ACL ACL 5500 User manual

ACL HIGH EFFICIENCY BURNER ASSEMBLY
Installation ManualInstallation Manual
for thefor the
ACL 5500ACL 5500
Combustion SafetyCombustion Safety
ControllerController
Installation Manual
for the
ACL 5500
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 [phone]

ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller

1
SINGLE & THREE TRIALS FOR IGNITION
FLAME MONITORING
INDICATION OF: PILOT ON, POWER ON, & MAIN ON
FIRST OUT ANNUNCIATION & SHUTDOWN FOR:
REMOTE STOP AND START CAPABILITIES
SINGLE OR DUAL BURNER 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
•POWER FAIL
•HI PRESSURE
•HIGH TEMPERATURE
•FLAME FAIL
•LOW PRESSURE
•PROOF OF CLOSURE
•REMOTE SHUTDOWN
•LOW LEVEL
•AUXILLARY 1
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller
ACL 5500 ProvidesACL 5500 ProvidesACL 5500 Provides

2
The ACL 5500 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 5500 utilizes a single ignitor/flame rod to provide both flame
acknowledgment and ignition at the pilot tip. When the ACL 5500 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 5500 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 module. If the
flame is still not lighting, the flame fail will then be displayed on the annunciation
panel.
If any of the shutdowns are tripped, the controller will not attempt any re-light,
solenoid outputs will de-energize immediately and that specific shutdown will
then be indicated on the annunciation panel. The shutdown must be cleared
before the controller will allow an ignition cycle.
In an application where the ACL 5500 is used to ignite and monitor two burners,
ignition will occur at both pilots simultaneously when a start is initiated. If a
flame is not established at both pilots during the 5 second trial for ignition the
solenoid #1 outputs will drop out closing both pilot valves and a flame fail will be
indicated on the annunciator panel (slow flash for pilot #1 and quick flash for pilot
#2). If both pilots have been proven for a period of 20 seconds solenoid #2
outputs will be energized allowing the main burner valves to open. During
normal operation should either pilot be extinguished there will be a 5 second trial
for re-ignition at that pilot, and the main solenoid outputs will be shut off during
the trial for ignition period. If a flame is not re-established during the 5 second
period the remaining pilot solenoid output will be de-generized closing the pilot
gas outputs immediately and will not attempt any re-light. The specific shutdown
will then be indicated on the front annunciator panel. The shutdown must be
cleared before the controller will allow an ignition cycle.
APPLICATION
THEORY OF
OPERATION
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller

3
ACL 5500 COMES
COMPLETE WITH
MOUNTING
POWER
CONNECTION
SOLENOID
OUTPUTS
The ACL 5500 can be mounted in a Class I, Div 2 area; usually close to the
burner. The 10’ of high voltage lead, (longer length 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
length 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 noise may
damage sensitive components. When the 5500 is used in a dual burner
application at least one of the ignition modules must be remotely mounted as the
controller housing will not accommodate two ignition modules. (Dual Burner kit
needed for dual burner applications)
The ACL 5500 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 four solenoid output terminals on the main circuit board marked pilot
solenoid and main solenoid, 2 for burner #1 and 2 for burner #2. 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. The solenoid
outputs are rated at 5A 250V each.
• ACL 5500 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 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller

4
S/D INPUTS &
ALARM
ANNUNCIATION
The shutdown input provides a means of connecting other shutdown devices for
High pressure, Low pressure, High temperature, Low level and Axillary 1 where
necessary for additional protection. Jumpers are installed at the factory and
should only be removed to utilize each individual shutdown. If any of the S/D
devices go to a fault condition their contacts will open, de-energizing the solenoid
outputs , shutting down fuel to the burner and disabling the re-light sequence.
The fault will be annunciated on the front of the controller. 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. 18 awg wire is recommended
for all the shutdowns for ease of wiring. Must be dry contacts.
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.
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 temperature control option is provided to allow the use of a temperature
switch to turn the main solenoid output on & off, controlling the main gas valve to
the burner. This does not override the shutdown logic of the output. When using
this option, the temperature switch must have dry contacts. When not in use, a
jumper must be installed as per drawings.
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.
NOTE: A jumper must be placed between terminal numbers 34 and 36 when the
ACL 5500 is being used for a single burner application.
REMOTE S/D
(STOP)
REMOTE START
PROOF OF
CLOSURE
(P.O.C)
TEMPERATURE
CONTROL
ALARM STATUS
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller

