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ACL CSC400 Installation And Operation Manual

Combustion safety controller
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Installation and Operations Manual
for the
CSC400 Combustion
Safety Controller
(Rev 1D)
WARNING
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.
ACL is not responsible for the misuse or incorrect application of this product.
V 2.21
805 Main Ave. West – Box 2002 Sundre, Alberta T0M 1X0 – Phone: (877) 638-5234 – Fax: (403) 638-4973 – Email:
aclmfg@telus.net
Website: www.aclmfg.com

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Summary of Contents for ACL CSC400

  • Page 1 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. V 2.21 805 Main Ave. West – Box 2002 Sundre, Alberta T0M 1X0 – Phone: (877) 638-5234 – Fax: (403) 638-4973 – Email: aclmfg@telus.net...

  • Page 2: Table Of Contents

    TC3 Auxiliary High Temperature Shutdown ........................47 Low Temperature Shutdown/Alarm ............................ 47 Dual TC1/TC2 Difference Shutdown ..........................47 CSC400 Controller Shutdown Display Codes ........................48 4-20mA Input Connection Notes for Rev 1D CSC400 Boards ................... 51 4-20mA Input DIP Switches ..............................51...
  • Page 3 Isolated (or Common) Ground ............................. 58 Appendix C - Programming a New Modbus Slave ID (Address) ....................59 Appendix D - Troubleshooting ..............................60 Additional Documents The following additional documents for the CSC400 Combustion Safety Controller are available. Document Filename Document Description CSC400_Modbus_Installation_Manual.pdf Modbus documentation containing more in-depth register descriptions and additional technical details.

  • Page 4: Introduction

    An alarm will signal if the CSC400 detects that either the pilot is out, or the flame failed to light. Once the Start button is pressed on the front of the unit, the CSC400 will automatically start sparking up to a maximum of three ignition trials providing that all shutdowns are in a permissive state.

  • Page 5: Csc400 Features

    Modbus RTU (over RS485) communications capability with full status and Shutdown logging readout 100% fail safe design • • Local and Remote On/Off controls Brownout Protection. CSC400 will continue in previous state if a brownout/blackout condition is detected. • First out annunciation of shutdowns • •...

  • Page 6: Operation Summary

    2 is above the TC2 setpoint. An option to use thermocouple 3 as an auxiliary high-temp shutdown is available as well. The CSC400 has a hardware revision of 1D and firmware version 00.02.09 (minimum). The menus in this version of the manual show firmware version 00.02.56.

  • Page 7: Quickstart Installation Procedure - Csc400 Combustion Safety Controller

    Quickstart Installation Procedure - CSC400 Combustion Safety Controller The Quickstart Installation Instructions assumes the user has some familiarity with Combustion Safety Controller Installation. Figure 1 – CSC400 Controller Main Board, Top View...
  • Page 8 Inputs/Control 5-pin Header connector that the flex cable from the Keypad overlay on the Header front panel connects to. The CSC400 will shut off all ignitor outputs and solenoid valves if the overlay is unplugged. Modbus DIP Modbus/RS485 DIP switches for selecting termination options for the Modbus/RS485...
  • Page 9 Extra earth ground terminal connections to assist in providing stable ground connections for solenoids, ignition modules, or other hardware Ignition Module Hardware The Ignition Module Mounting Location indicates the area where the ACL Mounting Ignition Module may be installed. Location "To Igniter 2"...

