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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.
801GAS
MODEL
Advanced Combination
Low-High-Low Step Modulating
Low Rate (Model 52600A)
1400
to
High Rate (Model 52600B)
2100 to 2500 MBH
In struction
Check burner cartons carefully. The Model 801GAS
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
Gas Burners
2100 MBH
Manual
North Haven, CT 06473
Fx 203-680-9403
carlincombustion.com
™
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Table of Contents
Related Manuals for Carlin 801GAS
Summary of Contents for Carlin 801GAS
- Page 1 2100 MBH High Rate (Model 52600B) 2100 to 2500 MBH In struction Manual Except where specifically stated otherwise, this manual Check burner cartons carefully. The Model 801GAS 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 In the state of Massachusetts, this product must be assembled gas train, the train was pressure tested installed by a licensed Plumber or Gas Fitter.
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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 Should overheating occur: 1. The Carlin Model 801GAS combination gas burner .....4 (1) Shut off the gas supply to the burner. (2) DO NOT shut off the control switch to the boiler circulator or the burner. 2. Prepare site • assemble burner • mount burner ...5 Follow the guidelines below to avoid potential severe 3. Install gas piping ..............11 personal injury, death or substantial property dam- age. 4. Wire the burner ..............12 Installer/service technician . -
Page 3: General Information
Reduce nozzle/firing rate when required — Maximum burner capacity is reduced when overfire pressure is positive and for Burner labels list compliance, when required, with special local, state • altitudes above 2,000 feet. See below, and adjust firing rate/ or provincial approvals. nozzle selection if necessary. Install this burner in accordance with all local codes and 801GAS – Maximum firing rate for authorities having jurisdiction. Regulations of these authori- positive overfire pressure and high altitutde ties take precedence over the general instructions provided 2520 in this manual. 2380 United States installations... -
Page 4: The Carlin Model 801Gas Combination Gas Burner
1. The Carlin Model 801GAS burner 801GAS overview Gas pressure requirements The Model 801GAS burner is a low-high-low (step modulating) burner that The 801G/O burner requires 3.4" w.c. minimum pressure at the butterfly utilizes a damper motor to control air (and gas fuel rate). The burner operates valve during high fire. Select a gas train that has a pressure drop no more on gas (natural or propane). than the available pressure at the gas train inlet minus the 3.4" needed at the butterfly valve. See page 12 for gas train pressure drop information. The Gas mode operation burner is equipped with a 1 ⁄ " gas train unless a larger gas train is ordered. Ignition for main flame is accomplished by a proved gas pilot of approximately Example: A boiler has an input rating of 2,500,000 Btuh. Gas pressure 75,000 Btuh. Pilot gas is introduced at the side of burner airtube assembly... -
Page 5: Prepare Site • Assemble Burner • Mount Burner
2. Prepare site • assemble burner • mount burner Vent system Vent and vent connector installations, typical Figure 1 Vent/chimney sizing 1. Follow all local codes when sizing the vent and chimney. 2. Refer to the appliance manufacturer’s manual, when available, for venting recommendations. 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- factuer’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. - Page 6 2. Prepare site • assemble burner • mount burner (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 property damage. Follow all applicable codes and available) to size combustion air openings. Use the following guidelines when guidelines below to ensure space has sufficient air appliance instructions are not available.
- Page 7 2. Prepare site • assemble burner • mount burner (continued) Prepare the appliance Ceramic fiber or Burner input: Install a burner sized for the normal input rating of the appliance. Do not install a burner with a higher firing rate Fiberglass insulation than the appliance rating. Do not install a burner with a firing rate more than 10% lower than the appliance rating. The appli- ance and vent system could be damaged due to condensation. Ceramic fiber materials, such as chamber liners, may Clean the appliance: Clean the appliance thoroughly. Test all contain carcinogenic particles (chrystobalites) after electrical components and verify the relief valve works (boilers exposure to heat. Airborne particles from fiberglass only). 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 8. Install or replace chamber liner if required by the appliance manufacturer. The Avoid breathing dust and avoid contact with skin or...
