Carlin Combustion Technology 702 Installation guide

Brand: Carlin Combustion Technology

Model: 702

Type: Installation guide

Instruction manual

™

126 Bailey Road North Haven, CT 06473

Ph 203-680-9401 Fx 203-680-9403

Carlin Combustion Technology, Inc.

Tech support 800-989-2275 carlincombustion.com

 Exceptwherespecicallystatedotherwise,thismanual

mustbeusedonlybyaqualied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.

 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.

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14

– 2 –

Where appliance instructions differ from this manual, follow the appliance instructions.

Contents

PLEASEreadthisrst.................................................................2

Generalinformation.....................................................................3

1. TheCarlinModel702G/Ocombinationgas/oilburner...........4

2. Preparesite•assembleburner•mountburner.............6

3. Installgaspiping...................................................................12

4. Installoilpiping.....................................................................14

5. Wiretheburner.....................................................................16

6. Checkoutprocedure—beforestartingtheburner...............18

7. Setburnerinitialheadanddamperpositions.......................19

8. Adjusttheburnerusingtestinstruments..............................20

9. Maintenanceandserviceprocedures..................................24

10.Repairparts........................................................................26

11.Dimensions.........................................................................30

Usercareandmaintenance........................................ Rearcover

PLEASE read this rst . . .

Special attention ags . . .

Pleasepayparticular attention to the following when you see them

throughoutthismanual.

 NotiesyouofhazardsthatWILLcauseseverepersonal

injury,deathorsubstantialpropertydamage.

 NotiesyouofhazardsthatCANcauseseverepersonal

injury,deathorsubstantialpropertydamage.

 Notiesyou of hazards that WILLor CAN cause minor

personalinjuryorpropertydamage.

 Notiesyouofspecialinstructionsoninstallation,operation

ormaintenancethatareimportant, but are not normally

relatedtoinjuryorpropertydamagehazards.

Before installing or

servicing:

 Shouldoverheatingoccur:

 (1)Shutofftheoilandgassuppliestotheburner.

 (2)DONOTshutoffthecontrolswitchtotheboiler

circulatorortheburner.

 Followtheguidelinesbelowtoavoidpotentialsevere

personalinjury,deathorsubstantialpropertydam-

age.

Installer/service technician . . .

• Readallinstructionsbeforeproceeding.Performallprocedures,

andintheordergiventoavoidpotentialofseverepersonalinjury,

deathorsubstantialpropertydamage.

• Beforeleavingthesiteafterstartuporservice,reviewtheUser

careandmaintenancepagewiththeuser.Maketheuseraware

ofallpotentialhazardsandperformthetrainingoutlinedbelow.

Installer/service technician —

Train the user . . .

• Toproperlyoperatetheburner/applianceperthismanualand

theapplianceinstructions.SeeUsercareandmaintenance.

• Tokeepthismanualatorneartheburner/applianceforready

accessbytheuserandservicetechnician.

• Tocontacttheservicetechnicianoroildealerifheencounters

problemswiththeburner/appliance.

• Tokeeptheappliancespacefreeofammableliquidsorvapors

andothercombustiblematerials.

• Toneveruselaundryproducts,paints,varnishesorotherchemi-

calsintheroomoccupiedbytheburner/appliance.

• Tocontacttheservicetechnicianatleastannuallyforstartupand

burner/applianceservice.

When servicing the burner . . .

• DISCONNECTELECTRICALSUPPLYandall otherelectrical

connectionstoburner before attempting toserviceto avoid

electricalshockorpossibleinjuryfrommovingparts.

• CLOSEallmanualgasandoilvalvesbeforedisconnectingany

portionoffuellinesandbeforecleaningorremovinganyparts

fromtheburnerorrelatedequipment.

• Burnerandappliancecomponentscanbeextremelyhot.Allow

allpartstocoolbeforeattemptingtohandleorservicetoavoid

potentialofsevereburns.

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14 – 3 –

Where appliance instructions differ from this manual, follow the appliance instructions.

Burner applications

Followallinstructionsinthismanual,theprimarycontroldatasheetand

theappliancemanual.

Verifytheburneriscorrectfortheappliancebeingusedandforallap-

plicablecodes/standards.

Adjustthenozzleselection/ringrateifnecessaryduetopositiveoverre

pressureand/oraltitudesmorethan2,000feetabovesealevel.Seethe

NOTICEundertheRatingsinformationatright.Whereapplianceappli-

cationinformationisavailable,therecommendedringrateandburner

informationwillincludeappropriate adjustments for positive overre

pressureandrecommendationsforhighaltitudes.Followtheappliance

manualguidelineswhenavailable.

Damage or shortage claims

Theconsigneeoftheshipmentmustledamageorshortageclaims

immediatelyagainstthetransportationcompany.SeetheNOTICEon

page1forburnercartoninformation.

When calling or writing about the

burner:

PleaseprovideuswiththeULserialnumberandburnermodelnumber

toassistusinlocatinginformation.Thisinformationcanbehelpfulwhen

troubleshootingorobtainingreplacementparts.

