ACL CSC400 Installation And Operation Manual Download

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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

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

Summary of Contents for CSC400

Page 1: ...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 ...

Page 2: ...Main 1 2 Menu Options 34 Solenoid Drivers Menu Options 35 Time and Date Set Menu Options 35 Modbus Settings Menu Options 35 4 20mA Output 1 2 Menu Options 36 4 20mA Input Level Pressure 1 2 Menu Options 38 AUX1 AUX2 Relay Settings Menu Options 38 Modbus Communications 39 Modbus RS 485 Cable Connections Field Installations 39 Commonly Used CSC400 Modbus Registers 41 Additional CSC400 Feature Detail...

Page 3: ...Line Polarization 57 Termination 58 Number of Allowed Devices on the RS 485 58 Slew Rate 58 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 Mo...

Page 4: ...he 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 The CSC400 can be configured to have both burners shut off if one goes into Flame Fail or have one remain running while indic...

Page 5: ... flame ionization ignition systems burners incinerators Five Shutdown inputs dry contact switches required High Low Gas ie pressure shutdown Level Shutdown and Auxiliary 1 2 Shutdowns Additional shutdowns may be added in series Any shutdown turns off both burners Two isolated fail safe solid state auxiliary configurable relay outputs NC COM NO NC COM in Alarm state NO COM when burner s is are on T...

Page 6: ...Main solenoid valve outputs will be turned on 10 seconds minimum after it is confirmed that the pilot has been lit adjustable up to 120s The Intermittent Continuous Pilot Menu setting selects the behavior of the controller once all solenoids are opened In Pilotless Intermittent pilot mode I once the measured temperature on thermocouple 1 reaches the TC1 setpoint temperature but TC2 temp is still b...

Page 7: ...tion Procedure CSC400 Combustion Safety Controller Figure 1 CSC400 Controller Main Board Top View The Quickstart Installation Instructions assumes the user has some familiarity with Combustion Safety Controller Installation ...

Page 8: ...y on the front panel connects to The CSC400 will shut off all ignitor outputs and solenoid valves if the overlay is unplugged 12 Modbus DIP Switch Modbus RS485 DIP switches for selecting termination options for the Modbus RS485 communications cable 13 Modbus Terminals Modbus RS485 Terminals for connecting a Modbus RS485 communications cable CSC400 is a Modbus RTU slave in a 8N1 9600 baud default c...

Page 9: ...n 12 24VDC input terminal connections 30 Ground Terminals Power Extra earth ground terminal connections to assist in providing stable ground connections for solenoids ignition modules or other hardware 31 Ignition Module Mounting Location Hardware The Ignition Module Mounting Location indicates the area where the ACL Ignition Module may be installed 33 To Igniter 2 Ignition Module Terminals Contro...

Page 10: ...10 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: ... If the system is already running the Proof of Closure input is allowed to open during operation Figure 3 Shutdown and Ignition Module s Power Flow Diagram Main Power Input The ACL CSC400 Combustion Safety Controller operates on an input voltage range between 10 and 30 Volts DC Typical input voltages are 12VDC and 24VDC Whatever input voltage is delivered to the CSC400 on the Main Power Input term...

Page 12: ... process temperature measurements 4 20 Output control or as an auxiliary high temp shutdown 9 T C 3 Red The temperature range for each thermocouple is 60 C to 1200 C 76 F to 2192 F 4 20mA Level Pressure Temperature Inputs The 4 20mA input terminals provide a powered 4mA to 20mA or 1V to 5V converter that reads a current or voltage input from an external transmitter The 4 20mA Inputs can be configu...

Page 13: ...s the risk of igniting a burner if the POC valve is partially open and the proof of closure switch indicates open This is also a failsafe input as it will not allow ignition to initiate if a wire is broken or disconnected These terminals must be wired to dry contacts of a remote Proof of Closure switch when used A wire jumper must remain across the Proof of Closure terminals when not in use The CS...

Page 14: ...ust remain across the Low Gas Shutdown terminals when not in use The CSC400 LED display will show High Gas when the High Gas Shutdown input is open The CSC400 LED display will show Low Gas when the Low Gas Shutdown input is open Terminal Number Description Allowable Input Range 22 High Gas Shutdown None use dry contacts 23 High Gas Shutdown None use dry contacts 24 Low Gas Shutdown None use dry co...

