ACL CSC 200 User manual

805Main Ave.West-Box2002Sundre, AlbertaT0M1X0-Phone:(877)638-5234-Fax:(403)638-4973-Email:[email protected]
Website:www.aclmfg.com
ManufacturingInc.
ACL ACL CSC200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 CSC200
CombustionSafety
Control
FOR

4
6
ManufacturingInc.
ACL
ACL CSC200CombustionSafetyControl

1ManufacturingInc.
ACL
ACL CSC200CombustionSafetyControl
FEATURES •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
I
NoProgramming
CSA approvedforClass ,Div2location
Operationalambienttemperatureof-40°to+60°Celsius
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
100%failsafedesign
Safetylockoutforhightemperaturesetting
Onboardsolenoiddriverforpowerreductiontosolenoidsandpeak-holdsolenoids
TwoadjustabletypeKthermocoupleinputsformonitoringtwo
separatetemperaturepoints(processtemp.&hightemp.)
Pilotlessburnercontrolselectable.Singleanddualstage,LowfireandHighfire
Shutdowninput(ie.Lowlevelshutdown,pressureshutdown)
2Selectablethermocouplerangesof-60°Cto1100°Cor0°Cto500°C(-75°Fto
2012°For32°Fto932°F)
Adjustabledeadbandfrom1,2,3and5degreesCor2,4,6and10degreesF
°C °F
The ACL CSC200isdesignedtobeusedinconjunctionwiththe ACL combustion
moduleforacompletesafetycombustiondevice. The ACL CSC200providesburner
ignitionandflamefail,aswellasmonitoringoftwoseparatethermocoupleinputswhich
canbeutilizedfortemperaturecontrolinprocessapplicationssuchastanks,line
heaters,re-boilersoranyotherapplicationwhereaccuratetemperaturemonitoringor
controlisrequired. Thesystemisdesignedtooperatewithorwithoutacontinuous
pilot.
Thetwoindependenttemperaturesetpointscanbeadjustedwiththethreemembrane
pushbuttonsonthefaceofthecontrollerwithLEDindicationof Temp1or Temp2.
Initialsetupfortemperatureranges,displayanddeadbandcanbeobtainedthroughdip
switchselectionsforvarioususerpreferences.
EasytoreadfourdigitsevensegmentLEDdisplay
LEDindicationofthermocouple1or2valuesdisplayed
or readout
12/24VDCandsolar
Lowpowerconsumption(Powersavemodeoperatesaslowas1.2Watts)
On/Offcontrol
“THISEQUIPMENTISSUITABLEFORUSEINCLASSIDIVISION2,GROUPSA,B,C,&DORNONHAZARDOUS
LOCATIONSONLY”
“WARNING-EXPLOSIONHAZARD-SUBSTITUTIONOFCOMPONENTSMAYIMPAIRTHESUITABILITYFOR
CLASSIDIVISION2”
DESCRIPTION

Supply12/24VDCtoControllerasperdrawingonpage7.Displaywillturnonand
indicateeither Temp1or Temp2whicheverwasselectedby½pushbutton. The
arrowsupanddownselectthetemperaturesetpoint.Onceselected,theignition
controllercanbeturnedtotheOnposition. Thiswillinitiateignitioncontroller,if
callingforheatandallshutdowninputsareclear.Iftheprocessisabovethe
temperaturesettings,itwillnotinitiatelightingoftheburner,butwillturnononce
processdropsbelowsetpointinthepilotlessmode(I).
Whentheignitionswitchisturnedonandthecontrolleriscallingforheat,the
controllerwillattemptignitionandthepilotoutputwillprovidevoltagetothe
solenoidtoallowpilotgasforignition.Shutdowns,POCandremoteon/offmustbe
inapermissivestateforthistooccur.Pilotoutputwillceaseifthereisafailureto
lightwithin5secondsandaFFwillappearonthedisplay.Whenusingasingle
trialmodule,thecontrollerwilllockoutandhavetobereset.Whenusinga3try
module,thecontrollerwillattempt2moreadditionaltriesbeforelockingout. This
canbereseteitherbythelocalon/offswitchortheremoteon/offswitch.Whether
theI(pilotlessorintermittent)selectionorC(continuospilot)selectionisused,the
controllerwillperformasaboveexceptthecontinuouspilotwillbeinitiatedbyon/off
aswellastemperaturedemandswitch,andremainonregardlessoftemperatures
setting.
The ACL CSC200CombustionSafetyControloperatesinavoltagerangebetween
10-30VoltsDC. Theterminalsare#19positive,#20negative,and#22ground.
POWER
CONNECTION
OPERATION
ACL CSC200CombustionSafetyControl
ManufacturingInc.
ACL
INPUTCONNECTIONS
THERMO-
COUPLE
INPUT
ON/OFF
ThecontrolleracceptstwotypeK(ungrounded)thermocouplesonterminals1,2,3
and4. Theyareclearlymarkedontheboardforeachthermocoupleandpolarity
(Seewiringdiagram). Thetemperaturerangecanbeselectedviathedipswitches
onthemaincircuitboardlocatedinthetoprightcorner.Rangescanbeselected
independentlyforeachthermocoupleinput,eitherhighorlow.Highrangeis-60 C
to1100 C(-76 Fto2012 F)orlowrange,0 Cto500 C(-32 Fto932 F).
Theswitchonthesideofthecontrollerisinternallywiredtoterminals5and6.
Thisturnsonandofftheignitionmoduleprovidedtheshutdowninputandremote
resetinputsareclosedandtemperaturevaluesforboththermocouplesareina
permissiverange. TheOn/Offswitchalsoactsasaresettoclearanylatchedshut
downsthatmayhavetrippedthencleared.
o
o o o oo o o
2

