition
P1
P1
PSV
P1
Fuel
Supply Pressure
Safety
Valve
MainBurner
Gas Pressure
Regulator
HighGas
Pressure
Switch
Temp
Control
Valve
Manual
Shutoff
Valve
LowGas
Pressure
Switch
Pilot
Regulator
Gauge
Gauge
Gauge
Manual
Shutoff
Valve
See
NoteC
Gauge
A/S
A
3-Way
Solenoid
Automatic Safety
Shut Down Valve
Proof of
Closure
Speed Control
(Note B)
SeeNoteA
SC
A
ACL5100
Ignition Control System
6.5
C/I
6.5
C/I

ACL 5100 SAFETY COMBUSTION CONTROL
9Manufacturing Inc.
ACL
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 Div 1 1/4” solenoid valve or
equivalent.
Note B: Solenoid CSA certified 6.5-2005 C/I Class 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.
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P1
LG
ACL5100
IgnitionControl System
Supply 12-24VDC
120 VAC50/60Hz
HG
Pilot
Main
PRV
PRV
HighVoltage
Ignition Wire
Provides Flame
Fail / S/D&Ignition
P1
P1
PSV
P1
Fuel
Supply
Pressure
Safety
Valve
MainBurner
Gas Pressure
Regulator
HighGas
Pressure
Switch
Temp
Control
Valve
Manual
Shutoff
Valve
1/4" Solenoid
Valve
LowGas
Pressure
Switch
Pilot
Regulator
Gauge
Gauge
Gauge
Manual
Shutoff
Valve
See
NoteA
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

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Manufacturing Inc.
ACL
ACL 5100 COMBUSTION SAFETY CONTROL
CAUTION
HI-VOLTAGE
Ground
Valve
Alarm
ACLManufacturing
Ignition Module
12 vdc +
ignition wire
Meter
Leads Red
Black
2.0?ADC
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. ACLM50
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 1-2 A reading on meter
5. Adjust air shutter on pilot mixer and adjust pressure on
regulator to achieve a flame signal close to 2 A or greater which is optimum
µ
µ

ACL 5100 SAFETY COMBUSTION CONTROL
11 Manufacturing Inc.
ACL
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-MSeries
(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" NPTBulkhead
1/2 " nipple
By Customer M50 Pilot Mixer
Low pressure ring
------------
------------
nozzle
insert
(Recommended SCH40/Reamed)
ACL 2 piece
nozzle supplied

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Manufacturing Inc.
ACL
ACL 5100 COMBUSTION SAFETY CONTROL
10"
8"
6"
11"
6"
11" 10"
6"
Ceramic
Insulator
Metal Strain
Relief
Adjustable
Bracket
Pilot
Nozzle
Approx 1/8 " Gap
Setting to inside
edge of Nozzle
Ignitor/Flame Rod
Ground Lug. ACLM50
Mixer
1/8" Gas
Connection
Air Shutter
1/2" Schedule 40 nipple
(customer supplied)
Note: Do not drill
out pilot orifice
PILOT ASSEMBLY
OPTIONAL PILOT ASSEMBLY (ACL 1500)
Control Box Dimensions
Outside Dimensions Side View Mounting Dimensions
Ground
Connection Ignition Wire
Connection
Protective
Shroud
ACLM50
Mixer
Air Shutter
1/8" Gas
Connection
3/4" Pipe
SSTPilot Nozzle
1 1/4" Strain
Relief

ACL 5100 SAFETY COMBUSTION CONTROL
Manufacturing Inc.
ACL
NOTES
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805 Main Ave West - Box 2002 Sundre, Alberta T0M 1X0
Phone: [phone] - Fax: [phone]
E-mail: [email protected]
ACL
Manufacturing Inc.
Website: www.aclmfg.com
Limited Warranty
Liability Statement
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.
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.