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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.
702GAS
MODEL
Low-High-Low Step Modulating
840 to 1600 MBH Gas
(High-fire input capacities)
Instruction Manual
Check burner cartons carefully. The Model 702GAS
combination 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 2020 — Carlin Combustion Technology
C a r l i n C o m b u s t i o n Te c h n o l o g y
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 702GAS
- Page 1 ™ MODEL Low-High-Low Step Modulating 840 to 1600 MBH Gas (High-fire input capacities) Instruction Manual Except where specifically stated otherwise, this manual Check burner cartons carefully. The Model 702GAS must be used only by a qualified service technician. combination gas 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...
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Page 2: Table Of Contents
PLEASE read this first . . . Contents PLEASE read this first ..............2 Before installing or servicing: General information ..............3 (1) Shut off the oil and gas supplies to the burner. 1. The Carlin Model 702GAS ...........4 (2) DO NOT shut off the control switch to the boiler circulator or the burner. 2. Pre-fire Inspection/Preparation ..........5 Follow the guidelines below to avoid potential severe 3. Install gas piping ..............13 personal injury, death or substantial property dam- age. 4. Wire the burner ..............15 Installer/service technician . -
Page 3: General Information
Damper motor ..........Siemens SQN71 to assist us in locating information. This information can be helpful when Ignition & Primary Control troubleshooting or obtaining replacement parts....Carlin Model 41800 solid state electronic ignitor Ignition voltage ............9,000 volts Codes and standards Primary control ........Honeywell RM7897C Certification Agencies ................UL Listed (US) -
Page 4: The Carlin Model 702Gas
1. The Carlin Model 702GAS burner 702GAS overview Firing rate adjustment Then gas flow is adjusted to match the air flow at low and high fire rates. The Model 702GAS burner is a low-high-low (step modulating) burner that • NOTE: High Fire must be set before Low Fire. utilizes a damper motor to control air (and gas fuel rate). See the “Starting and operating” section on page 12 of this manual for See the next page for gas train component locations. • the complete description of the adjustment process. The following is a brief summary only. Operation High-fire air is set by adjusting the combustion head position (to control Ignition for main flame is accomplished by a proved gas pilot of approximately • air flow through and around the retention ring). 70,000 Btuh. Pilot gas is introduced and ignited by a Carlin 9,000-volt elec- Low-fire air is then adjusted by altering the position of the low fire adjust- tronic ignitor wired to the electrode. After the pilot flame is proven, the two • main gas safety valves open. The pilot gas valve closes after a time delay ing screw. to allow main flame to establish. Flame is monitored both for pilot flame and Gas pressure requirements main flame with a UV scanner positioned in the mounting flange. The burner main flame begins at low fire. If additional input is required, the damper mo- Standard gas train requirements for the 702GAS burner requires a minimum tor opens the gas butterfly valve and air damper to their high fire positions. -
Page 5: Pre-Fire Inspection/Preparation
2. Pre-fire inspection • preparation Vent system Inspect, repair and/or replace vent Vent/chimney sizing system 1. Follow all local codes when sizing the vent and chimney. Do not install this burner unless you have verified 2. Refer to the appliance manufacturer’s manual, when available, for venting the entire vent system and the appliance are in recommendations. good condition and comply with all applicable codes. And . . . Combustion air/ventilation openings The vent and chimney must be sized and constructed in accordance with all applicable codes for gas firing. - Page 6 2. Pre-fire inspection • preparation (continued) Vent and vent connector installations, typical Prepare vent/chimney Figure 1 1. Secure all metal vent joints with screws, following the vent manufacturer’s instructions. Seal all joints in the vent system and chimney. Repair ma- sonry chimney lining and repair all mortar joints as needed. 2. Where draft fluctuations are likely, install a double-acting barometric draft regulator in the vent piping. (The damper must be located in the same space as the appliance.) Install a manual reset spill switch per manu- facturer’s instructions. Wire the switch into the appliance limit circuit to shut off the appliance/burner if sustained downdraft should occur. Refer to the appliance manufacturer’s instruction manual for recommendations regarding the need for a barometric draft regulator. 3. Provide support for the vent piping. Do not rest the weight of any of the vent piping on the appliance flue outlet. Clearances Check codes, standards and the equipment manual • Verify that the burner/appliance will maintain all clearances to combustible walls or floor and all clearances required for service/maintenance as required in the appliance manual and applicable codes.
