Residential Oil Burner Guide EZ/EZ-Pro EZ-1 (0.50 to 1.65 GPH) EZ-2 (1.50 to 2.25 GPH) EZ-3 (2.00 to 2.60 GPH) 99FRD/100CRD/ 102CRD 99FRD (0.50 to 3.00 GPH) 100CRD (0.50 to 2.25 GPH) 102CRD (2.00 to 4.
-1- Contents EZ / EZ-Pro EZ-Pro Data Sheet EZ-1/2/3 Burner Manual 99FRD / 102CRD 100CRD / 99/100/102 Data Sheet 99/100/102 Burner Manual Burner Components 48245, 40200, 50200, 60200 Control 41000 Electronic ignitor 98022 PSC Motor 98289 SVC Oil valve & kit 98435 Kool Kit cooling interface 90000 EZ-Temp control 90200 EZ-Temp control 90524 EZ-Temp control
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-4- Carlin EZ-Pro Advanced Oil Burner Features Specifications The EZ-Pro advanced oil burner combines the proven range and reliability of the EZ burner with Carlin’s line of electronic controls and high efficiency components. Purchase the EZ-Pro in any of three configurations — EZ-1, EZ-2 or EZ-3. Specify tube length when ordering. Firing rate ranges Input ................................................0.5 to 2.6 GPH ..........................70,000 to 364,000 Btuh Fuels U. S. .........................
-5- ™ Instruction manual Contents Ratings Input: EZ-1, EZ-1-HP......................................0.50 to 1.65 GPH EZ-2, EZ-2-HP..................................... 1.50 to 2.25 GPH EZ-3, EZ-3-HP..................................... 2.00 to 2.60 GPH Fuels: ......................No. 1 or No. 2 heating oil (ASTM D396) Fuel unit: ............................................................................. Suntec PLEASE read this first..........................................................
-6- Model EZ-1/2/3 oil burners — Instruction manual PLEASE read this first . . . Special attention flags Please pay particular attention to the following when you see them throughout this manual. Notifies you of hazards that WILL cause severe personal injury, death or substantial property damage. Notifies you of hazards that CAN cause severe personal injury, death or substantial property damage. Notifies you of hazards that WILL or CAN cause minor personal injury or property damage.
-7- Model EZ-1/2/3 oil burners — Instruction manual 1. EZ-1/2/3 application information Codes and standards OEM burners Certification General information — OEM burners EZ-1/2/3 burners are U.L. listed for the U.S. and Canada, certified to comply with ANSI/UL 296, for use with #1 or #2 heating oil (per standard ASTM D396). Burner labels list compliance, when required, with special local, state or provincial approvals.
-8- Model EZ-1/2/3 oil burners — Instruction manual 1. EZ-1/2/3 application information Table 1 –4– (continued) Apply the guidelines below to select a nozzle when appliance-specific nozzle data is not avialable from the manufacturer (see notes at end of table for application tips). DO NOT apply for EZ-1-HP, EZ-2-HP or EZ-3-HP models — see information supplied with appliance/burner. Carlin part number MNEZ123 Rev.
-9- Model EZ-1/2/3 oil burners — Instruction manual 2. Prepare site • assemble burner Inspect/repair/replace vent system Do not install this burner unless you have verified the entire vent system and the appliance are in good condition and comply with all applicable codes. And ... • The vent and chimney must be sized and constructed in accordance with all applicable codes. • Do not install or use an existing manual damper in the breeching (vent connector) or chimney.
- 10 - Model EZ-1/2/3 oil burners — Instruction manual 2. Prepare site • assemble burner Combustion/ventilation air checklist The burner may operate successfully under momentary downdraft conditions, but sustained downdraft is unsafe. This can occur with an inadequate or incorrectly installed chimney/vent. It can also occur in rooms/buildings equipped with exhaust fans or unsealed return air ducts. Always check operation of the burner under all conditions to verify vent system operates correctly.
- 11 - Model EZ-1/2/3 oil burners — Instruction manual 2. Prepare site • assemble burner Verify clearances Verify that the burner/appliance will maintain all clearances from combustible construction and clearances for service/maintenance as required in the appliance manual and applicable codes. Verify that the vent system components maintain all necessary clearances to combustible construction, including the correct design of thimbles and insulation where penetrating combustible walls.
