Owner manual

ManualsBrandsCarlin ManualsEquipment102CRD-99FRD-100CRD

Instruction manual

™

Contents

PLEASE read this ﬁ rst .......................................................2

Codes and standards ........................................................2

1. 99, 100, & 102 Oil nozzle selections ............................3

2. Prepare site • assemble burner • mount burner 4

3. Prepare burner ............................................................9

4. Wire burner • start burner – 48245 primary control .14

4. Wire burner • start burner – 40200 primary control .16

4. Wire burner • start burner – 50200 primary control .18

4. Wire burner • start burner – 60200 primary control .20

5. Adjustment and veriﬁ cation .......................................22

6. Annual start-up and service ......................................23

7. Repair parts ...............................................................24

8. Maintenance procedures ...........................................26

Warranty .........................................................................27

User care and maintenance ...............................Rear cover

70 Maple Street East Longmeadow, MA 01028

Ph 413-525-7700 Fx 413-525-8306

Carlin Combustion Technology, Inc.

TECH SUPPORT 800-989-2275

carlincombustion.com

Installer/servicer — Except where speciﬁ cally stated other-

wise, this manual must be used only by a qualiﬁ ed service

technician. Failure to comply with this or other requirements

in this manual could result in severe personal injury, death or

substantial property damage.

User — Refer only to User care and maintenance on back

page for information regarding operation of this burner. The

burner Instruction Manual is intended only for your service

technician. The burner and heat exchanger must be inspected

and started at least annually by your service technician.

Ratings

Input: 99FRD ....................................................0.50 to 3.00 GPH

100CRD................................................. 0.50 to 2.25 GPH

102CRD (2⁵⁄₈’’ air cone) ........................ 2.00 to 3.50 GPH

102CRD (3’’ air cone) ............................ 3.00 to 4.50 GPH

Fuels: U.S. ................................................No. 1 or No. 2 Fuel oil

Canada .................... No. 1 Stove oil or No. 2 Heating oil

Fuel unit: ...............................................................................Suntec

........................................ 100 to 150 PSIG nozzle pressure

Electrical: Power ..............................................120V/60 Hz/1-Phase

Motor................................Carlin PSC, 1/6 HP, 3450 RPM

Current

99FRD .........................................Approx. 5.5 amps

100CRD .......................................Approx. 5.5 amps

102CRD .......................................Approx. 6.0 amps

Ignition: ...............Carlin Model 41000 electronic — 14,000 volts

Control: ........................... U.L. Group I or II primary safety control

Agencies: ...............................................UL Listed (US and Canada)

Summary of content (28 pages)

PAGE 1
™ Instruction manual Ratings Contents PLEASE read this first .......................................................2 Input: Fuels: 99FRD ....................................................0.50 to 3.00 GPH 100CRD................................................. 0.50 to 2.25 GPH 102CRD (2⁵⁄₈’’ air cone) ........................ 2.00 to 3.50 GPH 102CRD (3’’ air cone)............................ 3.00 to 4.50 GPH Codes and standards ........................................................2 U.S. .......
PAGE 2
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.
PAGE 3
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.
PAGE 4
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.
PAGE 5
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.
PAGE 6
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.
PAGE 7
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.
PAGE 8
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.
PAGE 9
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.
PAGE 10
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.
PAGE 11
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.
PAGE 12
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.
PAGE 13
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.
PAGE 14
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 4. Wire burner • start burner — 48245 primary control Turn off power to appliance when servicing burner. Failure to comply could result in severe personal injury, death or substantial property damage. 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.
PAGE 15
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual Carlin part number MN99102 Rev.
PAGE 16
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 4. Wire burner • start burner — 40200 or 42230 primary control Turn off power to appliance when servicing burner. Failure to comply could result in severe personal injury, death or substantial property damage. 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.
PAGE 17
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual Carlin part number MN99102 Rev.
PAGE 18
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 4. Wire burner • start burner — 50200 primary control Turn off power to appliance when servicing burner. Failure to comply could result in severe personal injury, death or substantial property damage. 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.
PAGE 19
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual Carlin part number MN99102 Rev.
PAGE 20
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual 4. Wire burner • start burner — 60200 primary control Turn off power to appliance when servicing burner. Failure to comply could result in severe personal injury, death or substantial property damage. 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.
PAGE 21
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual Carlin part number MN99102 Rev.
PAGE 22
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.
PAGE 23
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.
PAGE 24
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.
PAGE 25
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual 7. Repair parts (continued) Carlin part number MN99102 Rev.
PAGE 26
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.
PAGE 27
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual Limited Warranty Carlin Combustion Technology, Inc.
PAGE 28
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.