- Page 7 2. Pre-fire inspection • preparation (continued) Combustion air/ventilation openings Installing the burner/appliance in a space that does not Sizing air openings provide enough air for combustion and ventilation can result in severe personal injury, death or substantial Follow all applicable codes and the appliance instruction manual (when available) property damage.
- Page 8 2. Pre-fire inspection • preparation (continued) Prepare the appliance Burner input: Install a burner sized for the normal input rating of the appliance. Do not install a burner with a higher firing rate Ceramic fiber or than the appliance rating. Do not install a burner with a firing Fiberglass insulation rate more than 10% lower than the appliance rating. The appli- ance and vent system could be damaged due to condensation. Clean the appliance: Clean the appliance thoroughly. Test all Ceramic fiber materials, such as chamber liners, may electrical components and verify the relief valve works (boilers contain carcinogenic particles (chrystobalites) after only). exposure to heat. Airborne particles from fiberglass or ceramic fiber components have been listed as po- Seal the appliance: Seal all flue-gas containing joints. Seal all tentially carcinogenic by the State of California. Take connections to the vent piping or breeching. the following precautions when removing, replacing Verify combustion chamber dimensions comply with the mini- and handling these items. mum dimensions recommended on page 9. Install or replace chamber liner if required by the appliance manufacturer. The Avoid breathing dust and avoid contact with skin or burner must not extend into the combustion chamber. The end eyes. Wear long-sleeved, loose-fitting clothing, gloves of the burner air tube must be withi 1/4" of the inside face of...
- Page 9 2. Pre-fire inspection • preparation (continued) Prepare burner and components Chamber dimensions & tube configurations Figure 3 Do not install or operate the burner if any component is dam- aged or if burner does not comply with the specifications of Table 2 and other guidelines in this manual. Combustion chamber minimum dimensions 1. For applications that have not been specifically tested (OEM applications), verify that the combustion chamber provides the minimum dimensions shown in Table 2 and Figure 3. For specific OEM applications, the appliance testing ensures suitability of the chamber. 2. Chamber dimensions may be larger than listed in Table 2, but should not be excessively large. Combustion chambers should be sized as recommended in Table 2. They should be constructed of refractory materials Minimum combustion chamber dimensions with the capacity to withstand 2600°F or higher.
- Page 10 2. Pre-fire inspection • preparation (continued) Mount burner in appliance 1. Welded-flange burners 4. Place gasket onto boiler front plate. 2. Verify the bolt pattern on the appliance chamber matches the flange 5. Slide the end of the air tube into the opening and secure the flange to pattern. the boiler front plate. 3. Verify the insertion depth (UTL) matches the depth of the appliance opening (so the end of the air tube is flush with, or slightly short of, the inside surface of the combustion chamber). Inspect components and wiring • 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. – 10 – MN702GE 060320...
- Page 11 2. Pre-fire inspection • preparation (continued) Removing the combustion head assembly Installing the burner/appliance in a space that does not 1. Shut off the burner. provide enough air for combustion and ventilation can 2. Remove the four gas orifice spuds from the manifold (Figure 4). result in severe personal injury, death or substantial property damage. Follow all applicable codes and 3. Remove the two housing cover locking screws and swing the housing guidelines below to ensure space has sufficient air open. openings. 4. Remove the combustion head assembly and inspect as needed. Exhaust fans and negative pressure conditions — Isolate the boiler room from areas subject to negative Gas orifice location Figure 4...
- Page 12 2. Pre-fire inspection • preparation (continued) Gas valve vent opening — The V48 diaphragm gas valve is Install gas train on burner NOT fitted with a vent limiting orifice in the vent connection. If 1. The standard burner gas train is shipped fully assembled, with the piping local codes require, install piping from the vent connection to disconnected at the gas train unions. See separate instructions if installing outside, sized and installed as required by codes. Because this an optional knocked down gas train. The gas train is available in either is a diaphragm-assisted solenoid valve, a small amount of gas an angled (standard) or straight (optional) configuration. will exit from the vent orifice each time the valve opens. 2. Connect the main trains at the unions (Figure 5). To avoid damage to gas train components, do not hold compo- Gas train installation (shown with straight gas train) Figure 5 nents with a pipe wrench or overtighten. Use only a crescent wrench or other means. Failure to comply could result in severe Connect pilot gas train at union personal injury, death or substantial property damage.