- 12 - Model EZ-1/2/3 oil burners — Instruction manual 2. Prepare site • assemble burner • mount burner (continued) Inspect burner and components • Check the air tube length. Verify the usable length of the tube UTL will be long enough (see “Mount burner in appliance”). • Visually inspect all burner components and wiring. • Verify that wiring is intact and leads are securely connected. • Verify that all burner components are in good condition.
- 13 - Model EZ-1/2/3 oil burners — Instruction manual 2. Prepare site • assemble burner Attach air tube to housing 1. The burner chassis is supplied with three screws mounted into the housing. 2. Loosen these screws about three turns. 3. Slide the air tube onto the housing, aligning the J-notches in the tube with the housing screws (Figure 4). 4. Turn the tube to engage the J-notches. 5. Tighten the screws.
- 14 - Model EZ-1/2/3 oil burners — Instruction manual 3. Prepare burner Removing/installing head assembly Figure 6 Inserting/removing combustion head assembly Figure 7 Inserting combustion head assembly Figure 8 Electrode placement, retention ring assembly and nozzle adapter Use care when handling burner components after the burner has been firing. Components can be hot and could cause severe personal injury.
- 15 - Model EZ-1/2/3 oil burners — Instruction manual 3. Prepare burner (continued) Inspect the nozzle adapter before replacing the nozzle. If the threads have been damaged or shows score marks, replace the nozzle line/adapter assembly. 4. Replace the retention ring assembly by slipping one of the riveted arms through the gap between the electrode tips. Align this arm straight up, with the ring clamp firmly against the nozzle adapter shoulder. Then tighten the clamping screw. 5.
- 16 - Model EZ-1/2/3 oil burners — Instruction manual 3. Prepare burner (continued) Inspect/install fuel supply Inspect the oil supply system. Ensure that the fuel lines are correctly sized and installed and that the fuel flow is unobstructed, the oil tank is clean and only # 1 or # 2 heating oil are supplied. Failure to supply a reliable oil flow could result in loss of heat and potential severe equipment damage.
- 17 - Model EZ-1/2/3 oil burners — Instruction manual 3. Prepare burner (continued) Two-line fuel system requirements Figure 13 Two-line fuel system See Figure 13 and Table 4. Use Table 4 only for burners equipped with Suntec fuel units. For burners using other fuel units, read the fuel unit manufacturer’s data sheet to determine maximum lengths and lifts. The standard burner fuel unit is a single-stage, 3450-RPM oil pump.
- 18 - Model EZ-1/2/3 oil burners — Instruction manual 4. Wire burner • start burner — 48245 primary control Wire burner — 48245 primary control 1. All wiring must comply with: • In the U.S — the National Electrical Code, ANSI Z223.1/NFPA 54. • In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1. • All applicable local codes/standards. 2. Wire the burner following Figure 14 and any special instructions or wiring diagram provided with the appliance, burner or other components. 3.
- 19 - Model EZ-1/2/3 oil burners — Instruction manual Carlin part number MNEZ123 Rev.
- 20 - Model EZ-1/2/3 oil burners — Instruction manual 4. Wire burner • start burner — 40200 or 42230 primary control Wire burner — 40200 primary control 42230 primary control 1. All wiring must comply with: • In the U.S — the National Electrical Code, ANSI Z223.1/NFPA 54. • In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1. • All applicable local codes/standards. 2.
- 21 - Model EZ-1/2/3 oil burners — Instruction manual Carlin part number MNEZ123 Rev.
- 22 - Model EZ-1/2/3 oil burners — Instruction manual 4. Wire burner • start burner — 50200 primary control Wire burner — 50200 primary control 1. All wiring must comply with: • In the U.S — the National Electrical Code, ANSI Z223.1/NFPA 54. • In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1. • All applicable local codes/standards. 2. Wire the burner following Figure 16 and any special instructions or wiring diagram provided with the appliance, burner or other components. 3.
- 23 - Model EZ-1/2/3 oil burners — Instruction manual Carlin part number MNEZ123 Rev.
- 24 - Model EZ-1/2/3 oil burners — Instruction manual 4. Wire burner • start burner — 60200 primary control Wire burner — 60200 primary control 1. All wiring must comply with: • In the U.S — the National Electrical Code, ANSI Z223.1/NFPA 54. • In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1. • All applicable local codes/standards. 2. Wire the burner following Figure 17 and any special instructions or wiring diagram provided with the appliance, burner or other components. 3.