Codes and standards

Certiﬁcation

702G/OburnersareU.L.listedfortheU.S.,certiedtocomplywith:

• ANSI/UL296,forusewith#1or#2heatingoil(perstandardASTMD396).

• UL795,forusewithnaturalgasorpropane.

• Burnerlabelslistcompliance,whenrequired,withspeciallocal,state

orprovincialapprovals.

 Installthisburnerinaccordancewithalllocalcodesand

authoritieshavingjurisdiction.Regulationsoftheseauthori-

tiestakeprecedenceoverthegeneralinstructionsprovided

inthismanual.

United States installations

Burner/applianceinstallationsintheUnitedStatesmustcomplywiththe

latesteditionsof:

• InstallationofDomesticGasConversionBurners,ANSIZ21.8.

• NationalFuelGasCode,ANSIZ223.1/NFPA54.

• StandardfortheInstallationofOil-BurningEquipment,NFPA31

• NationalElectricalCode,ANSI/NFPA70.

• Alladditionalapplicablenational,stateandlocalcodes.

Ratings

(With0.00”w.c.overrepressure,altitude2,000feetmax.;seeNOTICE

below)

Oil Input

................................................................Highre:6.0to11.2GPH

................................................................. Lowre:3.5to6.5GPH

Gas Input

............................................................ Highre:840to1,600MBH

...............................................................Lowre:490to940MBH

Fuels

......................................................................No.1orNo.2Fueloil

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

Fuel unit & oil valves:

................ Fuelunit,2-stage, 300 psig(withinternalblockingvalve)

..................................................................... (2)Oilsolenoidvalves

Gas train: (availableinstraightorangledconguration)

............................(2)Maingasvalves&RV-61orRV-81regulator

............................................ Butterygasvalveforinputregulation

................ 1"gastrainstandard;1¼",1½"or2"gastrainavailable

Electrical

 Power............................................................. 120V/60Hz/1-Phase

 Limitcircuitinput(RM7895CorRM7897C).............. 120vac/60hz

 Controlcircuitload(120vac)............................................. 1.2 amps

 Motor................................... 1/2 hp, 3450 rpm, 48-frame, “N” flaNge

.............................. 115 / 208-230 vac/60 hz/1-ph, 8.4 / 3.8-4.2 amps

 Oilvalve/gasvalvepower.......................................... 120 vac/60 hz

 Dampermotor(withendswitch).........................hoNeywell m436a

Ignition & primary control

.............................CarlinModel41000solidstateelectronicignitor

 Ignitionvoltage............................................................. 14,000volts

 Primarycontrol...............................................HoneywellRM7897C

Agencies

................................................................................. ULListed(US)

Reducenozzle/ring rate whenrequired— Maximum burner

capacityisreducedwhenoverrepressureispositiveandfor

altitudesabove2,000 feet. See below,and adjustringrate/

nozzleselectionifnecessary.

702G/O — Maximum firing rate for

positive overfire pressure and high altitude

Overfire pressure (Inches w.c.) Oil – GPH Gas – MBH

0.00 11.2 1,600

0.10 10.9 1,530

0.20 10.7 1,500

0.30 10.6 1,480

0.40 10.3 1,440

0.50 10.2 1,430

0.60 9.9 1,390

Altitudes:For altitudes more than 2,000 feet above sea level, reduce the above

capacities an additional 4% per 1,000 feet higher than 2,000 feet

above sea level.

General information

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14

– 4 –

Where appliance instructions differ from this manual, follow the appliance instructions.

702G/O overview

TheModel702G/Ocombinationgas/oilburnerisalow-high-low(step

modulating)burnerthatutilizesadampermotortocontrolair(andgasfuel

rate).FuelisselectedusingtheGas/oilchangeoverswitch.Theburner

operatesoneither#2fueloilorgas(naturalorpropane).

Seethenextpageforgastraincomponentlocations.

Gas mode operation

Ignitionformainameisaccomplishedbyaprovedgaspilotofapproxi-

mately280,000Btuh.Pilotgasisintroducedatthemainburnerame

retention ring, and is ignited by a Carlin 14,000-volt electronic ignitor

wiredtothetwoelectrodes.Afterthepilotameisproven,thetwomain

gassafetyvalvesopen.Thepilotgasvalveclosesafteratimedelayto

allowmainametoestablish.Flameismonitoredbothforpilotameand

mainamewithaUVscannermountedtotheundersideoftheburner

combustionheadassembly.Theburnermainamebeginsatlowre.

Ifadditionalinputisrequired,thedampermotoropensthegasbuttery

valveandairdampertotheirhighrepositions.

Gasisintroducedintotheburnerthroughamanifoldaroundtheairtube.

Thegasthencirculatesthroughasetoffouroricespudsintotheair

stream,aheadoftheretentionring.Thespinoftheairowattheretention

ringthoroughlymixesthegas/airbeforeitreachesthecombustionzone.