Page 15: ... when the CSC400 is in a shutdown state Eg a Shutdown switch or the Remote Start Stop switch is open This provides a complete fail safe indicator to a remote control center of the status of the CSC400 controller Terminal Number Description Max Contact Rating 32 Alarm Status NC Load current 120mArms mADC Voltage 30VDC 30VP AC 33 Alarm Status COM Load current 120mArms mADC Voltage 30VDC 30VP AC 34 A...

Page 16: ...itched states AUX1 Relay 41 NO Normally Open All NO is connected shorted to COM if TC1 IGN1measurement is higher than the TC1 IGN1 setpoint temperature AUX2 Relay 42 NC Normally Closed All NC is connected shorted to COM if TC3 measurement is lower than the TC3 setpoint temperature AUX2 Relay 43 COM Common All Common connection in both AUX2 Relay switched states AUX2 Relay 44 NO Normally Open All N...

Page 17: ...ct that the two ignitors are independently controlled a disabled ignitor does not need to have a jumper installed between the P and V terminals to ensure that the enabled ignitor still works All of the below signals need to be attached between the CSC400 and Ignition Module 1 for the burner system to work properly when Ignitor 1 is enabled The Pilot GND signal is used to connect the ground wire at...

Page 18: ... solenoid outputs Note All solenoid outputs can be configured to use separate Low Power Solenoid settings Therefore the setting for each solenoid output must be verified to work with the attached solenoid Larger solenoids with higher power requirements will need to be set to a higher setting 40 or 50 to remain open when desired Smaller solenoids Pilot valves should be able to work on a setting dow...

Page 19: ...in Solenoid Process Temperature Control Valve The Temperature Main T Main or TMain Solenoid terminals provide power to the T Main solenoid valve for process temperature control Power to these terminals is present a minimum of 10 seconds adjustable to 120s max after the pilot s flame is detected and the shutdowns are satisfied The T Main solenoid valve is also controlled by the measured temperature...

Page 20: ...yed are configurable in the menu settings but the default settings show a typical profile TC1 and TC2 displayed with setpoints and IGN1 enabled with IGN1 s solenoid output status The display will show Disab when thermocouples are not enabled through the menu system The display will show OPEN if the thermocouples are not connected or if they have failed in an open condition Figure 4 CSC400 Controll...

Page 21: ...m to stop power to ignitor outputs and shutdowns will be shutoff Valve solenoid power outputs will be turned off Pressing the Stop button will also clear any shutdown and shutdown latch indicators present on the LED display Other methods of shutting off the system include Remote Start Stop in the Stop position open contacts Note 12VDC power will remain on the shutdown terminals if only the Remote ...

Page 22: ...and you wish to change and then press the Select button The cursor will blink alternating with to indicate the current thermocouple s setpoint is now in Edit mode Use the Up and Down buttons to modify the temperature setpoint of the selected thermocouple to the new desired value and then press the Select button again to exit Edit mode Press the Menu button twice to return to the Main Screen TC1 25...

Page 23: ...23 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: ...24 Figure 9 CSC400 Wiring Diagram FI Flame Ionization Local IGN Module ...

Page 25: ...oid Output Level Shutdown jumper if not used Main Solenoid Output if a minimum of two valves are required Auxiliary 1 2 Shutdowns jumper if not used Alarm Status dry contacts Proof of Closure jumper if not used Main Solenoid Output keep open unconnected if not used T Main Solenoid Output keep open unconnected if not used Note Ignition Module connections are matched with their corresponding Pilot M...

Page 26: ...26 Figure 10 CSC400 Wiring Diagram Dual IGN Modules 1 Local 1 Remote Mounting ...

Page 27: ...27 Figure 11 CSC400 Wiring Diagram 4 20mA Controlled Temperature Control Valve Throttling Valve ...

Page 28: ...et Menu Set the time in the CSC400 2 9 Date Set Menu Set the date in the CSC400 2 10 Modbus Settings Menu Change Modbus Comm Settings 2 11 Diagnostics Information Shows firmware version diagnostics info 2 12 Reset SDLog Menu Reset clear Shutdown Log 2 13 Reset TLog Menu Reset clear Temperature Logs 2 14 Reset Settings Menu Reset Settings to default 2 15 Recalibrate TC Menu Recalibrate Thermocouple...