- 25 - Model EZ-1/2/3 oil burners — Instruction manual Carlin part number MNEZ123 Rev.
- 26 - Model EZ-1/2/3 oil burners — Instruction manual 5. Adjustment and verification Perform combustion test Verify burner/appliance operation Adjust burner using test instruments Check burner/appliance/controls operation 1. Operate burner for 15 minutes before making final adjustments using test equipment. 2. Check for leaks in fuel piping. • Test operating and limit controls on appliance as specified in appliance instructions. • Check operation of the primary control by forcing lockout to occur.
- 27 - Model EZ-1/2/3 oil burners — Instruction manual 6. Annual start-up and service Annual start-up & service Perform the following • • • • • • • • • This burner must be started and serviced at least annually by a qualified service technician. Failure to properly maintain and service the burner could result in severe personal injury, death or substantial property damage.
- 28 - Model EZ-1/2/3 oil burners — Instruction manual 7. Repair parts Item Description 1 Part No. Item Description Air tube, 4" nominal, approx. 4-3/8"oal (EZ -1), universal flange 77719 Air tube, 5" nominal, approx. 5-3/8" oal (EZ -1), universal flange 77727 Air tube, 7" nominal, approx. 7-3/8" oal (EZ -1), universal flange 98055 Air band (EZ -2), with 100 PSIG scale 98087 77735 Air band (EZ -3), with 100 PSIG scale 98089 Air tube, 9" nominal, approx.
- 29 - Model EZ-1/2/3 oil burners — Instruction manual 7. Repair parts (continued) Carlin part number MNEZ123 Rev.
- 30 - Model EZ-1/2/3 oil burners — Instruction manual 8. Maintenance procedures Maintenance/service procedures Motor maintenance • The Carlin PSC motor is constructed with permanently-lubricated bearings, and requires no oiling. Should you replace the original motor with another type of motor, occasional oiling may be required, depending on motor design and manufacturer’s recommendations.
- 31 - Model EZ-1/2/3 oil burners — Instruction manual Limited Warranty Carlin Combustion Technology, Inc.
- 32 - Model EZ-1/2/3 oil burners — Instruction manual EZ-1/2/3 oil burner User care and maintenance Refer only to the information on this page, intended for your use. The remainder of this manual is intended only for your service technician. Failure to comply could result in severe personal injury, death or substantial property damage. For other than routine maintenance, contact a qualified service company. Perform the following as needed.
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- 34 - Carlin 99FRD, 100CRD & 102CRD Advanced Oil Burners Features Specifications The 99FRD, 100CRD and 102CRD advanced oil burners feature Carlin’s adjustable head assembly — for unmatched fuel/air mixing, smooth light-offs and quiet running. Proven for years in the field and in extensive boiler and furnace testing, these burners cover the range from residential to semi-commercial, to meet your needs for oil-burning applications.
- 35 - ™ Instruction manual Contents Ratings PLEASE read this first........................................................2 Input: Fuels: 2. Prepare site • assemble burner • mount burner.4 U.S.............................................. No. 1 or No. 2 Fuel oil 3. Prepare burner.............................................................9 Canada................No. 1 Stove oil or No. 2 Heating oil Fuel unit: Electrical: Codes and standards........................................................
- 36 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual PLEASE read this first . . . Special attention flags Please pay particular attention to the following when you see them throughout this manual. Notifies you of hazards that WILL cause severe personal injury, death or substantial property damage. Notifies you of hazards that CAN cause severe personal injury, death or substantial property damage. Notifies you of hazards that WILL or CAN cause minor personal injury or property damage.
- 37 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual 1. 99, 100, & 102 Oil nozzle selections (when appliance data is not available) Table 1 Apply the guidelines below to select a nozzle when appliance-specific nozzle data is not avialable from the manufacturer. See notes at end of table for application tips. 99FRD wrapped-shield air tubes are intended only for approved applications in wet-base combustion chambers. Carlin part number MN99102 Rev.
- 38 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 2. Prepare site • assemble burner Inspect/repair/replace vent system Do not install this burner unless you have verified the entire vent system and the appliance are in good condition and comply with all applicable codes. And ... • The vent and chimney must be sized and constructed in accordance with all applicable codes. • Do not install or use an existing manual damper in the breeching (vent connector) or chimney.