Oil mode operation

OilignitionisaccomplishedbytheCarlin14,000-voltelectronicignitor

wiredtothetwoelectrodes.Theoilamebeginsatlowre,with100psig

oilpressureatthenozzle.Ifadditionalinputisneeded,thedampermo-

toropenstheairtothehighreposition.Thedampermotorendswitch

energizesthe2ndstageoilvalve(fuelunitblockingvalve)asthedamper

approachesitshighreposition.Thisprovides300psigpressuretothe

oilnozzleforhighre.FlameismonitoredbytheUVscannermounted

totheundersideofthecombustionheadassembly.

Firing rate adjustment

• Firingrateisdeterminedbytheoilnozzle.Airowismatchedtotheoil

owforoilring.Thengasowisadjustedtomatchtheairowatlow

andhighrerates.

• Seethe“Startingandoperating”sectionofthismanualforthecomplete

descriptionoftheadjustmentprocess.Thefollowingisabriefsummary

only.

• High-reairissetbyadjustingthecombustionheadposition(tocontrol

airowthroughandaroundtheretentionring).

• Low-reairisthenadjustedbyne-tuningthepositionofthelowre

adjustingscrew.

• Pilotgasowissetforasmoothlight-off.Thengasinputsareadjusted

forgoodcombustionatlowandhigh-reairsettings.

1. The Carlin Model 702G/O combination gas/oil burner

702G/O oil nozzles

 Usetheselectionsbelowwhentheheatingequipment

manufacturer’sspecicnozzleselectiondataisnotavailable,

eitherintheequipmentmanualortheCarlinOEMSpec

Guide.Followallinstructionsprovidedwiththeappliance.

Nozzle speciﬁcations

• Preferred— Hago45°SS

• Alternate— Hago45°PorMonarch45°PLP

Nozzle ratings

Fullinput(highre)occursat300psignozzlepressure.Sincenozzles

areratedat100psig,theactualowat300psigisapproximately73%

higherthan therated nozzlecapacity.See thetable belowfornozzle

ratingselections.

Table 1 702G/O oil nozzles

Oil Nozzle Sizing

Equipment

Input rating

GPH

Recommended

nozzle rating

GPH

Low fire

input

(100 psig)

High fire

input

(300 psig)

6.00 3.50 3.50 6.00

6.50 3.75 3.75 6.50

6.90 4.00 4.00 6.90

7.80 4.50 4.50 7.80

8.70 5.00 5.00 8.70

9.50 5.50 5.50 9.50

10.40 6.00 6.00 10.40

11.20 6.50 6.50 11.20

1. For a packaged appliance application on which the burner has been tested, use the noz-

zle given in the appliance manufacturer's instructions or supplement for the best

results.

Gas pressure requirements

The702G/Oburnerrequires3.4"w.c.minimumpressureatthebuttery

valveduringhighre.Selectagastrainthathasapressuredropno

morethantheavailablepressureatthegastraininletminusthe3.4"

neededatthebutteryvalve.Seepage13forgastrainpressuredrop

information.Theburnerisequippedwitha1"gastrainunlessalarger

gastrainisordered.

Example:Aboilerhasaninputratingof1,300,000Btuh.Gaspressure

availableatthe gas trainentranceis6.0" w.c.Subtract3.4” from the

available6.0"w.c.Thegastrainpressuredropmustbe2.6”orless.A1"

gastrainhasapressuredropof3.3"w.c.,andcannotbeused.Selecta

1¼"RV-61regulatorgastrain,whichhasapressuredropof0.87"w.c.

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14 – 5 –

Where appliance instructions differ from this manual, follow the appliance instructions.

1. The Carlin Model 702G/O combination gas/oil burner (continued)

1 Castaluminumburnerhousing

2 Airtube(withgasmanifold)

3 Burnerange

4 Burnermotor

7 Ignitor,Carlin41000

8 Dampermotor

9 Airdamper&lowre

adjustingscrew

10 Airdamperlinkage

11 Airowswitch

12 Controlpanel(connectionfor120

vacpowerand120vaccontrol

andlimitcircuitinputfromboiler)

13 Gas/oilchangeoverswitch

14 Lowreholdswitch(LFS)

20 Fuelpump

21 Combustionheadassembly

22 Oilvalvejunctionbox

23 1ststageoilvalve

24 Safetyoilvalve

25 2ndstageoilvalve(fuel

unitblockingvalve)

29 Gasmanifold

30 Gasspuds(4required)

31 Gasbutteryvalve

32 Butteryvalvelinkage

33 Union

34 Gasshut-offvalve(with

2testtappings)

35 Automaticgasvalve(diaphragmtype)

36 Automaticgasvalve

37 Gastrainjunctionbox

38 Gaspressureregulator

39 Manualgasvalve(with

twotesttappings)

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

62 Nozzleline

63 Electrodeleadwires

64 Thermalfuse

65 Electrodeceramicinsulators

66 Electrodes

67 Electrodeclamp

68 Nozzleadapter

69 Nozzle

70 Retentionringassembly

71 UVscannertube/adapter

72 UVscanner

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14

– 6 –

Where appliance instructions differ from this manual, follow the appliance instructions.

2. Prepare site • assemble burner • mount burner

Vent system

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

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uctuations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inthetopof

thedraftregulatoroutlet.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ueoutlet.