5
ONE BURNER TWO BURNER
VOLTAGE 12 VDC 24VDC 12 VDC 24 VDC
CURRENT 0.206A 0.139A 0.292A 0.200A
POWER 2.472W 3.336W 3.504W 4.80W
SOLENOID OUTPUT
RATINGS 5 amp 250 V Per Output 5 amp 250 V Per Output
OPERATING
TEMPERATURE -40 C to 60 C -40 C to 60 C
FLAME SENSITIVITY 1 micro amp minimum 1 micro amp minimum
FLAME FAILURE
RESPONSE TIME 0.8 seconds maximum 0.8 seconds maximum
SPARK RATE 25 sparks per second 25 sparks per second
SPECIFICATIONS DC
ONE BURNER TWO BURNER
VOLTAGE 120 VAC 240 VAC 12 VDC 24 VDC
CURRENT 0.306A 0.156A 0.292A 0.200A
POWER 36.72W 37.44W 3.504W 4.80W
FREQUENCY 50/60 HERTZ 50/60 HERTZ
SOLENOID OUTPUT
RATINGS 5 amp 250 V Per Output 5 amp 250 V Per Output
OPERATING
TEMPERATURE -40 C to 60 C -40 C to 60 C
FLAME SENSITIVITY 1 micro amp minimum 1 micro amp minimum
FLAME FAILURE
RESPONSE TIME 0.8 seconds maximum 0.8 seconds maximum
SPARK RATE 25 sparks per second 25 sparks per second
SPECIFICATIONS AC
Specifications DCSpecifications DCSpecifications DC
Specifications ACSpecifications ACSpecifications AC
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller
25 sparks per second
25 sparks per second
25 sparks per second
25 sparks per second

6
ACL 5500 12/24 VDC
1 Burner System
Note: If remote mounting of ignition
module is preferred, the ACL 5000R remote
mount kit is available upon request
1
2
3
4
6
7
8
9
10
5
11
12
13
14
15
16
17
18
19
20
21
Proof of Closure
Proof of Closure
Jumper when not in use
Temp Control
Temp Control Jumper when not in use
Remote Start
Remote Start
Jumper when not in use
Remote S/D
Remote S/D
Hi Press S/D
Hi Press S/D Jumper when not in use
Lo Press S/D
Lo Press S/D
Jumper when not in use
Hi Temp S/D
Hi Temp S/D Jumper when not in use
Lo Level S/D
Lo Level S/D Jumper when not in use
Aux 1 S/D
Aux 1 S/D
Jumper when not in use
Alarm Status NO
Alarm Status COM
Solenoid #2 Positive +
Solenoid #2 Negative -
Solenoid #1 Positive +
Solenoid #1 Negative -
(Main)
(Pilot)
Note: Solenoid O/P Voltage
Equal to Supply Voltage
Aux. S/D
#1
LL
SD
HT
SD
LP
SD
HP
SD
Remote Stop Button
Remote Start Button
Temp Switch
Burner #1
S/D Valve P.O.C.
MUST BE DRY CONTACTS.
MUST BE IN CLOSED POSITION
INITIALLY FOR BURNER TO START
To PLC or RTU
for Remote Status
Ignition
Module
To Ignitor/Flame Rod
25
26
27
28
29
Power
Alarm
Valve
Ground
Bonding Ground
22
23
24
12/24 VDC Positive
12/24 VDC Negative
System Ground
(Power Supply)
Power Supply
12/24 VDC
30
31
32
33
SV SV
SV
Burner #1 Pilot
1 or 2 Valve System
Alarm Status NC
Solenoid #2 Positive +
Solenoid #2 Negative -
Solenoid #1 Positive +
Solenoid #1 Negative -
(Main)
(Pilot)
34
35
36
37
38
Power
Alarm
Valve
Ground
Bonding Ground
39
40
41
42
Note: Run #18 AWG
for shutdowns
BURNER #1 BURNER #2 (Optional)
Note: Jumper between
34 & 36 when not in use
To Ignitor/Flame
Rod Ground
Pneumatic
Control Box
Prewired in Control Box
Red
Blue
Brown
Yellow
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller
YellowYellowYellow