  • Page 10: Input And Control Connections

    Input and Control Connections Refer to the below diagram when reading the Input and Control Connections section. Figure 2 - CSC400 Input and Control Connections...
  • Page 11 Main, T/Main) need to have matching control voltages (Eg. all 12VDC or all 24VDC). Although the CSC400 will operate with input voltages as low as 10VDC, some larger solenoid valves may not operate on such a low voltage. For this reason, try to maintain the input voltage as close to (or slightly higher than) the required voltage for the desired solenoids.
  • Page 12 The VDCIN - (negative) terminal is connected to ground internally on the CSC400 printed circuit board. The Main power inputs (VDCIN + and VDCIN -) are protected against reverse polarity. The CSC400 will not operate if the Main Power Input wires are reversed and it will not cause damage to the CSC400 electronics.
  • Page 13 Remote Start/Stop Input The Remote Start/Stop input allows the user to hard wire a remote switch or relay for controlling the CSC400. These terminals must be wired to dry contacts of a remote switch or relay when used. The Remote Start/Stop switch turns on and off the power delivered to the ignition modules as long as all other shutdowns and Proof of Closure inputs are closed and temperature values for TC1 &...
  • Page 14 Level Shutdown Input The Level Shutdown switch input allows the user to hard wire a remote level switch or relay for controlling the CSC400. These terminals must be wired to dry contacts of a remote level switch (or pressure or auxiliary switch) or relay when used. If more than one shutdown switch is used, they must be wired in series.
  • Page 15 Alarm Status contacts are open between "NO" and "COM" and closed between "NC" and "COM", indicating an Alarm condition. The contacts are also in an Alarm condition when the CSC400 is in a shutdown state. Eg: a Shutdown switch or the Remote Start/Stop switch is open.
  • Page 16 TMain solenoid (TMain Mirror), to be on during a Purge cycle, or via Modbus control. AUX1/AUX2 Relays are turned off ("NC" is connected to "COM") when the CSC400 system is off. If a thermocouple is enabled via the menu system, it needs to be attached to a Type-K thermocouple to operate properly.
  • Page 17 Ignition Module 1 and 2 Inputs & Outputs The four terminals marked as "To Igniter 1" on the main circuit board need to be wired directly to the ACL Ignition Module if Ignitor 1 is enabled in the menu system. The four terminals marked as "To Igniter 2" on the main circuit board need to be wired directly to the ACL Ignition Module if Ignitor 2 is enabled in the menu system.

  • Page 18: Solenoid Output Connections, Ignitor 1 And 2

    "IGN 2" Designation Description Ignition Module Direction Terminal Wiring Harness Number Color Power (12VDC) Power output to Ignition Module Alarm Blue Input signal from Ignition Module (12VDC level) Valve Brown Input signal from Ignition Module (12VDC level) Ground Yellow Ground Pilot GND Ground to Pilot Ground...
  • Page 19 The Pilot Solenoid terminals provide power to the Pilot Solenoid valve. The Pilot valve allows gas to flow through the pilot valve train for initial ignition and flame sensing. During normal operation, the CSC400 turns on the pilot solenoid first while attempting to light the pilot flame via the ignition module.

  • Page 20: Csc400 Front Panel Buttons And Led Display

    CSC400 Front Panel Buttons and LED Display The CSC400 Controller provides a simple status and control interface to the user on the overlay mounted on the outside of the CSC400's box. A 4-line, 20-character LED display provide temperature status, 4-20mA input levels, and shutdown status and feedback while six membrane push buttons provide control for setting temperature setpoints, selecting menu options, and configuring the CSC400.
  • Page 21 - Modbus Remote Start command The main Stop/Reset switch acts as a reset to clear any latched shut downs that have tripped and been detected by the CSC400. A shutdown configured as a latched shutdown prevents the system from automatically restarting after it detects any interruption in continuity on the input terminals for the selected shutdown.

  • Page 22: Adjusting Temperature Setpoints And Deadbands

    Set 300°C 50°C Set 600°C 1 P:OFF M:OFF T:OFF 1:OFF 2:OFF Figure 6 - CSC400 Top Menu >Configuration Line Display Config Temp Setpoints IGN1 Timer View/Set Move the cursor (">") to the "Temp Setpoints" line using the Down button and then press the Select button. The Temperature Setpoints menu will be displayed, showing the setpoints for all three thermocouples (even if they're disabled) as well as their deadband settings.