Clearances

Check codes, standards and the equipment

manual

• Verifythattheburner/appliancewillmaintainallclearancestocombustible

wallsoroor and allclearancesrequired for service/maintenanceas

requiredintheappliancemanualandapplicablecodes.

Inspect, repair and/or replace vent

system

 Donotinstallthisburnerunlessyouhaveveried

theentireventsystemandtheapplianceareingood

conditionandcomplywithallapplicable codes.

And...

 Thevent and chimney must be sized and con-

structedinaccordancewithallapplicablecodes.If

intendedforusewithanoilburneraswell,thevent

systemmustcomplywithrelevantcodesforboth

gasandoilring.

 Theventsystemmustnotbepressurizedunless

theventpipingandventsystemaredesignedac-

cordingly.Theventmustprovidedraftatalltimes

(negativepressureinvent).

 Donotinstalloruseanexistingmanualdamperin

theventconnectororvent.

 Donotconnecttheapplianceventconnectortoa

chimneyorventservingareplace,incineratoror

solid-fuel-burningapparatus.

 Inacoldclimate,donotventintoamasonrychimney

thathasoneormoresidesexposedtotheoutside.

Installalistedstainlesssteellinertoventtheue

products.

 Adefectiveventsystemcouldresultinsevereper-

sonalinjury,deathorsubstantialpropertydamage.

Figure 1 Vent and vent connector installations, typical

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14 – 7 –

Where appliance instructions differ from this manual, follow the appliance instructions.

2. Prepare site • assemble burner • mount burner (continued)

Combustion air/ventilation openings

Sizing air openings

Followallapplicablecodesandtheapplianceinstructionmanual(when

available)tosizecombustionairopenings.Usethefollowingguidelines

whenapplianceinstructionsarenotavailable.

• Allairfrominsidebuilding(buildingmustbewell-ventilated):

 Sizeairopeningsforafreearea(afterlouverdeduction)ofatleast1

squareinchper1,000Btuhinputofallappliancesinthespace.

• Allair throughopenings directlyfrom outsidethe buildingthrough an

adjacentoutsidewall:

 Ifairopeningsconnectdirectlytooutside,providetwoopenings,one

within12inchesoftheceiling,theotherwithin12inchesoftheoor.

Eachopeningmusthaveafreearea(afterlouverdeduction)of:

• Ifdirectlythroughside wall:1squareinchfor each4,000Btuhofall

appliancesinthespace.

• Ifthroughverticalducts:1squareinchforeach4,000Btuhofallappli-

ancesinthespace.

• Ifthroughhorizontalducts:1squareinchforeach2,000Btuhofallap-

pliancesinthespace.

Locating air openings

Followallapplicablecodesandtheapplianceinstructionmanual(when

available)tosizecombustionairopenings.RefertoFigure2whenap-

plianceinstructionsarenotavailable.

Estimating free area

Whenspecicinformationonthefreeareaoflouversisnotavailable,

estimatefreeareaasfollows:

1. Woodlouvers—freearea=areatimes0.25.

2. Metallouversorgrilles—freearea=areatimes0.60.

3. Screens,whenusedmustbenosmallerthan¼inchmesh.

Motorized vent dampers

Wiretheventdamperendswitchtopreventoperationoftheburneruntil

theairopeninglouversarefullyopen.

Combustion air/ventilation opening checklist

• Verifythatairopeningsareunobstructed.

• Verifythatappliancespaceandairsourcespacesarefreeof:

• Gasolineorotherammableliquidsorvapors.

• Combustiblematerials.

• Aircontaminants,suchaslaundryproducts,paint,thinner,varnish,etc.

• Conrmwithuserthattheareawillbekeptfreeofthesematerialsat

alltimes.

Figure 2 Locating combustion air/ventilation openings

Appliance

Minimum

24 inches above

grade or snow line

Air opening

Where air opening is high on the wall,

duct to within 12 inches of the floor

 Installingtheburner/applianceinaspacethatdoes

notprovideenoughairforcombustionandventila-

tioncanresultinseverepersonalinjury,deathor

substantialpropertydamage.Followallapplicable

codesandguidelinesbelowtoensurespacehas

sufcientairopenings.

 Exhaustfansandnegativepressureconditions

—Isolatetheboilerroom from areas subject to

negativepressure.Sizecombustionairopenings

toensureneutralairpressureintheboilerroom

whenevertheburneroperates.

 Makesurethespaceprovidesenoughventilation

topreventoverheatingoftheappliance,burnerand

controls.Ifthereisriskofoverheating,youmust

installventilationairopeningssizedlargeenough

toprovideairforcoolingtheequipment.Failureto

provideventilation can result in severe personal

injury,deathorsubstantialpropertydamage.

 Thespaceandcombustionairsupplymustnot

containcorrosive contaminants,suchas laundry

products,paints,varnishesorotherchemicals.

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14

– 8 –

Where appliance instructions differ from this manual, follow the appliance instructions.

Prepare the appliance

 Burnerinput:Installaburnersizedforthenormalinputrat-

ingoftheappliance.Donotinstallaburnerwithahigher

ringratethantheappliancerating.Donotinstallaburner

witharingratemorethan10%lowerthantheappliance

rating.Theapplianceandventsystemcouldbedamaged

duetocondensation.

