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DESCRIPTION

The ACL 5000 provides ignition, flame fail, proof of closure, run status, alarm and shutdown capabilities and temperature control contacts for all gas fired heaters.

Specifications ACL 5000 (12/24 VDC)/(120 VAC)

ACL 5000 12/24 VDC
Voltage	12 VDC/24 VDC
Current	.204 amps/.102 amps
Power	2.45 W/2.45 W
Solenoid valve rating per solenoid output	12 W
Operating temp	-40 C to 60 C
Flame sensitivity	1 micro amp minimum
Flame failure response time	0.S seconds maximum
ACL 5000 120 VAC
Voltage	120/240 VAC
Current	1.05 amps
Power	12.75 W
Solenoid valve rating per solenoid output	30 W
Operating temp	-40 C to 60 C
Flame sensitivity	1 micro amp minimum
Flame failure response time	0.8 seconds maximum
Spark rate	25 sparks/second

Features

• Simple to use, no programming necessary
• Built in logic allows for automatic ignition & relight, shutdown interlocks, alarm out, remote stop & remote start, proof of closure and temperature control contacts.
• Versatile power supply 9-30 VDC, 120 VAC 50/60 Hz. & Solar.
• Fastest flame out response time of 0.8 seconds.
• CSA approved for Class 1, Div 2 lo¬cation.
• CSA approved C22.2 No 199-M89. Combustion safety controls and solid-state Ignitors for Gas & Oil burning equipment.
• CSA B149.3 Compatible.
• Nema 4x enclosure, corrosion resis¬tant and weatherproof.

Simple Design

• No programming necessary
• Two button operation (Stop & Start)
• New innovative design allows ignition and flame fail with the use of one flame rod
• Control and ignition components are all housed in the Nema 4x enclosure control box
• Easily installed into any burner.

Application

The ACL 5000 ignition control system is designed to be used for industrial sized burner applications where a continuous pilot is used. An approved slow opening valve must be used for large BTU heaters.

Theory of Operation

The ACL 5000 utilizes a single ignitor/flame rod to provide both flame acknowledge¬ment and ignition at the pilot tip. When the ACL 5000 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 the ignitor/flame rod for flame acknowledgement and the unit stops sparking. If the pilot flame is extin¬guished , the current path is broken and the ignitor/flame rod starts sparking within 1 second.

Installation

Every ACL 5000 comes complete with:
• ACL 5000 controller
• ACL M-50 pilot mixer & nozzle
• 10' ground wire
• 10' high voltage wire complete with ends
• 6.5' non-metallic flex complete with connectors
• Ignitor/flame rod complete with mounting hardware
• Speed control valve

Mounting

The ACL-5000 can be mounted in a Class 1 Div 2 area, usually close to the burner. The 10' of high voltage ignition lead, (longer lengths not recommended) must be run in the non metallic flex provided or free air. 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. 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, ACL5000R remote mount kit.

Power Connection

The ACL-5000 is available in 12-24 VDC or an optional 120 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 power 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 acknowledgement current.

Solenoid Outputs

There are two solenoid output terminals on the main circuit board marked solenoid #1 and solenoid #2. The output voltage at these terminals is always the same as the controller supply voltage. The combined power consumption of solenoids connected to a system should not exceed 12 watts for a 12 VDC unit, 24 watts for a 24 VDC unit and 30 watts for a 120 VAC unit. (ACL Manufacturing carries a line of Class I Div I extra low watt solenoid valves available in all three voltages.) Solenoid #1 output connects to the pilot or low fire solenoid and is energized when a start is initiated. Solenoid #2, (main burner) energizes only after the pilot or low fire flame has been proven. The time delay between proof of flame and energizing of output #2 is factory set at 20 seconds and is adjustable with T1.

S/D Interlock

The shutdown interlock provides a means of connecting other shutdown devices such as low level or high temperature switches for additional protection. A jumper is installed at the factory and should only be removed to utilize this feature. Shut¬down devices connected (in series) to the S/D interlock terminals must be dry con¬tacts and be in a closed state during normal operating conditions. If any of the S/D switches go to a fault condition, their contacts will open, de-energizing the solenoid output and shutting down fuel to the burner. The controller will attempt one 5 sec¬ond re-light but will be unsuccessful and go into alarm. 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 con¬troller will again attempt a re-light, without energizing the solenoid output and will re¬turn to an alarm condition. Alternately the heater shutdown devices may be con¬nected in series to the remote S/D terminals. When using this wiring method the controller will not attempt a re-light when one of the switches opens due to a fault condition and subsequently will not give any local annunciation. When the shut¬down devices are connected to the remote S/D and not the S/D interlock a jumper must be placed across the S/D interlock terminals.

Alarm Output

Alarm output status provides the user with a normally closed and normally open set of dry contacts. The only time these contacts change state is when the controller has been unsuccessful in lighting the pilot assembly after 1 try.

Remote Stop

The remote stop function is available when the jumper is removed and a momen¬tary normally closed contact button or remote relay contact (N/C) is utilized. This remote stop shuts down the ACL 5000 completely. NOTE: Must be dry contacts. The remote stop can also be used to wire in the heater shutdowns. See S/D inter¬lock.

Remote Start

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.

Proof of Closure

This feature allows controller to use valves with proof of closure switches for valve status. When valve switch contacts are in an open state confirming the valve may be open, the controller will not start. The contacts must be closed in order for con¬troller to start. Once start is initiated, the contacts from proof of closure switch can then change state.

Temperature Control

The temperature control option is provided to allow the use of a temperature switch to turn on & off solenoid output #2, controlling the main gas valve to the burner. This does not override the shut down 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 electrical drawings.

Run Status

This output provides a run status of the controller. These contacts are a normally open set of dry contact when the controller is off or in alarm state. When the con¬troller is running normally, these contacts are closed.

ADDITIONAL INFORMATION

Note: low power solenoids of .85 and 1.S watts are available for solar power operations as well as all voltages