- 39 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual 2. Prepare site • assemble burner Combustion/ventilation air checklist The burner may operate successfully under momentary downdraft conditions, but sustained downdraft is unsafe. This can occur with an inadequate or incorrectly installed chimney/vent. It can also occur in rooms/buildings equipped with exhaust fans or unsealed return air ducts.
- 40 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 2. Prepare site Figure 1 • assemble burner • mount burner (continued) 99FRD, 100CRD and 102CRD Minimum combustion chamber dimensions (all dimensions in inches) Chamber configurations A B C D E F Chamber with water-backed floor and target wall, with refractory linings on floor and target wall. Chamber with water-backed floor and target wall, with refractory lining on target wall only.
- 41 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual 2. Prepare site • assemble burner Inspect burner and components • mount burner (continued) Figure 2 Universal flange mounting dimensions Figure 3 Mark insertion depth on air tube when using universal flange mounting • Check the air tube length. Verify the usable length of the tube UTL will be long enough (see “Mount burner in appliance”). • Visually inspect all burner components and wiring.
- 42 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 2. Prepare site • assemble burner Attach air tube to housing 1. See Figure 4. Loosen air tube holding clamp on the front of the burner chassis. 2. Open ignitor cover plate by loosening the hold-down tabs and swinging them away. 3. Spread the housing slightly using a flat screwdriver between the two halves of the housing on top at the air tube collar. 4.
- 43 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual 3. Prepare burner Removing/installing head assembly Use care when handling burner components after the burner has been firing. Components can be hot and could cause severe personal injury. You will need to remove the combustion head assembly for inspection of the assembly, replacement of the oil nozzle or adjustment of electrodes. To remove the assembly: 1. Loosen, and then rotate the two screw clamps securing the ignitor in place.
- 44 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 3. Prepare burner (continued) Figure 10 Combustion head/nozzle/electrode settings Figure 12 Combustion head and air band adjutsments Inspect the nozzle adapter before replacing the nozzle. If the threads have been damaged or show score marks, replace the nozzle line/adapter assembly. 4. Replace the retention ring assembly by slipping one of the riveted arms through the gap between the electrode tips.
- 45 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual 3. Prepare burner (continued) Figure 13 Combustion head/air tube combinations, typical Table 3 Approximate air band and combustion head settings Carlin part number MN99102 Rev.
- 46 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 3. Prepare burner (continued) Inspect/install fuel supply Inspect the oil supply system. Ensure that the fuel lines are correctly sized and installed and that the fuel flow is unobstructed, the oil tank is clean and only # 1 or # 2 heating oil are supplied. Failure to supply a reliable oil flow could result in loss of heat and potential severe equipment damage.
- 47 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual 3. Prepare burner (continued) Two-line fuel system requirements Figure 15 Two-line fuel system See Figure 15 and Table 4. Use Table 4 only for burners equipped with Suntec fuel units. For burners using other fuel units, read the fuel unit manufacturer’s data sheet to determine maximum lengths and lifts. The standard burner fuel unit is a single-stage, 3450-RPM oil pump.
- 48 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 4. Wire burner • start burner — 48245 primary control Wire burner — 48245 primary control 1. All wiring must comply with: • In the U.S — the National Electrical Code, ANSI Z223.1/NFPA 54. • In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1. • All applicable local codes/standards. 2. Wire the burner following Figure 16 and any special instructions or wiring diagram provided with the appliance, burner or other components.
- 49 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual Carlin part number MN99102 Rev.
- 50 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 4. Wire burner • start burner — 40200 or 42230 primary control Wire burner — 40200 primary control 42230 primary control 1. All wiring must comply with: • In the U.S — the National Electrical Code, ANSI Z223.1/NFPA 54. • In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1. • All applicable local codes/standards. 2.
- 51 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual Carlin part number MN99102 Rev.
- 52 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 4. Wire burner • start burner — 50200 primary control Wire burner — 50200 primary control 1. All wiring must comply with: • In the U.S — the National Electrical Code, ANSI Z223.1/NFPA 54. • In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1. • All applicable local codes/standards. 2. Wire the burner following Figure 18 and any special instructions or wiring diagram provided with the appliance, burner or other components.