  • Page 23: Wiring Diagrams - Fi (Flame Ionization)

    Wiring Diagrams - FI (Flame Ionization) The following diagram shows the wiring connections for the CSC400 Combustion Safety Controller. Figure 8 - CSC400 Wiring Diagram - FI (Flame Ionization), Remote IGN Module...
  • Page 24 Figure 9 - CSC400 Wiring Diagram - FI (Flame Ionization), Local IGN Module...
  • Page 25 Minimum Required Wiring Connections Optional or Additional Functionality Connections Thermocouple 1 Thermocouple 2 (Set TC2 menu option to Disabled if not used) Ignition Module: P, A, V, GND Remote Start/Stop (jumper if not used) Main Input Power (+12/24VDC, -12/24VDC) High / Low Gas Shutdowns (jumper if not used) Pilot Solenoid Output Level Shutdown (jumper if not used) Main Solenoid Output (if a minimum of two...
  • Page 26 Figure 10 - CSC400 Wiring Diagram - Dual IGN Modules: 1 Local, 1 Remote Mounting...
  • Page 27 Figure 11 - CSC400 Wiring Diagram - 4-20mA Controlled Temperature Control Valve (Throttling Valve)

  • Page 28: Csc400 Controller Menu System

    CSC400 Controller Menu System The CSC400 has an in-depth but intuitive and simple to use menu system. The entire menu system is accessed via the overlay buttons and the 4-line display. Individuals menus are explained in their respective sections following the CSC400 Menu System Chart.
  • Page 29 Both Ignitors must be enabled for this option to have an effect on the Alarm/Status contacts 2.1.14 Dual TC1&2 SD No Option Dual TC1&2 10°C Difference Shutdown Y/N Yes: Shutdown if TC1 & 2 are different by greater than 10°C (18°F) No: No link between TC1 &...
  • Page 30 Baud Rate Option Serial Baud rate for Modbus RTU Format Option Serial Format for the CSC400 (eg. "8N1": 8 bits, No parity bits, 1 stop bit) TLog Rate Option Period for logging temperatures into Temp Logs for reading via modbus 2.11...
  • Page 31 FS Ramp Time 10s Option Full-scale (4 to 20mA or 20 to 4mA) Ramp Time PVLV Ctrl IGN1 Option Proportional Valve Ignitor Control for 4-20 Output 1 PVLV Min Disabled Option Proportional Valve Minimum Mode Enable/Disable Min mA Set NA Option Minimum mA Value for Proportional Valve Minimum Mode...

  • Page 32: Top Menu Options

    Top Menu Options The CSC400 Top Menu allows users to select a variety of submenus with additional options and configurations available. It provides the most often used options at the top of the menu list. Top Menu Selections Type Description...

  • Page 33: Line Display Configuration Menu Options

    Line Display Configuration Menu Options The CSC400 allows the user to select what they wish to view on the top temperature / shutdown status screen. Lines 1 to 3 may be configured to show a variety of status and temperatures. Some selections show information on more than two lines.

  • Page 34: Show Last Ign Sd Menu Options

    Shutdown log. As an alternative to scrolling through the menu, the shutdowns may be read out via Modbus by a PC or a PLC. The CSC400 can currently store over 65000 shutdown events in the shutdown log. Note that the SD Log only stores shutdowns that are enabled for storing in the SD Log. By default, all shutdowns are stored in the SD Log except the Start/Stop buttons, the Remote Start/Stop terminal, and Modbus Remote Stop/Start commands.

  • Page 35: Solenoid Drivers Menu Options

    Duty Cycle time for TMain 2 solenoid output 10% - 100% Time and Date Set Menu Options The CSC400 allows the user to modify the current time and date. A time and date stamp is added to the shutdown log for each shutdown event. Menu...

  • Page 36: 4-20Ma Output (1 / 2) Menu Options

    4-20mA Output (1 / 2) Menu Options The 4-20mA Outputs on the CSC400 allow the user to configure a variety of options to support a wide variety of applications and equipment. Either a linear temperature mode, or a proportional valve mode can be used.
  • Page 37 4-20 Out 2 Temp TC2 Option 4-20mA Output 2 Mode Select "Temp" = Normal temperature output: TC1, TC2, or TC3 "PVLV" = Proportional Valve output: TC1, TC2, or TC3 "Level In" = 4-20mA Input 1 (Repeater/Splitter mode) "Press In" = 4-20mA Input 2 (Repeater/Splitter mode) Low ( 4) -60°C...

  • Page 38: 4-20Ma Input Level / Pressure (1 / 2) Menu Options

    4-20mA Input Level / Pressure (1 / 2) Menu Options The 4-20mA Inputs on the CSC400 allow the user to configure a variety of options to support a wide variety of applications and equipment. Normal 4-20mA or 1-5V ranges can be selected, or custom ranges and units can be entered by the user for displaying on the four-line display.