 Cleantheappliance:Cleantheappliancethoroughly.Test

allelectricalcomponentsandverifythereliefvalveworks

(boilersonly).

 Sealtheappliance:Sealallue-gascontainingjoints.Seal

allconnectionstotheventpipingorbreeching.

 Verify combustion chamber dimensions comply with the

minimumdimensionsrecommendedonpage9.Installor

replacechamberlinerifrequiredbytheappliancemanu-

facturer.Theburnermustnotextendintothecombustion

chamber.Theendoftheburnerairtubemustbewithin¼"

oftheinsidefaceofthechamber.Ifthespacearoundthe

burnerairtubeismorethan¼",wraptheburnerairtube

withminimum2300-°F-ratedceramicberblankettoseal

offthegap.

 Repairorreplacedamagedappliancecomponents.Inspect

theappliancethoroughly.Followappliancemanufacturer’s

guidelinesforrepairorreplacementofanycomponentfound

defective.

 Whencleaningtheapplianceorworkingwithceramicber

refractoriesorberglassinsulation,seeWARNINGonthis

page.

 Failuretocomplywiththe above could result in severe

personalinjury,deathorsubstantialpropertydamage.

Prepare appliance for burner mounting

 Positiveoverre pressure applications: When ring with

positiveoverrepressure,do not exceed the pressure

speciedintheappliancemanual.

 Positiveoverrepressurereducesmaximumburnercapac-

ity.SeePage3forestimatedreductioninburnercapacity

withpressurizedringandhighaltitudeapplications.

 Failuretocomplycouldresultin severe personal injury,

deathorsubstantialpropertydamage.

Ceramic ber or

Fiberglass insulation

Ceramicbermaterials,suchaschamberliners,

maycontaincarcinogenicparticles(chrystobalites)

afterexposuretoheat.Airborne particles from

berglassorceramicbercomponentshavebeen

listedaspotentiallycarcinogenicbytheStateof

California.Take the following precautions when

removing,replacingandhandlingtheseitems.

Avoid breathing dust and avoid contact with

skin or eyes. Wear long-sleeved, loose-tting

clothing,glovesandeyeprotection.UseaNIOSH

N95certifiedrespirator.Thisrespiratormeets

requirementsforprotectionfromchrystobalites.

Actualjob requirements or NIOSH regulations

mayrequireotheroradditional protection.

Forinformation,refertotheNIOSH website,

http://www.cdc.gov/niosh/homepage.html.

Ceramic ber removal:Topreventairbornedust,

thoroughly wet ceramic ber with water before

handling.Placeceramicbermaterialsinaplastic

bagandsealtodispose.

Avoid blowing, tearing, sawing or sprayingber-

glassorceramicbermaterials.Ifsuchoperations

arenecessary, wear extra protection to prevent

breathingdust.

Wash work clothes separately from other laun-

dry.Rinseclotheswasherthoroughlyafterwards

topreventcontaminationofotherclothing.

NIOSH First aid procedures:

 Eyeexposure—irrigateimmediately

 Breathing—freshair.

2. Prepare site • assemble burner • mount burner (continued)

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14 – 9 –

Where appliance instructions differ from this manual, follow the appliance instructions.

2. Prepare site • assemble burner • mount burner (continued)

Figure 3 Chamber dimensions & tube congurations

Table 2 Minimum combustion chamber dimensions

(see Figure 3)

Prepare burner and components

 Donotinstalloroperatetheburnerifanycomponentisdam-

agedorifburnerdoesnotcomplywiththespecicationsof

Table2andotherguidelinesinthismanual.

Combustion chamber minimum dimensions

1. Forapplicationsthathavenotbeenspecicallytested(OEMapplications),

verifythatthecombustionchamberprovidestheminimumdimensions

showninTable2andFigure3.Forspecic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

withthecapacitytowithstand2600°Forhigher.

 Itisdifculttoincludeallpossiblechamberconstructionsinthis

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

question,consultthefactory.

Using chamber linings

1. When using refractorylinersorlightweight chambers, use insulating-

typerefractoryrated2600°Fminimum,orasspeciedbytheappliance

manufacturer.

2. Youmustinstallatargetwalllinerifamelengthisclosetothelength

ofthechamber.

3. Useaoorlinerwhenpossible.Theoorlinerwillimproveringinmost

applications.Extendoorliner3to4inchesupthesidewalls.

4. Targetwallliners—Extendtargetwalllinersatleast3to4inchesabove

thecenteroftheamecorbelthetop1½to2½inchesdeep.

5. Usepreformedchamberlinerswhenavailable.Liningtheoorandtar-

getwallwater-backedcombustionchamberswithlightweightinsulating

refractorywillaccomplishthesame.

6. Whenconvertingcoal-redunits,installacombustionchamberinthe

ashpitarea,orlltheashpitwithsandupto2inchesabovethe“mud

ring”oftheboiler(ringthroughthedoor).Installalightweightrefractory

lineronthetargetwall.