- 53 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual Carlin part number MN99102 Rev.
- 54 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 4. Wire burner • start burner — 60200 primary control Wire burner — 60200 primary control 1. All wiring must comply with: • In the U.S — the National Electrical Code, ANSI Z223.1/NFPA 54. • In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1. • All applicable local codes/standards. 2. Wire the burner following Figure 19 and any special instructions or wiring diagram provided with the appliance, burner or other components.
- 55 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual Carlin part number MN99102 Rev.
- 56 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 5. Adjustment and verification Adjust burner using test instruments Firing against positive overfire pressure 1. Operate burner for 15 minutes before making final adjustments using test equipment. 2. Check for leaks in fuel piping. 1. Burner rating maximum inputs are based on operation with zero to slightly negative pressure overfire, typically 0.01 to 0.03 inches w.c. 2.
- 57 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual 5. Adjustment and verification (cont.) Verify burner/appliance operation 6. Annual start-up and service Annual start-up & service Check burner/appliance/controls operation • Test operating and limit controls on appliance as specified in appliance instructions. • Check operation of the primary control by forcing lockout to occur. For primary controls that enter latch-up after multiple lockouts, force latch-up to occur as well.
- 58 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 7. Repair parts For parts not shown or listed, contact factory and/or check separate documentation supplied with appliance/burner unit. Item Description 1 Blower housing 3 Air bands 5 Part No.
- 59 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual 7. Repair parts (continued) Carlin part number MN99102 Rev.
- 60 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 8. Maintenance procedures Maintenance/service procedures Motor maintenance • The Carlin PSC motor is constructed with permanently-lubricated bearings, and requires no oiling. Should you replace the original motor with another type of motor, occasional oiling may be required, depending on motor design and manufacturer’s recommendations.
- 61 - Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual Limited Warranty Carlin Combustion Technology, Inc.
- 62 - Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 99FRD, 100CRD, and 102CRD oil burner User care and maintenance Refer only to the information on this page, intended for your use. The remainder of this manual is intended only for your service technician. Failure to comply could result in severe personal injury, death or substantial property damage. For other than routine maintenance, contact a qualified service company. Perform the following as needed.
- 63 - Intermittent duty ignition 45-second trial for ignition Red LED lockout indicator Thermostat/aquastat compatible Installing and wiring SMC Technology (1) Warning — The 48245 control must be installed and serviced only by a qualified service technician. 1. Always disconnect power source before wiring to avoid electrical shock or damage to the control. All wiring must comply with applicable codes and ordinances. 2. Thermostat terminals (T–T) provide a current source.
- 64 - Model 48245 Cad cell Oil primary control — Data sheet — Operation/Troubleshooting Start-up & operation Do not start the burner if the combustion chamber contains oil or oil vapor. Per UL requirements, the control will not turn on if the cad cell senses flame during the self-test. If the cad cell sees light (flame) at the beginning of a cycle, the control will wait until it no longer senses the problem.
- 65 - Interrupted duty ignition 15-second trial for ignition 40200 (1.3-second flame failure response time (FFRT)) 30-second trial for ignition 42230 (1.3-second flame failure response time (FFRT)) Recycle on flame failure Thermostat/aquastat compatible SMC Technology (1) Installing and wiring Warning — 40200 and 42230 controls must be installed and serviced only by a qualified service technician. 1. Always disconnect power source before wiring to avoid electrical shock or damage to the control.
- 66 - Model 40200/42230 Cad cell Oil primary controls — Data sheet — Operation/Troubleshooting Start-up & operation Do not start the burner if the combustion chamber contains oil or oil vapor. Per UL requirements, the control will not turn on if the cad cell senses flame during the selftest. If the cad cell sees light (flame) at the beginning of a cycle, the control will wait until it no longer senses the problem. Power ON Open all manual oil line valves. Close the line switch.
- 67 - Interrupted duty ignition Recycle on flame failure Serviceman reset protection (Latch-up after three consecutive lockouts (1)) Diagnostic LED’s 15-second TFI (trial for ignition)(other timings available) (1.3-second flame failure response time (FFRT)) Alarm contacts Thermostat/aquastat compatible SMC Technology (2) Installing and wiring Warning — The 50200 control must be installed and serviced only by a qualified service technician. 1.