Page 29: ...ption Auxiliary 2 Shutdown Latched Unlatched 2 2 Line Display Config Menu Line Display Configuration Select items to display on the three top lines on the display Line 1 TC1 temp w setpoint Option Select information to display for Line 1 Line 2 TC2 temp w setpoint Option Select information to display for Line 2 Line 3 FI mode VLVs 1 Option Select information to display for Line 3 2 3 Temp Setpoint...

Page 30: ... ID Option Modbus Slave ID of the CSC400 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 Diagnostics Information Shows firmware version and diagnostics information 2 12 Reset SD Log Menu Reset SDLog to Default Reset clear al...

Page 31: ...dary 4 20 Input setpoint control for selected TMain None IGN1 IGN2 or IGN1 2 Lo Alarm Enabled Option Alarm if 4 20mA Input is Below Trip point Enable Disable Hi Alarm Enabled Option Alarm if 4 20mA Input is Above Trip point Enable Disable SD on Lo Alarm Yes Option Shutdown upon Low Alarm Yes No SD on Hi Alarm No Option Shutdown upon High Alarm Yes No SD Latched Option Shutdown Latched Unlatched Se...

Page 32: ...d values 4 20mA output and input modes and shutdown latch settings Configuration Menu Selections Type Description Possible Options Values 2 1 1 IGN1 Enabled Option Ignitor 1 Enabled Disabled Enabled Disabled 2 1 2 IGN2 Disabled Option Ignitor 2 Enabled Disabled Enabled Disabled 2 1 3 C F C Option Select C F C F 2 1 4 TC2 Enabled Option TC2 Enable Disable Enabled Disabled 2 1 5 TC3 Enabled Option T...

Page 33: ...tched Unlatched 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 Line 4 always shows shutdown status and Ignitor status On Off Flame Fail FF Line Possible Selections Type ...

Page 34: ...s are stored in the SD Log except the Start Stop buttons the Remote Start Stop terminal and Modbus Remote Stop Start commands see the CSC400 Modbus manual for additional details Shutdown Log Codes SD Log Code Shutdown Description 1 HTmp High Temperature TC2 2 HGas High Gas SD terminal 3 RStp Remote Stop terminal 4 Modb Modbus Remote Stop Start command received 5 PWRF Power Fail 6 Stop Stop Button ...

Page 35: ...time for Pilot 2 solenoid output 10 100 5 Main 2 Option Duty Cycle time for Main 2 solenoid output 10 100 6 TMain 2 Option 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 Menu Selections Type Description 1 Time Set Hours Op...

Page 36: ...m fully closed 4mA to fully open 20mA and vice versa 5s 120s 5 PVLV Ctrl IGN1 Option Proportional Valve Ignitor Control for 4 20 Output 1 Selects which ignitor to control in Proportional Valve mode 1 2 or 1 2 6 PVLV Min Disabled Option Proportional Valve Minimum Mode Enable Disable Minimum Fire position for Proportional Valve Mode If enabled while set to PVLV TC1 TC2 or TC3 modes this 4 20 output ...

Page 37: ...Valve Mode If enabled while set to PVLV TC1 TC2 or TC3 modes this 4 20 output will never output less than the Minimum mA Value set in the Min mA Set line below Possible Values Enabled Disabled 14 Min mA Set NA Option Minimum mA Value for Proportional Valve Minimum Mode If PVLV Minimum Mode is enabled and this output is set to PVLV TC1 TC2 or TC3 modes this 4 20 output will never output less than t...

Page 38: ... and or SD Below this value 4 00 20 00 0 32000 60 1200 depending on selected units 12 Hi TrpPt 18 00mA Option High Trip point value Alarm and or SD Above this value 4 00 20 00 0 32000 60 1200 depending on selected units 13 Setpoint 4 00mA Option Setpoint for Secondary TMain control TC1 2 still have priority 4 00 20 00 0 32000 60 1200 depending on selected units 14 Deadband 0 00mA Option Deadband v...

Page 39: ...rving proper connections The RS 485 standard suggests using twisted pair type cables CAT5E or a shielded twisted pair with ground for connecting devices together This is definitely a requirement for longer cable runs 25m to 1000m and for use in noisy environments like industrial or commercial installations The RS485 signal naming convention used in this document and by many RS485 transceiver vendo...

Page 40: ...evice and is required for the RS 485 bus in this installation two Line Polarization DIP switches on the CSC400 Controller are available To enable the Line Polarization terminations move them to the right towards the Line Pol text as shown in the picture below If the DIP switches are moved towards the left the Line Polarization terminations are removed from the RS 485 bus on this CSC400 device Line...