- Page 8 2. Prepare site • assemble burner • mount burner (continued) Combustion chambers should be sized as recommended in Minimum combustion chamber dimensions Table 2 Table 2A and 2B. They should be constructed of refractory materials with the capacity to withstand 2600°F or higher. TABLE 2A 801GAS MINIMUM DIMENSIONS RECOMMENDED IN REFRACTORY It is difficult to include all possible chamber constructions in this COMBUSTION CHAMBERS–(Inches) manual. Therefore, you should use the information presented in this manual combined with commonly practiced techniques when determining chamber design. If certain conditions are in Minimum question, consult the factory.
- Page 9 2. Prepare site • assemble burner • mount burner (continued) Inspect burner and components Fire assembly spacing Figure 3 Check the air tube length. Verify the insertion length of the tube UTL will • be long enough (see “Mount burner in appliance”). 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. • Do not install or operate the burner if any component is dam- aged or if burner does not comply with other guidelines of this manual and the appliance manual. Mount burner in appliance Welded-flange burners 1. Verify the bolt pattern on the appliance chamber matches the flange pattern.
- Page 10 2. Prepare site • assemble burner • mount burner (continued) Install gas train on burner Gas train installation (shown with angled gas train) Figure 4 1. The standard burner gas train is shipped fully assembled, with the piping Connect pilot gas disconnected at the gas train unions. See separate instructions if installing train at union an optional knocked down gas train. The gas train is available in either an angled (standard) or straight (optional) configuration. 2. Connect the main and pilot gas trains at the unions (Figure 4). To avoid damage to gas train components, do not hold compo- nents with a pipe wrench or overtighten. Use only a crescent wrench or other means. Failure to comply could result in severe personal injury, death or substantial property damage.
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Page 11: Install Gas Piping
3. Install gas piping Piping from gas meter to burner Connecting gas supply piping to burner Figure 5 1. Verify the gas train on the burner is correctly sized. The gas train pres- (shown with angled gas train) sure drop must not be more than the gas pressure at the burner gas train entrance minus 3.4" w.c. (pressure required at entrance to butterfly valve). See Figure 6 for gas train pressure drop information. The standard gas train is 1 ⁄ inch. 2. If possible, install a new gas line directly from the gas meter. If you are using an existing gas line, verify it is clean and in good condition, and verify it is large enough to handle the load of all connected appliances. 3. When branching from a common gas line, do not tap off from the bottom of horizontal sections — only from the side or top. 4. Install a main manual shutoff valve, sediment trap and ground joint union near the burner gas train connection as shown in Figure 5. -
Page 12: Wire The Burner
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. - Page 13 Figure 7 to comply could result in severe personal injury, death or substantial property damage. Figure 8 801GAS 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 7 for a legend to callouts.
- Page 14 1. To take advantage of the energy-saving potential of the Model 801GAS 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 9A 801GAS Mass Code wiring diagram (burners with RM7897C primary only); see Figure 9 for a legend to callouts Figure 9 Legend for Figure 9A – 14 – MN801GAS 060520...
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Page 15: Checkout Procedure - Before Starting The Burner
5. Checkout procedure – before starting the burner Burner nozzle verified per appliance manufacturer’s instructions, ❏ Before firing the burner . . . Gas lines in good condition, sized and designed correctly? ❏ Should overheating or an emergency occur, immediately do the following: Gas connections and fittings tight? ❏ • Shut off gas supply valves. • Under some circumstances power should remain on for ❏ Burner, appliance and all components inspected and in good water pumps or blowers. Determine proper response condition? before attempting start-up. • If burner fails ignition on several attempts, use burner Appliance limit and operating controls properly installed, wired and ❏... -
Page 16: Set Burner Initial Head And Damper Positions
6. Set burner initial head and damper positions Set the air damper linkage Follow the procedures given here and on the following 1. Make sure Air Damper Linkage is set at 1/2" from the top of the Damper pages to ensure the burner is correctly adjusted. Take Motor and the center of the linkage screw (see figure 11A). If your set- your time and the burner should operate properly and tings are off, loosen the two hex head screws found on the linkage arm you will avoid return service calls. bosses at the top and bottom of the Air Damper Linkage (see figure 11 for bottom example). Adjust the linkage accordingly, then tighten screws You must perform the adjustments in the sequence to set position. given in this manual. Failure to follow the correct procedures could result in Determining final adjustments severe personal injury, death or substantial property 1. The burner is now adjusted to the air settings for the firing approximate damage. rate used. Follow the procedures on the following pages to use test instruments and make final burner adjustments. - Page 17 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 1 Step 4: Verify operation of burner, appliance, and controls. Check gas pilot operation Use test instruments The Model 801GAS uses a gas pilot for ignition of the gas main flame. The gas pilot is ignited by the pilot electrode. 1. Use combustion test equipment and an accurate manometer or draft gauge to correctly set the burner as required. 1. Make sure the gas line has been completely bled. Then turn the service switch to ON. 2. Overfire pressure must not exceed the appliance manufacturer’s recom- 2. The pilot will usually light the first time once the pilot gas train has been mendations. The burner must never be fired at an overfire pressure more...
