Carlin 702G/O Instruction Manual
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Carlin 702G/O Instruction Manual

Advanced combination gas/oil burners. low-high-low step modulating. 6.0 to 11.2 gpl oil 840 to 1600 mbh gas (high-fire input capacities)
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Except where specifically stated otherwise, this manual
must be used only by a qualified service technician.
In the state of Massachusetts, this product must be
installed by a licensed Plumber or Gas Fitter.
Failure to comply with the above 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 an-
nually by your service technician.
Instruction manual
Check burner cartons carefully. The Model 702G/O
combination gas/oil burner was assembled and tested
at the factory before shipment. If the burner was ordered
with a completed assembled gas train, the train was
pressure tested and electrically checked for proper
operation. Where possible, the gas train or components
were shipped in the same carton as the burner. Check
your packing slip for the number of cartons shipped
from the factory.
©
Copyright 2011 — Carlin Combustion Technology, Inc.
Carlin Combustion Technology, Inc.
126 Bailey Road
Ph 203-680-9401
T
800-989-2275
ech support
™
North Haven, CT 06473
Fx 203-680-9403
carlincombustion.com

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Summary of Contents for Carlin 702G/O

  • Page 1 ™ Instruction manual Except where specifically stated otherwise, this manual Check burner cartons carefully. The Model 702G/O must be used only by a qualified service technician. combination gas/oil burner was assembled and tested at the factory before shipment. If the burner was ordered In the state of Massachusetts, this product must be with a completed assembled gas train, the train was installed by a licensed Plumber or Gas Fitter. pressure tested and electrically checked for proper operation. Where possible, the gas train or components Failure to comply with the above or other requirements were shipped in the same carton as the burner. Check in this manual could result in severe personal injury, your packing slip for the number of cartons shipped death or substantial property damage.

  • Page 2: Table Of Contents

    Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. PLEASE read this first . . . Contents PLEASE read this first ..............2 Before installing or servicing: General information ..............3 Should overheating occur: 1. The Carlin Model 702G/O combination gas/oil burner ...4 (1) Shut off the oil and gas supplies to the burner.

  • Page 3: General Information

    Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. General information Burner applications Ratings Follow all instructions in this manual, the primary control data sheet and ( With 0.00” w.c. overfire pressure, altitude 2,000 feet max.; see NOTICE the appliance manual. below) Verify the burner is correct for the appliance being used and for all ap- Oil Input plicable codes/standards..............High fire: 6.0 to 11.2 GPH Adjust the nozzle selection/firing rate if necessary due to positive overfire .............. Low fire: 3.5 to 6.5 GPH pressure and/or altitudes more than 2,000 feet above sea level. See the Gas Input NOTICE under the Ratings information at right. Where appliance appli-...

  • Page 4: The Carlin Model 702G/O Combination Gas/Oil Burner

    — Hago 45° SS Preferred • Gas mode operation — Hago 45° P or Monarch 45° PLP Alternate • Ignition for main flame is accomplished by a proved gas pilot of approxi- mately 280,000 Btuh. Pilot gas is introduced at the main burner flame Nozzle ratings retention ring, and is ignited by a Carlin 14,000-volt electronic ignitor Full input (high fire) occurs at 300 psig nozzle pressure. Since nozzles wired to the two electrodes. After the pilot flame is proven, the two main are rated at 100 psig, the actual flow at 300 psig is approximately 73% gas safety valves open. The pilot gas valve closes after a time delay to higher than the rated nozzle capacity. See the table below for nozzle allow main flame to establish. Flame is monitored both for pilot flame and rating selections. main flame with a UV scanner mounted to the under side of the burner combustion head assembly. The burner main flame begins at low fire. 702G/O oil nozzles Table 1 If additional input is required, the damper motor opens the gas butterfly valve and air damper to their high fire positions.
  • Page 5 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 1. The Carlin Model 702G/O combination gas/oil burner (continued) 40 Gas entrance connection 41 Pressure tap & bleed port 42 Pilot gas line manual valve (with 2 test tappings) 43 Combination pilot gas valve 60 Head position indicator scale 61 Head position adjustment screw...