3ManufacturingInc.
ACL
REMOTE
ON/OFF
ALARM
STATUS
PROOFOF
CLOSURE
IGNITION
MODULE
CONNECTION
S/D
SHUTDOWN
ACL CSC200CombustionSafetyControl
Theremoteon/offterminals7and8,whenopenedwillturnofftheignitionmodule
andvalveoutputswhenopenedandresetanylatchedshutdownthatmayhave
trippedthencleared.Controllerwillnotresetunlessshutdownshavecleared.
Theseterminalsmustbewiredtodrycontactsofaremoteswitchorrelaywhen
used. A jumpermustremainacross7and8whennotinuse.Whenremoteon/off
isopened, willappearondisplay.
Theshutdownterminals9and10areusedtoturnofftheignitionmodulewhen
opened. Theseterminalsarewiredtodrycontactshutdownssuchaslevel
switches,pressureswitches,oranyothertypeofauxiliaryshutdowndevice.If
morethanoneshutdownswitchisused,theymustbewiredinseries.Openingof
anyswitchconnectedtoshutdownterminals9and10willshutofftheignition
moduleandde-energizeall3valveoutputs. Theseterminalscanbeselectedto
latchorunlatchwhenshutdownisclearedviathedipswitchsettings(Seedip
switchdiagram).Unlatchallowsthemoduletorestartignitionwhencleared,latch
locksoutarestartuntilamanualresetoftheOn/Offswitchisturnedoffthenonor
theremoteresetswitchisopenedthenclosed.
ThealarmstatusprovidesforremoteindicationofwhethertheCSC200isina
normaloperatingmodeorifitisinashutdownstate,orturnedoffeitherremotely
orlocally. Alarmstatusterminals11and12areadrysetofcontacts.Whenpower
tocontrollerisoff,thecontactsareopen.Contactsarealsoopenwhencontroller
isinashutdownstate(ie.Powerfailureorshutdownisopen).Thisprovidesfora
completefailsafeindicationofthestatusofthecontroller.
ThePOC(ProofofClosure)terminals13and14areusedwhenaproofofclosure
safetyshutdownvalveisused. ThispreventsthestartingofanyignitionifthePOC
switchisopened. Thissafetyfeatureeliminatestheriskofignitingaburnerifthe
valveispartiallyopenandproofofclosureswitchindicatesopen. Thisisalsoa
failsafeinputasitwillnotallowignitiontoinitiateifwireisbrokenordisconnected.
willappearonthedisplay. A jumpermustbeinstalledbetween13and14if
thisfeatureisnotused.
Theterminals15,16,17and18aretobewireddirectlytothe ACL ignitionmodule.
Thisprovidescommunicationbetweenthetwo,allowingforacompletecombustion
safetycontrolandignitionofburner(Seewiringdiagram).
Rr
POC