7
ACL 5500 12/24 VDC
2 Burner System
HG
SD
1 or 2 Valve System
1
2
3
4
6
7
8
9
10
5
11
12
13
14
15
16
17
18
19
20
21
Proof of Closure
Proof of Closure
Jumper when not in use
Temp Control
Temp Control Jumper when not in use
Remote Start
Remote Start
Jumper when not in use
Remote S/D
Remote S/D
Hi Press S/D
Hi Press S/D Jumper when not in use
Lo Press S/D
Lo Press S/D
Jumper when not in use
Hi Temp S/D
Hi Temp S/D Jumper when not in use
Lo Level S/D
Lo Level S/D Jumper when not in use
Aux 1 S/D
Aux 1 S/D
Jumper when not in use
Alarm Status NC
Alarm Status COM
Solenoid #2 Positive +
Solenoid #2 Negative -
Solenoid #1 Positive +
Solenoid #1 Negative -
(Main)
(Pilot)
Note: Solenoid O/P Voltage
Equal to Supply Voltage
Aux. S/D
#1
LL
SD
HT
SD
LG
SD
Remote Stop Button
Remote Start Button
Temp Switch
Burner #1
S/D Valve P.O.C.
Burner #2
S/D Valve P.O.C.
MUST BE DRY CONTACTS.
MUST BE IN CLOSED POSITION
INITIALLY FOR BURNER TO START
To PLC or RTU
for Remote Status
Ignition
Module
To Ignitor/Flame Rod
25
26
27
28
29
Power
Alarm
Valve
Ground
Bonding Ground
Ignition
Module
Burner #2
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
22
23
24
12/24 VDC Positive
12/24 VDC Negative
System Ground
(Power Supply)
Power Supply
12/24 VDC
30
31
32
33
SV SV SV
SV
SV
SV
Burner #1 Pilot Burner #2 Pilot
1 or 2 Valve System
Alarm Status NO
Solenoid #2 Positive +
Solenoid #2 Negative -
Solenoid #1 Positive +
Solenoid #1 Negative -
(Main)
(Pilot)
34
35
36
37
38
Power
Alarm
Valve
Ground
Bonding Ground
39
40
41
42
Field Wiring
By Customer Max 50 Ft.
Min #16 Guage
Note: Run #18 AWG
for shutdowns
BURNER #1 BURNER #2
Note: Jumper between
34 & 36 when not in use
To Ignitor/Flame
Rod Ground
Remote Mount Option
ACL 5000R
Prewired in Control Box
HG
SD
This output has
dry contacts rated
@ 5A, 250V
Red
Blue
Brown
Yellow
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller
YellowYellowYellow

8
ACL 5500 120/240 VAC
1 Burner System
1
2
3
4
6
7
8
9
10
5
11
12
13
14
15
16
17
18
19
20
21
Proof of Closure
Proof of Closure
Jumper when not in use
Temp Control
Temp Control Jumper when not in use
Remote Start
Remote Start
Jumper when not in use
Remote S/D
Remote S/D
Hi Press S/D
Hi Press S/D Jumper when not in use
Lo Press S/D
Lo Press S/D
Jumper when not in use
Hi Temp S/D
Hi Temp S/D Jumper when not in use
Lo Level S/D
Lo Level S/D Jumper when not in use
Aux 1 S/D
Aux 1 S/D
Jumper when not in use
Alarm Status NO
Alarm Status COM
Solenoid #2 HOT
Solenoid #2 NEU
Solenoid #1 HOT
Solenoid #1 NEU
(Main)
(Pilot)
Note: Solenoid O/P Voltage
Equal to Supply Voltage
Aux. S/D
#1
LL
SD
HT
SD
LP
SD
HP
SD
Remote Stop Button
Remote Start Button
Temp Switch
Burner #1
S/D Valve P.O.C.
MUST BE DRY CONTACTS.
MUST BE IN CLOSED POSITION
INITIALLY FOR BURNER TO START
To PLC or RTU
for Remote Status
Ignition
Module
To Ignitor/Flame Rod
25
26
27
28
29
Power
Alarm
Valve
Ground
Bonding Ground
22
23
24
120/240 HOT
120/240 NEU
System Ground
(Power Supply)
Power Supply
120/240 VAC
30
31
32
33
SV SV
SV
Burner #1 Pilot
1 or 2 Valve System
Alarm Status NC
Solenoid #2 HOT
Solenoid #2 NEU
Solenoid #1 HOT
Solenoid #1 NEU
(Main)
(Pilot)
34
35
36
37
38
Power
Alarm
Valve
Ground
Bonding Ground
39
40
41
42
Note: Run #18 AWG
for shutdowns
BURNER #1 BURNER #2 (Optional)
Note: Jumper between
34 & 36 when not in use
To Ignitor/Flame
Rod Ground
Pneumatic
Control Box
Prewired in Control Box
Red
Blue
Brown
Yellow
Note: If remote mounting of ignition
module is preferred, the ACL 5000R remote
mount kit is available upon request
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller
YellowYellowYellow