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Page 13: Install Gas Piping
3. Install gas piping Connecting gas supply piping to burner Figure 5A Connect from the gas supply to the burner gas train (shown with angled 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. - Page 14 3. Install gas piping (continued) Capacities of black iron pipe, cubic feet gas/hour Gas train pressure drop Table 3 Figure 6 NATURAL GAS Capacities in Cubic feet per hour for Schedule 40 metal pipe Total length of gas piping, Pipe size from meter to burner connection (feet) (inches) Natural gas @ .60 specific gravity, pressure drop 0.3 in.
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Page 15: Wire The Burner
4. Wire the burner — RM7897C primary control Turn off power to appliance when servicing burner. Failure to comply could result in severe personal injury, death or substantial property damage. Figure 7 702GAS 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);... - Page 16 1. To take advantage of the energy-saving potential of the Model 701GAS 4. The burner includes a pre-wired manual high-fire switch. Close this switch burner, it should be wired to operate at low-high-low cycles. The firing to hold the burner in high fire mode. Open the switch to hold the burner cycle can be much longer using low-high-low firing, because the burner in low fire mode. can cycle to low fire as demand decreases. This keeps the burner on longer, reducing cyclic losses. Figure 8 702GAS Mass Code wiring diagram (burners with RM7897C primary only); see Figure 8A for a legend to callouts Legend for Figure 8 Figure 8A – 16 – MN702GE 060320...
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Page 17: Checkout Procedure - Before Starting The Burner
5. Checkout procedure — before starting the burner Gas lines in good condition, sized and designed correctly? Before firing the burner . . . ❏ ❏ Gas line connections and fittings tight? Should overheating or an emergency occur, immediately do the following: Burner, appliance and all components inspected and in good ❏ • Shut off gas supply valves. condition? • Under some circumstances power should remain on for water pumps or blowers. Determine proper response Appliance limit and operating controls properly installed, wired and ❏ before attempting start-up. adjusted? • If burner fails ignition on several attempts, use burner blower to purge appliance chamber before restart. -
Page 18: Set Burner Initial Head And Damper Positions
6. Set burner initial head and damper positions (continued) Set air damper (low fire position) Set air damper linkage Figure 10A See Figure 10. Adjust the blue cam on damper motor until the air opening between the damper blade and the damper housing equals the initial low-fire opening in Table 5. Set air damper linkage Make sure Air Damper Linkage is set at ¾" from the top of the Damper Motor 3/4" and the bottom of the linkage screw (see Figure 10A). If your settings are off, loosen the two hex head screws found on the linkage arm bosses at the top and bottom of the Air Damper Linkage. Adjust the linkage accordingly, then tighten screws to set position. Set initial low fire air damper setting Figure 10 Determining final adjustments The burner is now adjusted to the approximate air settings for the firing rate... -
Page 19: Adjust The Burner Using Test Instruments
7. Adjust the burner using test instruments The settings given in Section 6 are initial settings only. You must use test instruments to check combustion, and adjust the burner as necessary, following the procedures given in the following pages of this manual. Failure to properly adjust the burner can result in severe personal injury, death or substantial property damage. Adjustment procedure, summary Step 1: Set gas pilot operation. See details following. Step 2 Set high-fire gas flow to match high-fire air. See details following. Step 3 Adjust the butterfly valve linkage to match low-fire gas to low-fire air. See details following. Step 4: Verify operation of burner, appliance, and controls. Use test instruments 1. Use combustion test equipment and an accurate manometer or draft gauge to correctly set the burner as required. - Page 20 7. Adjust the burner using test instruments (continued) Pilot Test Port Figure 12 Check all joints with a soap suds mixture or electronic gas leak detector to ensure the gas train and all compo- nents are tight and leak-free. Shut down the burner and correct any leak immediately. Failure to comply could result in severe personal injury, death or substantial property damage. Step 1 Check gas pilot operation The Model 702GAS uses a gas pilot for ignition of the gas main flame. The gas pilot is ignited by the pilot electrode. The butterfly gas valve is factory set to a preliminary setting of 30% open for low fire, and 100% open for high fire. 1. Make sure the gas line has been completely bled. Then turn the service switch to ON. 2. The pilot will usually light the first time once the pilot gas train has been completely purged of air. 3. The pilot flame is approximately 70 MBH. If the pilot fails to light, be sure 3. Check the flame signal after the pilot has shut down to ensure the signal the gas line has been bled properly. If the primary control is equipped is still strong with main flame on.