Page 41: ...lay OFF Alarm condition 1 relay ON no Alarm 6 6 5 Not used N A Reserved 7 7 6 Proof of closure IGN1 output relay Control relay 1 relay ON 8 8 7 IGN1 Temperature Main solenoid relay Solenoid relay 1 relay ON 9 9 8 IGN2 Pilot solenoid relay Solenoid relay 1 relay ON 10 10 9 IGN2 Main solenoid relay Solenoid relay 1 relay ON 11 11 10 IGN2 Temperature Main solenoid relay Solenoid relay 1 relay ON 12 1...

Page 42: ...tly 10015 15 14 1 6 HT HT latch condition 1 Latch is on presently 10016 16 15 1 7 MSB High Gas SD SD latch condition 1 High Gas SD Latch is on presently 10017 17 16 2 0 LSB Thermocouple 1 open fault 1 TC fault 0 no fault 10018 18 17 2 1 Thermocouple 2 open fault 1 TC fault 0 no fault 10019 19 18 2 2 Modbus Remote Stop condition 1 Modbus Remote Stop is active CSC400 is stopped via Modbus 10020 20 1...

Page 43: ... not pressed 0 button is pressed 10037 37 36 4 4 Start Button input 1 Start button is high not pressed 0 button is pressed 10038 38 37 4 5 CSC400 System State 1 System On 0 System Off 10039 39 38 4 6 Reserved Reserved 10040 40 39 4 7 MSB 4 20mA Pressure Input 2 Shutdown SD Latch 1 4 20mA Pressure Input SD has tripped and is active 10041 41 40 5 0 LSB Igniter 2 Alarm input 1 Alarm signal high Alarm...

Page 44: ...gister Modbus Inputs Register Address Description Notes 30001 1 0 TC1 current temp deg C 30002 2 1 TC2 current temp deg C 30003 3 2 TC1 current temp deg F 30004 4 3 TC2 current temp deg F 30005 5 4 TC3 current temp deg C 30006 6 5 TC3 current temp deg F Function Code 0x05 Write Single Coil or setting The individual coils can t actually be written to they re influenced by the temperature Remote Sto...

Page 45: ... coils or settings 0x0000 or OFF has no effect on the Setpoints or Remote Stop Start settings Remote Stop disables all power going to ignition modules and closes turns of power to all six valve solenoids Remote Stop can be cleared by a physical toggling of the Remote Start Stop power rung or by pressing the Stop button then the Start button Remote Stop can also be cleared by receiving a Modbus mes...

Page 46: ...o which shutdown caused the latch out Intermittent Pilotless or Continuous Pilot Feature The CSC400 incorporates a feature that allows the user to select between Pilotless Intermittent Pilot I or Continuous pilot C modes for burner control using the menu system This option is set through the Configuration Menu Options see page 32 Intermittent Pilotless Pilot I The ACL CSC400 controller provides th...

Page 47: ...s composed of very wet gas high water content Once the selected process temperature TC1 2 3 rises above the Low Temp SD ALM setpoint a flag is triggered so that an Alarm or shutdown trips if this temperature then falls below this setting Note that for this Low Temp Alarm or shutdown feature to trip the measured temperature needs to fall below the Low Temp setpoint minus the deadband used for the s...

Page 48: ...rom going to the ignition module and allowing the system to start RemStop Remote Stop Indicates that the Remote Start Stop input terminals are in the Off or Stop open position Jumper with a wire jumper when not used High Gas High Gas Shutdown Indicates that the High Gas Shutdown switch inputs or terminals are open in shutdown Jumper with a wire jumper when not used Low Gas Low Gas Shutdown Indicat...

Page 49: ...down Indicates that the 4 20mA Input 1 Low Alarm has been triggered but Ignitors and output solenoids are not shutdown If Lo Alarm is Enabled in the 4 20mA Input 1 settings and SD on Lo Alarm is set to OFF the measured 4 20mA input has fallen below the selected Low Trip point value 420 1 Hi 4 20mA Input 1 Hi Alarm no shutdown Indicates that the 4 20mA Input 1 High Alarm has been triggered but Igni...

Page 50: ... Solenoid Output Fail IGN2 IGN2 s Pilot solenoid output has failed but it s supposed to be open ie no output voltage is present on the Pilot terminal P2 Fault Solenoid Fault Pilot IGN2 There has been a fault on IGN2 s Pilot Solenoid output due to a short circuit or excessive current draw on the Pilot terminal to ground M2 Fault Solenoid Fault Main IGN2 There has been a fault on IGN2 s Main Solenoi...