9
ACL 5500 120/240 VAC
2 Burner System
HG
SD
1 or 2 Valve System
1
2
3
4
6
7
8
9
10
5
11
12
13
14
15
16
17
18
19
20
21
Proof of Closure
Proof of Closure
Jumper when not in use
Temp Control
Temp Control Jumper when not in use
Remote Start
Remote Start
Jumper when not in use
Remote S/D
Remote S/D
Hi Press S/D
Hi Press S/D Jumper when not in use
Lo Press S/D
Lo Press S/D
Jumper when not in use
Hi Temp S/D
Hi Temp S/D Jumper when not in use
Lo Level S/D
Lo Level S/D Jumper when not in use
Aux 1 S/D
Aux 1 S/D
Jumper when not in use
Alarm Status NC
Alarm Status COM
Solenoid #2 HOT
Solenoid #2 NEU
Solenoid #1 HOT
Solenoid #1 NEU
(Main)
(Pilot)
Note: Solenoid O/P Voltage
Equal to Supply Voltage
Aux. S/D
#1
LL
SD
HT
SD
LG
SD
Remote Stop Button
Remote Start Button
Temp Switch
Burner #1
S/D Valve P.O.C.
Burner #2
S/D Valve P.O.C.
MUST BE DRY CONTACTS.
MUST BE IN CLOSED POSITION
INITIALLY FOR BURNER TO START
To PLC or RTU
for Remote Status
Ignition
Module
To Ignitor/Flame Rod
25
26
27
28
29
Power
Alarm
Valve
Ground
Bonding Ground
Ignition
Module
Burner #2
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
22
23
24
120/240 HOT
120/240 NEU
System Ground
(Power Supply)
Power Supply
120/240 VAC
30
31
32
33
SV SV SV
SV
SV
SV
Burner #1 Pilot Burner #2 Pilot
1 or 2 Valve System
Alarm Status NO
Solenoid #2 HOT
Solenoid #2 NEU
Solenoid #1 HOT
Solenoid #1 NEU
(Main)
(Pilot)
34
35
36
37
38
Power
Alarm
Valve
Ground
Bonding Ground
39
40
41
42
Field Wiring
By Customer Max 50 Ft.
Min #16 Guage
Note: Run #18 AWG
for shutdowns
BURNER #1 BURNER #2
Note: Jumper between
34 & 36 when not in use
To Ignitor/Flame
Rod Ground
Remote Mount Option
ACL 5000R
Prewired in Control Box
HG
SD
This output has
dry contacts rated
@ 5A, 250V
Red
Blue
Brown
Yellow
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller
YellowYellowYellow

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 which is optimum
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller

11
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller
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
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 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
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller

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
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller
Fails to Attempt IgnitionFails to Attempt IgnitionFails to Attempt Ignition
BMS Troubleshooting GuideBMS Troubleshooting GuideBMS Troubleshooting Guide
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
13
setting

NOTES
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller
14

NOTES
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller
15

NOTES
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety Controller
16

NOTES
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
ACL 5500 Combustion Safety ControllerACL 5500 Combustion Safety ControllerACL 5500 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 [phone]