- 68 - Model 50200 Microprocessor oil primary control — Data sheet — Operation/Troubleshooting Start-up & operation Do not start the burner if the combustion chamber contains oil or oil vapor. Per UL requirements, the control will not turn on if the cad cell senses flame during the self-test. If the cad cell sees light, the control will remain in self-test mode until the cad cell no longer senses light (flame). The amber LED will remain on, but blink off momentarily every 3 to 4 seconds.
- 69 - Interrupted duty ignition Recycle on flame failure Serviceman reset protection (Latch-up after three consecutive lockouts (1)) Diagnostic LED’s Valve delay on/motor delay off (Pre/post purge — contact Carlin for available timings) 15-second TFI (trial for ignition)(other timings available) (1.
- 70 - Model 60200 Microprocessor oil primary control — Data sheet — Operation/Troubleshooting Start-up & operation Do not start the burner if the combustion chamber contains oil or oil vapor. Per UL requirements, the control will not turn on if the cad cell senses flame during the self-test. If the cad cell sees light, the control will remain in self-test mode until the cad cell no longer senses light (flame). The amber LED will remain on, but blink off momentarily every 3 to 4 seconds.
- 71 - Installing and wiring 1. 2. 14,000-volt and 20,000-volt output for smoother ignition Solid state technology yields high performance, long life and durability 3. 4. 5. 6. 7.
- 72 - Models 41000/40700/40900 14-KV & 20-KV electronic ignitors & kits — Part numbers Mounting hole template (41000 & 40700 ONLY) s 5SE THE TEMPLATE AT RIGHT TO DRILL CLEARANCE holes in the base plate to replace an existing ignitor or transformer with a Carlin 41000 or 40700 ignitor. Mounting 40900 ignitors — Do not use this template for 40900 ignitors. Consult Carlin for 40900 applications. 0OSITION THE TEMPLATE WITH THE TERMINAL POST holes centered within the existing hole(s) in the plate.
- 73 - Installing and wiring Carlin PSC motors must be installed and serviced only by a qualified service technician. More Efficient — • both starting and running More Reliable — • • • • • auto reset thermal overload quiet sealed ball bearings eliminates centrifugal start switch 3-year warranty UL recognized More Versatile — • replace 1/15 to 1/4 HP motors • replaceable capacitor 1. Always disconnect power source before wiring to avoid electrical shock or damage to the electrical components.
- 74 - PSC Motors — Data sheet — Construction/Operation/Troubleshooting/Dimensions Construction Dimensions (inches) • All Carlin PSC motors are cast aluminum and Class A insulation. • The Carlin PSC Motor utilizes a capacitor to assist startup and run of the motor. This eliminates the need for a start switch used in the split phase motor. The Carlin motor capacitor is field replaceable for ease of service. • The Carlin PSC Motor has sealed ball bearings — not sleeve bearings.
- 75 - SVC10-FF (valve only) Kit # 98289 (SVC10-FF only) Instant opening Normally-closed, two-way Installing and wiring The Carlin SVC oil valve or oil valve kit must be installed and serviced only by a qualified burner service technician. See back page for kit installation instructions. Application tips UL recognized as a safety shut-off valve SVC-10FF available in field retrofit kit (part number 98289) 1.
- 76 - P/N 98289 Oil valve kit — Installing/wiring/kit contents Installing and wiring (P/N 98289 kit) P/N 98289 Kit contents The Carlin SVC oil valve or oil valve kit must be installed and serviced only by a qualified burner service technician. Follow burner manufacturer’s instructions for installation of oil valve. 1. Always disconnect power source before wiring to avoid electrical shock or damage to the electrical components. All wiring must comply with applicable codes and ordinances. 2.
- 77 - Interfaces with any Carlin primary control Terminals C, Y and G connect to cooling equipment Kit includes 40 VA transformer, 120/24 VAC Designed for quick installation Direct replacement, without rewiring, for Honeywell R8184M Low-cost upgrade to ‘M’ type control, with a high-performance Carlin primary Installing and wiring Warning Wiring 1. The 98435 kit must be installed only by a qualified service technician. 2.