- Page 18 7 Adjust the burner using test instruments (continued) Step 2 Step 3 Set main gas pressure regulator Set butterfly gas valve linkage 1. Switch the low-fire hold switch to low fire. The butterfly gas valve is factory set to a preliminary setting of 2. Check CO and CO. The CO should be between 9.0% and 10.0% (natural 30% open for low fire, and 100% open for high fire. The pilot gas) or between 10.0% and 11.2% (propane); with CO less than 100 PPM. regulator is set for 3.0 inches w.c. Use manometer inthe pilot test port (Figure 12A) provided to confirm settings. 3. To adjust the low-fire air (change CO ), move the burner fuel selector switch to OFF. Adjust the butterfly gas valve linkage as described in 1.
- Page 19 7. Adjust the burner using test instruments (continued) Step 4 Step 3a Verify operation Verify operation Burner/appliance/controls operation Perform all of the checkout procedures given in Step 6 of the burner manual. In addition, verify operation of the gas pressure Test operating and limit controls on appliance as specified in appliance ❏...
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Page 20: Maintenance And Service Procedures
8. Maintenance and service procedures Turn off power to appliance when servicing burner. A fter servicing, Removing the combustion head assembly always operate burner/appliance to verify all components are 1. To check the electrode settings or change the nozzle, you must remove functioning correctly and that the burner is properly adjusted. the combustion head assembly from the air tube. Follow the steps below, Failure to comply could result in severe personal injury, death and reverse the sequence to reassemble. or substantial property damage. 2. Shut off the burner. General maintenance 3. Remove the two housing cover locking screws and swing the housing open. Cleaning blower wheel 4. Partially remove the combustion head assembly, and disconnect the two 1. The blower wheel accumulates dust and debris from normal operation. ignition cables from the electrodes and thermal fuse wire. You will need to clean the wheel blades periodically to prevent reduction 5. Remove the combustion head assembly from the tube. in airflow. Inspect the blower wheel regularly by opening the housing cover. - Page 21 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 22: Dimensions
9. Dimensions Dimensional data Figure 14 – 22 – MN801GAS 060520... - Page 23 9. Dimensions (continued) Dimensional data, angled gas train configuration Figure 19 – 23 – MN801GAS 060520...
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Page 24: Repair Parts
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 PART NO. DESCRIPTION 27730S Motor: 3/4HP 115/208-230V 60HZ, 1 Phase, 3450 RPM 51564S 15" Tube with pressurized flange 1-1/2" main gas inlet; external pilot; 4" UTL 98522S Air Flow Switch 120 Volt 51573S Gasket 51317S... - Page 25 For parts not shown or listed, contact factory and/or check separate documentation supplied with appliance/burner unit. 10. Repair parts (continued) – 25 – MN801GAS 060520...
- Page 26 ** To rotate damper and cam stack by hand, disengaging pin must be pushed in. The pin must be out when the burner is operating **Transition cam sets the transition point between Low Fire and High Fire © Tech support 800-989-2275 carlincombustion.com Copyright 2020 – Carlin Combustion Technology...
- Page 27 Settings Color Position 701CRD, 801CRD,1050FFD, 702GO, 702GAS, All Carlin burners with the SQN71 damper 702CRD 1150FFD 801GO, 801GAS motor should be set at the recommend High-Fire 60-70 settings shown in the table at the right.
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Page 28: User Care And Maintenance
801GAS 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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