4
6
4
ManufacturingInc.
ACL
PILOT Theterminals27&28providepowertothepilotsolenoidvalvetoallowgasfor
initialignitionandflamesensing. Thevoltagetothisoutputisthesamevoltage
suppliedtothecontroller. Thisoutputhasalowpowerfeatureforthesolenoids
providedbyanonboardsolenoiddrivercircuit. Thiscircuitcanreducepower
consumptionofsolenoidsasmuchas80%powerreduction. Thiscircuitalsohelps
eliminateanynoisethatmaybeproducedbysomesolenoids,andhelpsextend
thelifeofthesolenoids. Toutilizeonboardsolenoiddriver,seedipswitchsettings.
Theterminals25and26providepowertothemainsolenoidvalves.Powerto
theseterminalsarepresentonly10secondsafterpilotflameispresentand
shutdownsaresatisfied. Thisoutputalsohasthesamelowpowerfeatureofthe
onboardsolenoiddriver.
Theterminals23and24providespowertothemainsolenoidsthroughthe
temperature1setting. Thisallowsforanindividualtemperaturecontrolofoneof
themainsolenoidseliminatingunnecessarystrokingofthemainsafetyshutdown
valvestocontrolmaingastotheburnerfortemperaturecontrol. Thisoutputalso
hasthelowpowerfeatureoftheonboardsolenoiddriver.
T-MAIN
INTERMITTENT
PILOT (Pilotless)
MAIN
OUTPUTCONNECTIONS
The ACL CSC200controllerprovidesthisfeatureforapplicationswherea
continuouspilotmaynotbedesirable. Thepilotoutputisonlyenergizedwhenthe
controlleriscallingforheat.Inthiscase,thepilotturnson,thenafter10seconds
themainand T mainoutputsbecomeenergized. Thisallowsforalowfirestart
throughthemainburnersorapilot/mainstartwhereanindividualpilotandmain
areused. Thisisonlyinitiatediftheon/offswitchisintheonpositionandall
shutdownsandPOCareclosed.
Whencontinuouspilot(C)isselectedvia(dipswitchsettings)thepilotoutput
becomesenergizedwhentheon/offswitchisturnedtoon,andallshutdownsand
POCareclearandpermissive,regardlessofwhetherthecontrolleriscallingfor
heat.
Intermittentpilot(I)orContinuouspilot(C)featurescanbeaccessedthroughthe
dipswitchsettings.Seedipswitchdiagram,indicatedbyI/C.
PILOTLESSORCONTINUOUSPILOTFEATURE
CONTINUOUS
PILOT
ACL CSC200CombustionSafetyControl

5ManufacturingInc.
ACL
INSTALLATION
ADJUSTINGSETPOINTS
12
Selectstemperatureinput1or2ondisplay
Temp1-Bathorprocesstemperature
Temp2-Hightemperatureshutdown
Displaysandincreasestemperature
setpoint-Holdbuttondowntoscroll
todesiredsetpointthenrelease.
Displaywillthenreturntoactual
temperaturereading
Displaysanddecreasestemperature
setpoint.Holdbuttondowntoscroll
todesiredsetpointthenrelease.
Displaywillthenreturntoactual
temperaturereading.
Ifleftwithnobuttonspushedthedisplaywillrevertbacktoshowtheactualthermocoupletemperature
readingaccordingtotheLEDindication(Temp1or Temp2).
Displaywillshow(----)whenthermocouplesarenotenabledthroughthedesignateddipswitchsetting
or(OPEN)ifthethermocouplesarenotconnectedorfailedopen.
ACL CSC200CombustionSafetyControl
PowerFailure-Indicationiflossof
powertocontrolleroccurs.
FlameFail-Indicatesthatpilothas
goneoutandfailedtore-light.
Processtemperatureindicationof
either TC-1or TC-2,whicheveris
selected.
Indicatesswitchhasbeenturnedoff
toignition.
RemoteReset
Shutdown-Indicatesanopenswitch
orshutdownwhichistiedinto
terminals9&10.
Indicates TC-2temperatureisator
abovesetpointwhichwillshutdown
controllervalveoutputs.
ProofofClosure-IndicatesthePOC
switchterminalsareinanopenstate.
Jumpershouldbeinplacewhennotusing
ProofofClosurevalve.
Indicates TC-2disabled.Maybe
selectedwithdipswitch.
Indicatesanopenthermocouple
conditiononeitherthermocouple1or
2.Controllervalveoutputsbecome
de-energized.
CONTROLLERDISPLAYCODES