- Page 21 7. Adjust the burner using test instruments (continued) To adjust the linkage, loosen set screw in the adjustable link in 12. With the burner running in high fire, adjust the main gas pressure small increments. A 1/8-inch move can cause CO to change regulator to achieve: as much as 1.5%. Natural gas: 9.6% to 10.0% CO • If more gas is needed (to increase CO ), slide linkage UP. Propane: 10.7% to 11.2% CO • • If less gas is needed (to decrease CO ), slide linkage DOWN. Measure the CO content. It should be no greater than 100 PPM. • • 6. Tighten the set screw in the adjustable link. High CO readings may indicate the combustion is on the wrong 7.
- Page 22 7. Adjust the burner using test instruments (continued) Step 4 Combustion/ventilation air Verify combustion/ventilation air openings are not, and will not be ob- ❏ Verify operation structed. Verify air opening louvers are fully open. ❏ Burner/appliance/controls operation ❏ If louvers are motor-operated, verify motor and end switch are interlocked with appliance/burner wiring to prevent operation of the burner if the air Test operating and limit controls on appliance as specified in appliance ❏ louvers are not fully opened. instructions. Check operation of the primary control by forcing lockout to occur. For ❏ Prepare burner for normal operation primary controls that enter latch-up after multiple lockouts, force latch-up ❏ Cycle burner off with appliance controls. to occur as well. Reset primary control per control data sheet instructions Turn off power to the appliance. ❏...
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Page 23: Maintenance And Service Procedures
8. Maintenance and service procedures When servicing the burner . . . Motor maintenance • Refer to motor manufacturer’s instructions for oiling the motor as needed. DISCONNECT ELECTRICAL SUPPLY and all other electrical connec- • tions to burner before attempting to service to avoid electrical shock or Checking ignitor possible injury from moving parts. Never test an ignitor by placing a screwdriver (or other metallic CLOSE all manual gas valves before disconnecting any portion of fuel • object) across the high voltage clips. This could cause ignitor lines and before cleaning or removing any parts from the burner or damage or severe personal injury. related equipment. 1. Turn off the power to the burner/appliance. - Page 24 8. Maintenance and service procedures (continued) Annual start-up and service Remove combustion head assembly to clean and adjust if necessary. ❏ This burner must be started and serviced at least annually by (See above.) a qualified service technician. Failure to properly maintain and service the burner could result in severe personal injury, death If the inside surface of the air tube and/or retention ring need to be ❏ or substantial property damage. cleaned, clean them with a vacuum cleaner with brush attachment while the combustion head assembly is out of the burner. ❏ Discuss burner/appliance operation with user to determine any problems that may have occurred during the previous season and to verify user is Close the housing cover plate and secure in place. ❏ aware of proper operation and care of the burner/appliance. Perform the complete checkout procedures of pages 16, including system ❏...
- Page 25 8. Maintenance and service procedures (continued) Installation/service certificate Installation data Burner model Serial number Measured gas firing rate, Manifold gas pressure, Inlet gas pressure, IWC Btuh IWC (High fire/Low fire) Were limit controls tested? Gas Low Fire: ______ Gas Low Fire: ______ Gas High Fire: ______ Gas High Fire: ______ Comments about installation/start-up:...
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Page 26: Repair Parts
ST7800A1054 Timing Card 51562S external pilot, 4" UTL EMX51UVS EMX51UV KIT includes all of the above 51575BS 14" Combustion Head Assembly for 702GAS 27706S Motor: 1/2 hp, 115/230V, 60HZ, 1 Phase, 3450 rpm 4180002FS Gas Ignitor Blower Wheel, Coupling, Augmentor, 98857KITS... - Page 27 For parts not shown or listed, contact factory and/or check separate documentation supplied with appliance/burner unit. 9. Repair parts (continued) PHOTO TO COME ITEM PART NO. DESCRIPTION 35824S Motor Contactor 20 AMP R4242B1005 EMX51UVS EMX51UV KIT includes all of the below 35311S C7027A1023 UV Scanner 97656S Q7800B1003 Sub Base 99766S RM7897C1000 Programming Control 97662S R7849A1023 Amplifier 97716S ST7800A1054 Timing Card Consult Factory...
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Page 28: Dimensions
10. Dimensions Dimensional data Figure 14 – 28 – MN702GE 060320... - Page 29 10. Dimensions (continued) Dimensional data, angled gas train Figure 14A – 29 – MN702GE 060320...
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Page 30: User Care And Maintenance
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. Failure to comply could result in severe personal injury, death or substantial property dam- age. For other than routine maintenance, contact a qualified service company. Perform the following as needed. • Keep the area around the burner clear and free from combustible vapors and liquids. • Do not obstruct the flow of combustion and ventilating air.
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