Page 51: ... series resistor added to each 12 24V Output terminals 10 and 12 A DIP switch is On when it is moved to the right side towards the Local Mount of the Ignition Module area The inline resistance options are present to assist with 4 20mA Input impedance adjustments and for possible HART communication devices DIP Switches labeled 1 correspond to Level Input 1 DIP Switches labeled 2 correspond to Press...

Page 52: ... 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 The 4 20mA Output terminals 14 and 16 should be connected directly to the external I P valve 4 20mA PLC input or other 4 20mA controlled device Figure 14 CSC400 4 20mA Output Connections Wiring Diagram Examples Notes An output of 3 5m...

Page 53: ...ing that the OLED type display is attached to the CSC400 This DIP switch should only be changed by factory personnel or by trained technicians OLED VFD Select switch indicating that the VFD vacuum fluorescent display type display is attached to the CSC400 This DIP switch should only be changed by factory personnel or by training technicians 3 DIP SW 3 Default Normal operation of 4 20mA Output Outp...

Page 54: ... Human Body Model and up to 8kV Contact Discharge IEC61000 4 2 Specification Default Value Possible Values or Range Modbus Protocol Modbus RTU Modbus RTU Modbus Slave ID address 2 1 247 Modbus RS 485 Serial Settings Baud rate 9600 300 1200 2400 4800 9600 19200 38400 Number of data bits 8 8 Parity bit setting None None Even Odd Stop bits 1 1 2 only with parity set to None Operating Temperature 40 C...

Page 55: ...noid terminals 12VDC main input Main Power Input minus a small voltage drop that is dependent on current draw and temperature Solenoid outputs are 11 85V to 11 98V approx Voltage Output on Solenoid terminals 24VDC main input Main Power Input minus a small voltage drop that is dependent on current draw and temperature Solenoid outputs are 23 85V to 23 98V approx Voltage Output on Solenoid terminals...

Page 56: ...er the two RS 485 wires one differential pair at a time 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 Cable Types Master Used Cable Type To Use For Testing Notes PC USB to RS485...

Page 57: ...ld be used one long cable with short stub connections to each device Ensure that short stub connections are made at each device to the main RS485 cable to reduce signal reflections and interference A star or ring wiring topology should not be used An example of a star configuration would be separate multiple cables branching out from the Master to each individual slave device Only one cable should...

Page 58: ...dance is 96kohm which is 1 8th the input impedance of older transceivers at 12kohm 1 8th of a Unit Load The Modbus specification limits this theoretical maximum further to 247 devices allowed on an RS 485 bus Any Modbus system allows a minimum of 32 devices on the RS 485 bus without use of a repeater More devices may be allowed depending on the characteristics of all devices on the RS 485 bus The ...

Page 59: ... Press the Menu key to show the Top Menu Press and hold the Down Arrow key to scroll down the Top Menu s options until the cursor reaches Modbus Settings see Figure 15 Press the select button The cursor should be on the Slave ID line of the Modbus Settings Menu If not use the Up and Down arrow keys to move the cursor to this line Press the Select button The cursor will blink alternating with to in...

Page 60: ...made at the CSC400 and at the Pilot burner valve Pilot solenoid failure Check supplied power to solenoid Check gas flow through solenoid Plugged orifice on Pilot Clean out Pilot orifice Do Not redrill 3 Weak or Erratic Spark Gap setting too wide or rod not cut to a point Shorten gap setting to approximately 1 8 3 175mm and recut the ignitor rod tip Ignition cable defective or insulation worn Check...

Page 61: ...air cable like CAT5e cable or other appropriate cable is used for the RS485 bus 2 Modbus communication interrupted noise issues suspected Inadequate or ineffective grounding Ensure that an adequate connection has been made between the earth ground terminal on the CSC400 and an appropriate earth ground external to the CSC400 eg thick spike in the ground underground water pipes earth ground pin on a...

Page 62: ...will not respond to Modbus requests when the ignition module is powering its high voltage sparker to ignite the Pilot If a USB to RS485 conversion cable has been used the PC test software may have lost connection to the virtual COM port or noise may have interfered with USB communications Unplug the USB to RS485 conversion cable from the USB port on the PC wait 10 seconds then plug it back in Retr...

Page 63: ...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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