Carlin 201GAS Instruction Manual

Gas burner

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Ratings

Input:

................................................. 150,000 to 399,000 Btuh

.........................................Natural gas or propane gas

Fuels:

Max. supply pressure ..........................14 inches w.c.

Min. supply pressure .............................5 inches w.c.

Manifold pressure...............................3.5 inches w.c.

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

Motor.....................................1/6 or 1/4 HP, 3450 RPM

Current ...................................Approx. 2.5 or 4.4 amps

........................ Carlin Model 41800 solid state ignitor

Ignition:

Control:

........ Carlin Model 60200FR microprocessor control

Agencies: ..........................................................................UL Listed

Installer/servicer - Except where specifically

stated otherwise, this manual must be used only by a quali-

fied service technician. (In the state of Massachusetts, this

product must be installed by a licensed Plumber or Gas Fitter.)

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's Information booklet for

information regarding operation of this burner. The burner

Instruction Manual is intended only for your service techni-

cian. The burner and heat exchanger must be inspected and

started at least annually by your service technician.

Instruction manual

Contents

PLEASE read this first.......................................................... 2

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

201GAS burner at-a-glance ................................................ 3

Prepare site • prepare burner • mount burner .............. 4

Install gas piping .................................................................. 9

Wire burner ......................................................................... 10

Check system • start-up burner/appliance .................. 11

Perform checkout procedures • fill out certificate..... 13

Maintenance and service procedures ........................... 16

Troubleshooting ................................................................. 17

Dimensions and mounting information........................... 19

Replacement parts............................................................. 20

Carlin Combustion Technology, Inc.

70 Maple Street

Ph 413-525-7700

800-989-2275

ech support

™

East Longmeadow, MA 01028

Fx 413-525-8306

carlincombustion.com

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Summary of Contents for Carlin 201GAS

Page 1: Table Of Contents
Motor........1/6 or 1/4 HP, 3450 RPM Maintenance and service procedures ......16 Current ........Approx. 2.5 or 4.4 amps Troubleshooting ..............17 ......Carlin Model 41800 solid state ignitor Ignition: Dimensions and mounting information......19 Control: ..Carlin Model 60200FR microprocessor control Replacement parts.............
Page 2: Please Read This First
Installation of Domestic Gas Conversion Burn- Burner listings ers, ANSI Z21.8, the National Fuel Gas Code, ANSI Z223.1/NFPA 54-latest Carlin 201GAS burners are tested and approved under standards ANSI edition, and the National Electrical code, ANSI/NFPA 70-latest edition for U. Z21.17-latest edition and CSA 2.7-M86.
Page 3: 201Gas Burner At-A-Glance
21 Combination gas valve (with integral gas pressure regulation — set for 3½” w.c. outlet pressure) 10 Ignitor (Carlin Model 41800 solid state electronic ignitor — 9,000 volts, continuous duty rated) 22 Gas supply entrance — ¾” NPT; 5” w.c. min; 14” w.c. max 11 Primary control —...
Page 4: Prepare Site • Prepare Burner • Mount Burner
Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 1. Prepare site • prepare burner • mount burner Prepare installation site Figure 1 Vent and vent connector installation Inspect, repair and/or replace vent system...
Page 5 Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 1. Prepare site • prepare burner • mount burner (continued) Prepare installation site Figure 2 Locating & sizing air openings Verify combustion/ventilation air openings...
Page 6 Prepare appliance for burner mounting turer’s guidelines for repair or replacement of any component found defective. The universal flange supplied with 201GAS burners is When cleaning the appliance or working with ceramic fiber refrac- intended only for firing chambers with negative overfire pres- tories or fiberglass insulation, see WARNING on this page.
Page 7 Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 1. Prepare site • prepare burner • mount burner (continued) Prepare burner and components Diffuser plate • Verify correct diffuser plate (item 2, page 3). Compare diffuser plate listed Do not install or operate the burner if any component is damaged on air tube label with diffuser plate listed in Table 1.
Page 8 • If gas orifice is larger than required, obtain a replacement orifice nipple from Carlin. If necessary, drill the orifice hole in the replacement orifice nipple to the correct size. To avoid damage to gas valve, do not hold valve with a pipe wrench or overtighten.
Page 9: Install Gas Piping
Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 2. Install gas piping from meter to combination gas valve Code compliance 4. If the burner is installed inside an appliance jacket, install the main manual gas valve and sediment trap external to the jacket.
Page 10: Wire Burner
The minimum flame signal needed to satisfy the 60200FR sensing circuit is 0.8 microamps. The control will register flame failure at any lower signal. Figure 8 Wiring diagram — 201GAS burner with 60200FR primary control – 10 – Carlin part number MN201GAS Rev. 03/14/11...
Page 11: Check System • Start-Up Burner/Appliance
Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 4. Check sytem • start-up burner/appliance Inspect/check system Figure 9 Air band adjustment Before starting the burner and appliance, verify the system has been installed as directed by this manual and the appliance instructions.
Page 12 Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 4. Check system • start-up burner/appliance (continued) Model 60200FR diagnostic LED’s Should overheating or an emergency occur, immediately: • Shut off main manual gas valve.
Page 13: Perform Checkout Procedures • Fill Out Certificate
Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 5. Perform checkout procedures • fill out certificate Installer/servicer Make final burner adjustments (continued) Please check off and fill in certificate Inspect flame Look at flame through appliance observation port.
Page 14 Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 5. Perform checkout procedures • fill out certificate (continued) Verify burner/appliance operation Verify burner/appliance operation Check burner/appliance/controls operation Verify vent system operation Test operating and limit controls on appliance as specified in appliance Verify vent is operating correctly and flue products are properly ex- instruction manual.
Page 15: Maintenance And Service Procedures
Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 6. Maintenance and service procedures Annual start-up & service To remove assembly: 1. Remove the connector wires from the flame rod and ignitor electrode.
Page 16: Maintenance And Service Procedures
Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 6. Maintenance and service procedures (continued) Maintenance/service procedures 3. Loosen the Allen screw securing the blower to the motor shaft and remove the wheel.
Page 17: Troubleshooting
Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 7. Troubleshooting – 17 – Carlin part number MN201GAS Rev. 03/14/11...
Page 18 Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 7. Troubleshooting (continued) Problem Possible Corrective action cause These procedures must only be performed by a qualified service techni- cian. Use care when performing tests on electrically or mechanically live WARNING parts.
Page 19: Dimensions And Mounting Information
Figure 10 Dimensional data Mounting burner to appliance Figure 11 Flange mounting information The universal flange supplied with 201GAS burners is intended only for firing chambers with negative overfire pres- sure. For pressurized firing, you must obtain a burner with a welded flange, designed for use with the appliance.
Page 20: Replacement Parts
Hinged cover plate for Carlin ignitor 98534 Ignitor, Carlin electronic Model 41800 4180002 Primary control, Carlin 60200FR microprocessor flame rod control 6020002FR Ignitor electrode/flame rod assembly, complete (depends on air tube length) Contact factory Electrode holding base with hardware (depends on air tube length)
Page 21 Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 9. Replacement parts (continued) Burner is shown with welded flange, supplied only on burners ordered for specific appliance applications. Other burners are supplied with the universal flange (item 23) or optional forced draft flange (item 24).
Page 22 Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. – 22 – Carlin part number MN201GAS Rev. 03/14/11...
Page 23 Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. – 23 – Carlin part number MN201GAS Rev. 03/14/11...
Page 24 Model 201GAS burner — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. – 24 – Carlin part number MN201GAS Rev. 03/14/11...

Carlin 201GAS Instruction Manual

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