  • Page 39: Modbus Communications

    Cabling Connect a cable from a PLC (Programmable Logic Controller) or a PC to the 3-pin terminal strip of the CSC400 labeled "Modbus", observing proper connections: The RS-485 standard suggests using twisted pair type cables (CAT5E or a shielded twisted pair with ground) for connecting devices together.
  • Page 40 The CSC400 Controller has a 4-pin DIP switch with the third switch from the top labeled “120ohm term”. This can be used to connect a built-in 120 ohm resistor. Simply push the third DIP switch to the right and the 120ohm termination resistor will be connected.

  • Page 41: Commonly Used Csc400 Modbus Registers

    Commonly Used CSC400 Modbus Registers Notes: SCADAPack Register Addresses are listed for reference when programming SCADAPack PLC units. See the CSC400 Modbus Installation Manual for additional registers and specific details about reading and writing registers. Function Code 0x01 - Read Coils Function used to read the state of each relay.
  • Page 42 Thermocouple 2 open/fault 1 = TC fault, 0 = no fault 10019 Modbus Remote Stop 1 = Modbus Remote Stop is condition active (CSC400 is stopped via Modbus) 10020 Level Shutdown input 1 = Level Shutdown input is High (12VDC present,...
  • Page 43 0 = button is pressed 10037 Start Button input 1 = Start button is high, not pressed, 0 = button is pressed 10038 CSC400 System State 1 = System On, 0 = System 10039 Reserved Reserved 10040 7 (MSB) 4-20mA Pressure Input (2)
  • Page 44 Remote Stop and Remote Start are allowed though. Remote Stop will turn off all relays in the CSC400. CSC400 can only be started again by a Remote Start command, or by turning ON/OFF switch to OFF, then back to ON.
  • Page 45 Remote Stop can also be cleared by receiving a Modbus message turning Remote Start ON Remote Start enables the CSC400 to be turned on Remote Start can be interrupted if Remote Start/Stop is open, if a Shutdown is open, or if POC is still open...

  • Page 46: Additional Csc400 Feature Details

    (Pilot, Main, TMain for IGN1 and IGN2). If the S/D Latch menu option for any shutdown is in "Unlatched S/D" mode, the CSC400 will attempt to restart ignition (on enabled ignitors) when any switch attached to the Shutdown inputs clears. If the S/D Latch menu option is in "Latched S/D"...

  • Page 47: Purge Cycle Feature

    Purge Cycle Feature The CSC400 incorporates a feature that allows the user to enable a Purge Cycle when the Start button is pushed or when the Remote Start/Stop terminal is toggled. The Purge Cycle On/Off and Purge Cycle duration time options are set through the Configuration Menu Options (see page 32).

  • Page 48: Csc400 Controller Shutdown Display Codes

    CSC400 Controller Shutdown Display Codes The following table provides a summary of all the possible Shutdown Display codes that the user may see on the CSC400 Controller's 4-line LED display. LED Display Indicator Name Description and/or Corrective Action if Necessary...
  • Page 49 MB RStop Modbus Remote Indicates that the CSC400 has received a Modbus Remote Stop Stop command and is waiting for either a Modbus Remote Start command, or a toggling of the On/Off or Remote On/Off switch before the system will start again.
  • Page 50 Open or Failed If a thermocouple indicating "OPEN" is enabled, all solenoid valve Open outputs will not open and the CSC400 system will not start until the thermocouple "OPEN" condition is fixed. Uncal Uncalibrated Indicates that the CSC400 Controller's thermocouples are uncalibrated.

  • Page 51: 4-20Ma Input Connection Notes For Rev 1D Csc400 Boards

    4-20mA Input Connection Notes for Rev 1D CSC400 Boards The CSC400 Rev 1D board changes how the 4-20mA inputs and outputs are powered. The CSC400 Rev 1D board provides a shared 12-24VDC power switch with a combined maximum output current of 1A for all 4-20mA Inputs and Outputs. The provided input voltage (eg: 12VDC or 24VDC) will be the same voltage on the power output terminals for the 4-20mA Inputs (terminals 10 and 12) and the same voltage supplied to the two sets of 4-20mA Output circuitry.