  • Page 6: Prepare Site • Assemble Burner • Mount Burner

    Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 2. Prepare site • assemble burner • mount burner Vent system Vent and vent connector installations, typical Figure 1 Vent/chimney sizing 1.
  • Page 7 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 2. Prepare site • assemble burner • mount burner (continued) Combustion air/ventilation openings Installing the burner/appliance in a space that does Sizing air openings not provide enough air for combustion and ventila- Follow all applicable codes and the appliance instruction manual (when tion can result in severe personal injury, death or available) to size combustion air openings. Use the following guidelines substantial property damage. Follow all applicable...
  • Page 8 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 2. Prepare site • assemble burner • mount burner (continued) Prepare the appliance Burner input: Install a burner sized for the normal input rat- Ceramic fiber or ing of the appliance. Do not install a burner with a higher Fiberglass insulation firing rate than the appliance rating. Do not install a burner with a firing rate more than 10% lower than the appliance rating. The appliance and vent system could be damaged...
  • Page 9 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 2. Prepare site • assemble burner • mount burner (continued) Prepare burner and components Chamber dimensions & tube configurations Figure 3...
  • Page 10 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 2. Prepare site • assemble burner • mount burner (continued) Inspect burner and components Adjustable flange Figure 4 Check the air tube length. Verify the usable length of the tube UTL will • be long enough (see “Mount burner in appliance”).
  • Page 11 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 2. Prepare site • assemble burner • mount burner (continued) 5. Slide the flame scanner sight pipe assembly forward until the 3/8" pipe Install gas train on burner fits against the retention ring assembly. Then tighten the 1/8" Allen screw 1. The standard burner gas train is shipped fully assembled, with the piping to secure the tube in place.

  • Page 12: Install Gas Piping

    Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 3. Install gas piping Connect from the gas supply to the burner gas train inlet using new, clean black iron pipe and malleable iron fittings only. Do not use copper, brass, cast iron or galvanized pipe or fittings. Provide support for gas piping. Do not rest the weight of the gas piping on burner gas train. Provide a support for the burner gas train. Apply pipe dope sparingly at all joints. Use only pipe dope listed for use with propane gas. Do not use pipe sealing tape. Do not hold the gas valve with pipe wrench. Use crescent wrench or other smooth-jawed device. Do not overtighten. Failure to comply with above could result in severe personal injury, death or substantial property damage. Do not expose the gas train to gas pressure in excess of 14 inches water column. Higher pressure could damage the valve seat, resulting in potentially hazardous condition. When pressure testing piping at higher pressures, disconnect burner from gas line before testing. If the gas supply pressure can exceed 14 inches water column at any time, you must install a lockup type gas pressure regulator in the gas supply piping, ahead of the main manual gas valve installed at the burner. Piping from gas meter to burner...
  • Page 13 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 3. Install gas piping (continued) Capacities of black iron pipe, cubic feet gas/hour Gas train pressure drop Table 3 Figure 8...

  • Page 14: Install Oil Piping

    Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 4. Install oil piping Inspect/install fuel supply Use two-line oil piping only Inspect the oil supply system. Ensure that the fuel lines are correctly sized and installed and that the fuel flow is unob- The fuel unit must be connected to a two-line fuel structed, the oil tank is clean and only # 1 or # 2 heating oil to ensure oil flow through the pump during system are supplied. Failure to supply a reliable oil flow could result gas operation. This is needed to keep the pump...
  • Page 15 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 4. Install oil piping (continued) Figure 9 Two-line fuel system 702G/O fuel unit and flow diagram Figure 10 (Low fire pressure is 100 PSIG, adjusted by screw on top of blocking valve;...

  • Page 16: Wire The Burner

    Figure 13 702G/O burner wiring using Honeywell RM7897C primary control (see appliance manual or separate wiring information for burner equipped with a primary control not covered in this manual); see Figure 12 for a legend to callouts.
  • Page 17 Figure 13a 702G/O burner Mass Code wiring using Honeywell RM7897C primary control (see appliance manual or separate wiring information for burner equipped with a primary control not covered in this manual); see Figure 12 for a legend to callouts.
  • Page 18 3. See Figure 14 to connect the high fire control to the burner firing rate (remove jumper) circuit. 4. The burner includes a pre-wired manual high-fire switch. Close this switch to hold the burner in high fire mode. Open the switch to hold the burner in low fire mode. Figure 15 702G/O ladder wiring diagram (burners with RM7895C or RM7897C primary only); see Figure 12 for a legend to callouts – 18 – Carlin part number MN702GO Rev. 06/23/14...
  • Page 19 Figure 14a (RM7895C or RM7897C only) 1. To take advantage of the energy-saving potential of the Model 702G/O combination gas/oil burner, it should be wired to operate at low-high-low cycles. The firing cycle can be much longer using low-high-low firing, because the burner can cycle to low fire as demand decreases.