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- 79 - Data sheet Specifications s s #ARLIN S -ODEL MICROPROCESSOR OPERATED MULTIPLE CONTACT TEMperature limit controls are available in four configurations, described below. Each model provides two contacts — one for operating limit and one from high limit. 2EFER TO SEPARATE PRODUCT LISTING SHEETS FOR PRE DElNED MODELS OR REquest a control to meet your specifications, within the available ranges listed below. Multiple sensor option (1 or 2) 90000A 90000AL Dual limit temperature control 7 .
- 80 - Model 90000 Microprocessor Temperature Controls — Data sheet — Operation & Dimensions Model 90000A, B & C diagnostic LED’s Configurations GREEN – OFF – ON Power s RED – OFF – ON Lockout AMBER – OFF – ON Control call for heat – FLASHING Latch-up s Electrical shock hazard: Disconnect power to appliance when wiring or servicing any electrical component. Operation Power OFF s s (See wiring diagrams below for wiring connections.
- 81 - Data sheet Specifications s #ARLIN S -ODEL !, ", $, AND ', MICROPROCESSOR OPERATED TEMPERATURE CONTROLS ARE 5, ,ISTED AND PROVIDED AS A COMPLETE PACK AGE CONSISTING OF CONTROL * BOX SENSOR AND WELL -ODEL ! " $ OR ' CONTROLS ARE 5, 2ECOGNIZED AND PROVIDED AS INDIVIDUAL COMPONENTS WITH * BOX SENSOR AND WELL AVAILABLE SEPARATELY s #ARLIN S MODEL MICROPROCESSOR OPERATED TEMPERATURE CONTROLS ARE AVAILABLE IN FOUR CONlGURATIONS DESCRIBED BELOW %ACH MODEL PROVIDES ONE LIMIT DUTY RATED CO
- 82 - Model 90200 Microprocessor Temperature Controls — Data sheet — Operation & Dimensions Model 90200 diagnostic LED’s GREEN n OFF n ON Power on n FLASHING Lockout Center AMBER n OFF n ON Call for low fire (90200G only) Right AMBER n OFF n ON Control call for heat or high fire Electrical shock hazard: $ISCONNECT POWER TO APPLIANCE WHEN WIRING OR SERVICING ANY ELECTRICAL COMPONENT Operation 3EE WIRING DIAGRAMS BELOW FOR WIRING CONNECTIONS 90200 CONTROLS HAVE A GREEN ,%$ POWER LOCKOUT INDIC
- 83 - Data sheet Functions s s s Carlin’s 90524 triple limit control provides high limit function and can also provide: s Minimum water temperature control for operation with a tankless heater in a boiler. (Function can be turned off by turning LOW LIMIT setting to “OFF.”) s Low temperature limit to prevent flow through boiler if temperature is below preset minimum — for preventing condensation in conventional boilers. s Operates as a cold-start control when Low Limit is in “OFF” position.
- 84 - Model 90524 Microprocessor Temperature Controls — Data sheet Figure 1 Equivalent circuit diagram (the 90524 controls power to the burner and circulators as in the simplified circuit below) Model 90524 diagnostic LED’s Configurations LED’s s 90524 controls have a green LED (power/lockout indicator) and amber LED’s (operation indicator) for Burner and Circulator.
- 85 - EZ-Temp TM Microprocessor Temperature Controls Instruction Manual Installer/servicer — Except where specifically stated otherwise, this manual must be used only by a qualified service technician. Read and follow all instructions in this manual and in the appliance manual. Failure to comply with this or other requirements in this manual could result in severe personal injury, death or substantial property damage.
- 86 - EZ-Temp Microprocessor Temperature Control — Instruction manual Install sensor(s) Configurations To install a new immersion well: 1. Turn off power to the appliance and close isolation valves. 2. Follow appliance instructions to drain the appliance so water line is below the insertion tapping. 3. Remove existing well and sensor. Apply a small amount of pipe dope to the new well and secure in tapping. 4. Insert EZ-Temp sensor into well and secure sensor in place as described in the following. 5.
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T E C H S U P P O R T H O T L I N E 8 0 0 - 9 8 9 - 2 2 7 5 Carlin Combustion Technology, Inc. 70 Maple Street East Longmeadow, MA 01028 e-mail us at: info@carlincombustion.com © Copyright 2008 — Carlin Combustion Technology, Inc. Phone 413–525–7700 Fax 413–525–8306 vist our website: www.carlincombustion.com Carlin part number MNRES Rev.