Air tube insertion length (UTL)

1. Usableairtubelength(UTL)isthedistancefrommountingangetoend

ofairtube.Verifythattheendoftheairtubewillbeushwith,ornomore

than¼inchshortof,theinsideoftheappliancecombustionchamberfront

wallwhentheburnerismounted.SeeFigure3forfurtherinformation.

High fire input Refactory combustion chamber applications

(all dimensions in inches)

Oil–GPH Gas–MBH “L” “W” “C” “H”

6.00 840 21 15.0 7.5 15

6.50 910 23 15.5 8.0 16

6.90 966 25 16.0 8.0 16

7.80 1092 28 17.0 8.5 17

8.70 1218 31 17.5 9.0 18

9.50 1330 34 18.0 9.0 18

10.40 1456 38 19.0 9.5 19

11.20 1568 43 20.0 10.0 20

High fire input Refactory combustion chamber applications

(all dimensions in inches)

Oil–GPH Gas–MBH “L”

W/ target

“L”

No target “W” “C” “D”

6.00 840 21 25 17.0 8.5 10.5

6.50 910 23 27 17.5 9.0 11.0

6.90 966 25 29 18.0 9.0 11.0

7.80 1092 28 32 19.0 9.5 11.5

8.70 1218 31 35 19.5 10.0 12.0

9.50 1330 34 38 20.0 10.0 12.0

10.40 1456 38 42 21.0 10.5 12.5

11.20 1568 43 47 22.0 11.0 13.0

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14

– 10 –

Where appliance instructions differ from this manual, follow the appliance instructions.

Inspect burner and components

• Checktheairtubelength.Verifytheusable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

damaged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 ange

pattern.

2. Verify the insertion depth (UTL) matches the depth of the appliance

opening(sotheendoftheairtubeisushwith,orslightlyshortof,the

insidesurfaceofthecombustionchamber).

3. Placegasketontoboilerfrontplate.

4. Slidetheendoftheairtubeintotheopeningandsecuretheangeto

theboilerfrontplate.

Burners with adjustable ﬂanges

1. Verifytheangemountingslotswilllineupwiththeappliancebolts.(See

Figure4foradjustableangedimensions.)

2. Placetheangegasketinpositionontheappliancemountingplate.

3. Measurethedistancefromtheinsideofthecombustionchambertothe

outsideoftheappliancemountingplate.Slidetheadjustableangeon

theairtubeuntilitisthisdistancefromtheendoftheairtube.

4. Markthispositionoftheangeontheairtubewithapencilorpensoyou

canverifytheangeiscorrectlypositionedasyoucompletetheinstalla-

tion.Theendoftheairtubemustbeush,oralmostush,withtheinside

ofthecombustionchamberwall.(SeeFigure3,page9)

5. Tightentheangelockingscrewsngertight.

6. Inserttheairtube/angeassemblyintotheapplianceopening.(Rotate

theangeifneededtoalignwiththemountingbolts.)Securetheange

totheappliancefrontplate.

7. Seethefollowinginstructionstoinstalltheburnerpedestal,neededto

properlysupporttheburner.

 Aforceddraftadjustableangemustbesealedtotheair

tubetopreventpossibleleakageofueproducts.Failure

tocomplycouldresultinseverepersonalinjury,deathor

substantialpropertydamage.

Figure 4 Adjustable ange

2. Prepare site • assemble burner • mount burner (continued)

Install the burner pedestal

 702G/Oburnerssuppliedwithanadjustableangearealso

suppliedwithapedestalforsupporting the burner.(The

pedestalisavailableasanoptionforaburnerequipped

withaweldedange.)

1. Adjustthepedestalsothattheheightoftheairtubematchesthelocation

oftheburneropening.

2. Thepedestalhasapproximately3"ofadjustment.Iftheburneropening

istoohighforthepedestaltorestontheoor,thenconstructabase.

Twosolidcementblocks,sidebyside,isrecommended.Alternatethe

directionaslayersareputdown.

3. Placeaspiritlevelontheairtube.Adjustthepedestalsotheairtube

slopesdownslightlytowardtheappliance.Theslopeshouldbeabout

2degrees.

4. Tightenthepedestalboltsecurely.

Install the oil nozzle

1. Follow the instructions on page 24 to remove the combustion head

assembly.

2. Installandtightenthenozzlelistedintheapplianceinstructionmanualor

theCarlinOEMSpecGuide.Ifnozzleinformationisnotavailable,begin

withthenozzlelistedonpage4.(Youmayhavetochangethenozzle

laterifcombustionresultsarenotacceptable.)

3. Slidetheamescannersightpipeassemblytotherearbylooseningthe

1/8”Allenscrewontheholdingbase.

4. Holdthenozzleadaptersecurelywhenremovingorreplacingthenozzle.

Takecarenottodamagetheelectrodeinsulatorsortobendtheelectrodes

intheprocess.

 Inspectthenozzleadapterbeforereplacingthenozzle.Ifthe

threadshavebeendamagedorshowscoremarks,replace

thenozzleline/adapterassembly.

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14 – 11 –

Where appliance instructions differ from this manual, follow the appliance instructions.