  • Page 52: 4-20Ma Output Connection Notes For Rev 1D Csc400 Boards

    4-20mA Output Connection Notes for Rev 1D CSC400 boards The CSC400 Rev 1D board changes how the 4-20mA inputs and outputs are powered. The CSC400 Rev 1D board provides a shared 12-24VDC power switch with a combined maximum output current of 1A for all 4-20mA Inputs and Outputs. The provided input voltage (eg: 12VDC or 24VDC) will be the same voltage on the power output terminals for the 4-20mA Inputs (terminals 10 and 12) and the same voltage supplied to the two sets of 4-20mA Output circuitry.

  • Page 53: Dip Switch Option Settings

    Normal operation of 4-20mA Output (Default) Output 20mA on 4-20mA Output 2 (Pressure) when CSC400 is "Off", in a Purge Cycle, and after a shutdown has occurred. Output normal mA (eg: "Temp TC1 IGN1") after purge cycle is done and burner is on.

  • Page 54: Appendix A - Csc400 Rev 1D Technical Specifications

    (adding a pullup resistor to “A” and a pulldown resistor to “B”). Line polarization may be enabled (via the two DIP switches on the top of the CSC400 Controller's Modbus DIP switches (4 half-pitch DIP switches)) for use with other devices on the same RS-485 bus.
  • Page 55 Inputs and Control Outputs: Main Power Input, Voltage Range 10VDC (minimum) to 29VDC (maximum) System Current Draw, no solenoid outputs on, 350mA Max, 143 mA typical (at 12VDC) OLED display on, system off System Current Draw, no solenoid outputs on, 300mA Max, 100mA typical (at 12VDC) OLED display off, system off System Current Draw, no solenoid outputs on,...

  • Page 56: Appendix B - Modbus/Rs-485 Cabling Technical Details

    Full-duplex communication adds another pair of wires to allow bi-directional communication between a PC/PLC master and a slave unit simultaneously. The CSC400 provides a three pin terminal for half-duplex communication between the CSC400 and a host master Modbus device.

  • Page 57: Wiring Topology

    Line Polarization should only be enabled on one device on the RS485 bus, if necessary. Usually this is done at the end of the bus where the master device resides. The CSC400 Controller allows the implementation of Line Polarization via two DIP...

  • Page 58: Termination

    The CSC400 Controller has a 4-pin DIP switch with the third switch from the top labeled “120ohm term”. This can be used to connect a built-in 120 ohm resistor. Simply push the third DIP switch to the right and the 120ohm termination resistor will be connected.

  • Page 59: Appendix C - Programming A New Modbus Slave Id (Address)

    Due to the potential for large amounts of noise to be conducted onto the RS485 cable, the Isolated GND terminal is connected to the CSC400 earth ground to shunt noise away locally instead of at the Modbus master. This is done using a wire jumper soldered onto the main CSC400 circuit board at jumper J23, to the left of the three Modbus terminals and Modbus DIP switch.

  • Page 60: Appendix D - Troubleshooting

    Multimeter should read close to zero ohms. If not, cable needs to be replaced. Poor ground connection Ensure that good, thick ground connections are made at the CSC400 and at the Pilot/burner valve. Pilot solenoid failure Check supplied power to solenoid. Check gas flow through solenoid.
  • Page 61 RS485 cable isn’t connected Ensure the wires for the RS485 cable are connected temperature values from properly properly at the CSC400 and at the master and that the CSC400 (or any other screw terminals are gripping the metal wire, not the data) insulation.
  • Page 62 Verify the CSC400 has power locally. been interrupted Modbus communication CSC400’s ignition module may The CSC400 will not respond to Modbus requests works for writing Remote be “sparking”. when the ignition module is powering its high-voltage Stop, Remote Start, but no sparker to ignite the Pilot.
  • Page 63 Notes:...
  • Page 64 805 Main Ave West - Box 2002 Sundre, Alberta T0M 1X0 Phone: (403) 638-5234 - Fax: (403) 638-4973 E-mail: aclmfg@telus.net...

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