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Carlin 702GAS Instruction Manual

Advanced gas burners with low-high-low step modulating 840 to 1600 mbh gas (high-fire input capacity)
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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 annually by your
service technician.
702GAS
MODEL
Advanced Gas Burners
with Low-High-Low Step Modulating
840
1600 MBH Gas
TO
(High-fire input capacity)
Instruction Manual
Check burner cartons carefully. The Model 702GAS gas
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
Phone 203-680-9401
T
800-989-2275
ech support
™
North Haven, CT 06473
Fax 203-680-9403
carlincombustion.com

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Summary of Contents for Carlin 702GAS

  • Page 1 (High-fire input capacity) Instruction Manual Except where specifically stated otherwise, this manual Check burner cartons carefully. The Model 702GAS gas must be used only by a qualified service technician. burner was assembled and tested at the factory before shipment. If the burner was ordered with a completed...

  • Page 2: Table Of Contents

    Model 702GAS Advanced gas 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.

  • Page 3: General Information

    ............Carlin Model 41000 solid state electronic ignitor Ignition voltage ..................14,000 volts Certification Primary control ................Honeywell RM7897C 702GAS burners are U.L. listed for the U.S., certified to comply with: Agencies UL 795, for use with natural gas or propane. • ......................UL Listed (US) Burner labels list compliance, when required, with special local, state •...

  • Page 4: The Carlin Model 702Gas Gas Burner

    702GAS overview LEGEND for page 5 The Model 702GAS gas burner is a low-high-low (step modulating) burner Cast aluminum burner housing that utilizes a damper motor and butterfly valve to control air (and gas fuel Air tube (with gas manifold) rate).
  • Page 5 Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 1. The Carlin Model 702GAS gas burner (continued) Angled gas train (standard configuration) (components same as straight train) Flame retention head &...

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

    Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 2. Prepare site • assemble burner • mount burner Vent system Figure 1 Vent and vent connector installations, typical Vent/chimney sizing 1.
  • Page 7 Model 702GAS Advanced gas 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...
  • Page 8 Model 702GAS Advanced gas 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 rating of the appliance.
  • Page 9 Model 702GAS Advanced gas 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 Figure 3 Chamber dimensions & tube configurations...
  • Page 10 Model 702GAS Advanced gas 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 Figure 4 Adjustable flange Check the air tube length. Verify the usable length of the tube UTL will be •...
  • Page 11 Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 2. Prepare site • assemble burner • mount burner (continued) Install gas train on burner Figure 5 Electrode settings 1. The standard burner gas train is shipped fully assembled, with the piping disconnected at the gas train unions.

  • Page 12: Install Gas Piping

    Model 702GAS Advanced gas 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.
  • Page 13 Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 3. Install gas piping (continued) Table 3 Figure 8 Capacities of black iron pipe, cubic feet gas/hour Gas train pressure drop...

  • Page 14: Wire The Burner

    Figure 13 702GAS burners 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 15 Figure 14 702GAS field wiring connections (RM7897C only) 1. To take advantage of the energy-saving potential of the Model 702GAS gas 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 16: Checkout Procedure - Before Starting The Burner

    Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 5. Checkout procedure — before starting the burner Before firing the burner . . . Checklist before firing . . .

  • Page 17: Set Burner Initial Head And Damper Positions

    Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 6. 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.

  • Page 18: Adjust The Burner Using Test Instruments

    ONLY need adjustment if the damper motor or the damper rod is replaced. With the burner The Model 702GAS uses a gas pilot for ignition of the gas main in high-fire position, there should be minimal play flame. The gas pilot is ignited by the burner electrodes.
  • Page 19 Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 7. Adjust the burner using test instruments (continued) Step 3 Figure 18 Butterfly gas valve linkage Set main gas pressure regulator...
  • Page 20 Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 7. Adjust the burner using test instruments (continued) Step 4 Set butterfly gas valve linkage Smell around the gas train and check all joints with a soap suds mixture to ensure the gas train and all 1.
  • Page 21 Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 7. Adjust the burner using test instruments (continued) Step 5 Step 5a (for Mass Code) Verify operation Verify operation Perform all of the checkout procedures given in Step 5 of Burner/appliance/controls operation the burner manual.

  • Page 22: Maintenance And Service Procedures

    Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 8. Maintenance and service procedures Turn off power to appliance when servicing burner. After servicing, Remove the four gas orifice spuds from the manifold.

  • Page 23: Installation Data

    Model 702GAS Advanced gas 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, Btuh _____________________________________________________________ Gas regulator outlet pressure:...

  • Page 24: Repair Parts

    Model 702GAS Advanced gas 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. 9. Repair parts — Burner housing and components...
  • Page 25 Model 702GAS Advanced gas 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. 9. Repair parts (continued) 14 15 –...

  • Page 26: Dimensions

    Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 10. Dimensions Figure 19 Dimensional data, angled gas train configuration 14 1/4" 9 1/4" 30 1/2" 22 1/4" 11 1/2" a Control panel with Honeywell...

  • Page 27: Mn702G

    Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 10. Dimensions (continued) Figure 20 Dimensional data, straight gas train configuration 43" 11 1/2" a Control panel with Honeywell e Motor, 1/2 HP 48N-frame...
  • Page 28 Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. NOTES – 28 – MN702G 092916...
  • Page 29 Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. NOTES – 29 – MN702G 092916...

  • Page 30: User Care And Maintenance

    Model 702GAS Advanced gas burners — Instruction manual Where appliance instructions differ from this manual, follow the appliance instructions. 702GAS 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.

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