5. Slidetheamescannersightpipeassemblyforwarduntilthe3/8"pipe

tsagainsttheretentionringassembly.Thentightenthe1/8"Allenscrew

tosecurethetubeinplace.

6. Checktheelectrodesandrepositionifnecessary.Positiontheelectrodes

asshowninFigure5.Thesesettingsarecriticalinensuringareliable

ignition.

7. Oncetheelectrodesareset,checkallclampstobesuretheyaresecurely

tightened.

8. Insertthecombustionhead/nozzleassemblyintotheburnerandsecure

inplace.Seeinstructionsonpage24.

Figure 5 Electrode settings

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.

Install gas train on burner

1. Thestandardburnergastrainisshippedfullyassembled,withthepiping

disconnectedatthegastrainunions.Seeseparateinstructionsifinstalling

anoptionalknockeddowngastrain.Thegastrainisavailableineither

anangled(standard)orstraight(optional)conguration.

2. Connectthemainandpilotgastrainsattheunions(Figure6).

 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.

3. Connecttheexibleconduit,pre-attachedtotheburnerJ-box,tothegas

trainJ-box,andattachthewirestotheterminalstripinsidethegastrain

J-box.

a. Matchwirecolorsoftheincomingwirestothosepre-wiredtotheterminal

stripinsidethegastrainJ-box.

b. Seethelabelintheburnerjunctionboxorthewiringdiagramonpage17.

 Gasvalveventopening—TheV48diaphragmgasvalveis

NOTttedwithaventlimitingoriceintheventconnection.

Iflocalcodesrequire,installpipingfromtheventconnection

tooutside,sizedandinstalledasrequiredbycodes.Because

thisisadiaphragm-assistedsolenoidvalve,asmallamountof

gaswillexitfromtheventoriceeachtimethevalveopens.

Figure 6 Gas train installation (shown with straight gas train)

2. Prepare site • assemble burner • mount burner (continued)

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14

– 12 –

Where appliance instructions differ from this manual, follow the appliance instructions.

3. Install gas piping

Piping from gas meter to burner

1. Verifythegastrainontheburneriscorrectlysized.Thegastrainpres-

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buttery

valve).SeeFigure8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7.

5. Iftheburnerisinstalledinsideanappliancejacket,installthemainmanual

gasvalveandsedimenttrapexternaltothejacket.

6. Sizepiping(orverifysize)usingTable3.Youwillndadditionalinformation

ongaslinesizingintheNationalFuelGasCode,ANSIZ223.1.

7. Gassupplypressure—naturalgasorpropane

• Maximumsupplypressure: 14inchesw.c.

• Minimumsupplypressure: 5inchesw.c.

Test and purge gas line

ReadWARNINGabove.

Pressuretestandpurgetheline.Pressuretestingshouldbedonebythegas

supplierorutility,followingallapplicablecodes.

Check pilot gas line oriﬁce nipple

 Checkthelabel on the pilot linegasorice nipple (item1,

page29).Thelabelontheoricenipplemustagreewiththe

gasused(naturalorpropanegas).Ifthenippleisnotcorrect

forthegasbeingused,obtainthecorrectoricenippleand

replace.Makesurethenippleisinstalledinthecorrectdirec-

tion,asshownbythearrowonthelabel.

Figure 7 Connecting gas supply piping to burner

(shown with straight gas train)

1 Pipetometerorbranch

2 T-handlemainmanualgasvalve

3 Useclean,burr-freeblackiron

pipeandmalleableironttings

4 Groundjointunion

5 Sedimentleg

6 Upstreampressuretap,1/4"

7 Outletpressuretap,1/4"

8 Gasregulatoraccessscrew

(theregulatorspringislocated

undertheadjustingscrew)

9 Gastrainwirejunctionbox

 Connectfromthegassupplytotheburnergastraininletusingnew,cleanblackironpipeandmalleableironttingsonly.Donotuse

copper,brass,castironorgalvanizedpipeorttings.

 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.

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14 – 13 –

Where appliance instructions differ from this manual, follow the appliance instructions.

NATURAL GAS

Capacities in Cubic feet per hour

for Schedule 40 metal pipe

Pipe size

(inches)

Total length of gas piping,

from meter to burner connection (feet)

20 40 60 80 100

Natural gas @ .60 specific gravity, pressure drop 0.3 in. w.c.

(note 1)

1¼ 730 500 400 350 305

1½ 1,100 760 610 530 460

22,100 1,450 1,150 990 870

2½ 3,300 2,300 1,850 1,600 1,400

Natural gas @ .60 specific gravity, pressure drop 0.5 in. w.c.

(note 1)

1¼ 950 660 530 460 400

1½ 1,460 990 810 690 620

22,750 1,900 1,520 1,300 1,150

2½ 4,350 3,000 2,400 2,050 1,850

Note 1 For natural gas with specific gravity other than 0.60,

consult National Fuel Gas Code for correction factor.