  • Page 20: Checkout Procedure - Before Starting The Burner

    Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 6. Checkout procedure — before starting the burner Burner nozzle verified per appliance manufacturer’s instructions, Before firing the burner . . . ❏ Carlin OEM Spec Guide or Table 1, page 4? Should overheating or an emergency occur, immediately Gas and oil supply lines in good condition, sized and designed ❏...

  • Page 21: Set Burner Initial Head And Damper Positions

    Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 7. Set burner initial head and damper positions Set initial combustion head position Figure 16 Follow the procedures given here and on the follow- ing pages to ensure the burner is correctly adjusted. Take your time and the results in both gas and oil modes should result in good operation, and avoid return service calls. You must perform the adjustments in the sequence given in this manual.

  • Page 22: Adjust The Burner Using Test Instruments

    Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 8. Adjust the burner using test instruments Start the burner (firing on oil) The settings given in Section 7 are initial settings Do not start the burner if the combustion chamber contains only. You must use test instruments to check oil or oil vapor.
  • Page 23 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 8. Adjust the burner using test instruments (continued) 3. See Figure 17, page 19. Adjust the low-fire damper screw until the low-fire is between 11% and 12%. Rotate the screw clockwise to increase The linkage between the damper motor arm and airflow (reduced CO ). Rotate the screw counterclockwise to decrease the air damper crank is set at the factory, and...
  • Page 24 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 8. Adjust the burner using test instruments (continued) is still strong with main flame on. 4. Move the burner fuel selector switch to OFF. The burner will shut down. Smell around the gas train and check all joints with 5. Temporarily install two U-tube manometer connections to check gas pres- a soap suds mixture to ensure the gas train and all sures. Install connections at the inlet pressure tap of the main manual components are tight and leak-free. Shut down the gas valve and at the downstream pressure tap of the manual gas valve burner and correct any leak immediately. Failure to next to the butterfly valve. (See items 41, page 5.) comply could result in severe personal injury, death 6.
  • Page 25 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 8. Adjust the burner using test instruments (continued) 11. Tighten the two hex head screws on the butterfly valve linkage arm boss. Step 6 (firing on gas) Then lower the damper motor linkage to the low fire position. Set butterfly gas valve linkage 12.
  • Page 26 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. Step 7 (firing on oil and on gas) Verify operation Burner/appliance/controls operation Test operating and limit controls on appliance as specified in appliance instruc- ❏ tions. 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. Reset primary control per control data sheet instructions after each test. Start and stop the burner several times, allowing the primary control to sequence ❏...

  • Page 27: Maintenance And Service Procedures

    Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 8. Maintenance and service procedures Disconnect the 1/4" O.D. copper oil line. Turn off power to appliance when servicing burner. After servic- ing, always operate burner/appliance to verify all components Remove the two housing cover locking screws and swing the housing open. are functioning correctly and that the burner is properly adjusted. Remove the zip-tie holding the UV scanner cable and air tube thermal fuse Failure to comply could result in severe personal injury, death or lead. substantial property damage.
  • Page 28 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 8. Maintenance and service procedures (continued) Installation/service certificate Installation data Burner model Serial number Measured gas firing rate, Oil nozzle size & pattern:...
  • Page 29 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. – 29 – Carlin part number MN702GO Rev. 06/23/14...
  • Page 30 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 9. Dimensions Dimensional data, straight gas train configuration Figure 19 1 Honeywell R7897C primary control (standard) 2 Air tube 3 Universal flange (standard) 4 Carlin 41000 solid state ignitor 5 Junction box 6 Motor, 48N-frame – 30 – Carlin part number MN702GO Rev. 06/23/14...
  • Page 31 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 9. Dimensions (continued) Dimensional data, angled gas train configuration Figure 20 1 Honeywell R7897C primary control (standard) 2 Air tube 3 Universal flange (standard) 4 Carlin 41000 solid state ignitor 5 Junction box 6 Motor, 48N-frame – 31 – Carlin part number MN702GO Rev. 06/23/14...
  • Page 32 Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. For parts not shown or listed, contact factory and/or check separate documentation supplied with appliance/burner unit. 10. Repair parts — Burner housing and components Item Description Part No. Blower housing with cover and pressure augmentor Fuel line...

  • Page 33: Repair Parts

    Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. For parts not shown or listed, contact factory and/or check separate documentation supplied with appliance/burner unit. 10. Repair parts (continued) – 33 – Carlin part number MN702GO Rev. 06/23/14...

  • Page 34: User Care And Maintenance

    Model 702G/O Advanced gas/oil burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 702G/O 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 dam- age.

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