4
6
6ManufacturingInc.
ACL
DipSwitchOptionChart
Switch#1
Switch#2
Switch#3
Switch#4
Switch#5
Switch#6
Switch#7
Switch#8
Switch#9
Switch#10
Switch#11
Switch#12
Selectsdisplaytemperaturetoreadineither Cor F.
Deadbandsetting.(seechart)
Deadbandsetting.(seechart)
Disablesorenablesupanddownbuttonsfor TC2settings.
Thermocouple1highandlowtemperaturerangesetting.-H(-60 Cto1100 Cor-76 Fto2012 F)-L(0 Cto
500 Cor-32 Fto932 F)
Thermocouple2disablewhennotinuseandenablewheninuse.
Thermocouple2highandlowtemperaturerangesetting.- to to to
to
Powersavemodeldisplayautomaticallydimsafter2minuteswhennobuttonsarepressed.
Continuouspilotmode(C)whenselectedorpilotlessmode(intermittent)(I)whenselected.
Latchestheshutdownandlockscontrollerfromrestartingwhenshutdownclears.Whensettooff,controller
ignitionresumesautomaticallyifshutdownclearsandcontrollercallsforheat.
Latchestemp#2andlockscontrollerfromrestartingwhentemperatureclearsbelowsetpoint.Whensetto
off,controllerignitionresumesautomaticallyiftemperaturefallsbelowsetpoint,andallshutdownsareclear.
Ifpowerfailuretocontrolleroccurs,thepowerfaillatchsettingdoesn’tallowcontrollertorestartignitionwhen
powerreturns.Whensettooff,controllerignitionresumesautomaticallywhenpowerreturns.
00
00 0 0 0
0 0 0
H(-60 C 1100 Cor-76 F 2012 F)-L(0 C
500 Cor-32 F 932 F)
0 0 0 0 0
0 0 0
124
3
12
11
10
9
8
7
6
5
4
3
2
1
SW3
SW2
0C
0F
ON ON OFF OFF
ON
1
2
OFF
2
4
ON
3
6
OFF
5
10
PWRFAIL LATCH
HIGH TEMP LATCH
S/DLATCH
I/CPILOT
PWRSAVE
TC2H/L
TC2D/E
TC1H/L
BTND/E
DBAND2
DBAND1
00
C/ F
40 20 10
DEADBAND
SETTINGS
OFF/ON
SOLENOIDDRIVER
DIP SWITCHES
ACL CSC200CombustionSafetyControl
Selectingdipswitch1,2,or3or
anycombinationwillprovidea
percentageofcycletimefor
thesolenoidoutputsforpower
saving.
(Ie.)Switch1(40%)and
Switch3(10%)whenselected
willprovide50%cycletime.
0C0000
0
000

7
ManufacturingInc.
ACL
ACL CSC200CombustionSafetyControl
Yel l ow
Red
Alarm
contact
POC (Jumper when not used)
+
-
+12/24VDC
-12/24VDC
+
+
-
-
TC-1
TC-2
Type K
Thermocouple
inputs
Ignition
ON/OFF
CSC 200
Remote Mount Kit
ACL Combustion
Safety Control
Ignition Module
High Voltage
Ignition Wire
To I gni t or / Fl ame
Rod on Burner
P
G
V
(TC-1)
(TC-2)
Remote reset
S/D (Jumper when not used)
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
25
26
27
28
P
A
G
V
Yel l ow
Red
AUX LLSD PSD
Shutdowns
Proof of closure +
+
-
+
-
Main
Pilot
+
-
+
-
+
-
Pilot solenoid
Main solenoid
Temper at ur e cont r ol l e d
main solenoid
(dry contacts)
To gr o und l u g
on pilot or burner
22
T-Main
-
24
23

Voltage
Current
(max)
Controller Only
Current
(power save mode)
Controller Only
Power
(max)
Controller Only
Power
(power save mode)
Controller Only
Relay Contact
Max Allowed Operating Temp.
12 VDC .500A .10A 6W 1.2W 2ampPerOutput -40Cto60C
24 VDC .250A .05A 6W 1.2W 2ampPerOutput -40Cto60C
SPECIFICATIONSCHART
CSA StandardC22.2No.0-10-GeneralRequirements-CanadianElectricalCodePartII
CAN/CSA-C22.2No.0.4-04-BondingofElectricalEquipment
CSA StandardC22.2No.94-M91-SpecialPurposeEnclosures
CSA StandardC22.2No.142-M1987-ProcessControlEquipment
CSA C22.2No.199-M89-CombustionSafetyControlsandSolid-StateIgnitorsforGasandOilBurning
Equipment
CSA StandardC22.2No.213-M1987-Non-IncendiveElectricalEquipmentforUseinClass ,Division2
HazardousLocations
UL Standard50,12thEdition-IndustrialControlEquipmentforUseinHazardous(Classified)Locations
UL746C,6thEdition-StandardforPolymericMaterials-UseinElectricalEquipmentEvaluations
UL 508,17thEdition-IndustrialControlEquipment
ANSI/UL 69813thEdition-IndustrialControlEquipmentforuseinHazardous(Classified)Locations
ANSIZ21.20-2005- AutomaticGasIgnitionSystemsandComponents
ANSIISA 12.12.01-2007-NonIncendiveElectricalEquipmentforUseinClass and ,Division2andClass
,Divisions1and2Hazardous(Classified)Locations
I
I II
III
*NOTE:Maximumcurrentnottoexceed5A total
ACL
ManufacturingInc.
ACL CSC200CombustionSafetyControl
8
APPLICABLESTANDARD&
CODEREQUIREMENTS

NOTES
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
4
6
9ManufacturingInc.
ACL
ACL CSC200CombustionSafetyControl

805Main AveWest-Box2002Sundre, AlbertaT0M1X0
Phone:(877)638-5234-Fax:(403)638-4973
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.