PROPANE GAS

Capacities in Btuh for

Schedule 40 metal pipe

Propane gas @ 1.5 specific gravity, pressure drop 1 psi

½1,839 1,264 1,015 869 770

¾3,845 2,643 2,122 1,816 1,610

17, 2 4 3 4.978 3,998 3,422 3,033

Propane gas @ 1.5 specific gravity, pressure drop 0.5 in. w.c.

1787 541 434 372 330

1¼ 1,616 1 , 111 892 677 543

1½ 2,422 1.664 1,337 1 , 11 4 1,014

Table 3 Capacities of black iron pipe, cubic feet gas/hour Figure 8 Gas train pressure drop

3. Install gas piping (continued)

Regulator spring:

 Thestandardmaingaspressureregulatorspring(seeitem8,Figure7,page12)

isplated.Therangeisfrom3.0to6.0incheswatercolumn.

 The1"RV61regulatorisavailablewithanoptionalbluespring,witharangeof

5.0to12.0incheswatercolumn.

 The1¼"or1½"RV81regulatorisavailablewiththestandardplatedspring(3.0

to6.0incheswatercolumn)oravioletspring,witharangeof4.0to12.0inches

watercolumn.

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14

– 14 –

Where appliance instructions differ from this manual, follow the appliance instructions.

Inspect/install fuel supply

 Inspecttheoilsupplysystem.Ensurethatthefuellinesare

correctlysizedandinstalledandthatthefuelowisunob-

structed,theoiltankiscleanandonly#1or#2heatingoil

aresupplied.Failuretosupplyareliableoilowcouldresult

inlossofheatandpotentialsevereequipmentdamage.

1. SeeFigure9fortypicaltwo-lineoilpiping.

2. Seepage15,Figures10and11,forfuelunitoilowdiagrams.

3. Installthefuelunitbypassplug(two-linesystemsonly).

Fuel supply to multiple burners

• Whenpossible,useseparatefuelsupplylinesforeachoilburner.Using

manifoldedoilsupplylinescancreateproblems.Ifthelinesareunder-

sized,operatingvacuumwillexceed limits.Ifthe linesareoversized,

fuelunitsmayhavedifcultypriming.Becausethelinesmustbesized

tohandlethecapacityofalltheburners,thelinesizewillalmostalways

betoolargewhenonlyasingleburnerisrunning.

• Ifmanifoldingcannotbeavoided,carefullysizethelinesfollowingthe

fuelunitsmanufacturer’sinstructions.

Fuel unit vacuum limitations

• SeeTable4forallowableliftsandlengthsofoillines.

• Thevacuumatthefuelunitinletportmustnotexceed12inchesmercury

duringanyoperatingcondition.

• Attachavacuumgaugetoeitherofthefuelunitinletports,andverify

thevacuumdoesnotexceedthelimitbelowduringallringconditions.

Oil ﬂow schematic / fuel unit

connections

• Figure10showsoilowandfuelunitportfunctionsforCarlin702G/O

burners.

• Figure11appliesonlyforoptionalNYC-DARpressureregulationkits.

4. Install oil piping

Use two-line oil piping only

Thefuelunitmustbeconnectedtoatwo-line fuel

systemtoensureoilowthroughthepumpduring

gasoperation.Thisisneededtokeepthepump

coolandlubricated.Failuretoprotect the pump

canresultinearlypumpfailure.

Fuel unit bypass plug

 Thefuelunitisshippedwithitsbypassplugnotin-

stalled.Installthebypassplugonlywhenconnecting

toatwo-lineoilsystem.Operatingwiththeplugin

placeonaone-linesystem(notrecommended)will

damagethefuelunitandcouldleadtooilleakage

andrehazard.

 Ifthefuellineorfuelsupplyisabovetheburner,never

exceed3PSIGpressureatthefuelunitinlet.Install

asuitableOSVtoreducethepressure.Operating

thefuelunitwithhigherinletpressurecouldresult

infuelunitsealdamage,oilleakageandpotential

rehazard.

Guidelines:

• When installing oil lines, use continuous runs of heavy-wall

coppertubingifpossible.

• Check fuel unit (oil pump) data sheet for recommended line

sizing,liftlimitationsandmaximumlength.

• Checkallconnectionsandjointstoensuretheyareair-tight.

• Usearettings.DONOTusecompressionttings.

• Neverusepipesealingtape.Fragmentscanbreakoffandplug

fuellinecomponents.

• Installashut-offvalveatthetankandoneneartheburner.(Use

fusiblehandledesignvalveswhenpossibleorwhenrequired

bycodes.)

• Installalargecapacityfuellter(ratedfor50micronsorless)

neartheburner.

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14 – 15 –

Where appliance instructions differ from this manual, follow the appliance instructions.

Figure 9 Two-line fuel system

Table 4 Two-line fuel system - allowable lengths and lifts

Lift

(feet)

Length of tubing (feet)

3/8” O.D. 1/2” O.D.

041 100

237 100

432 100

628 100

824 96

10 20 80

12 16 64

14 — 48

16 — 32

Figure 11 702G/O burner with NYC-DAR pressure regulation

kit

 ObtainpressureregulatorkitsforNewYorkCityDepartment

ofAirResourcesfromCarlin.Kitsmustbesetfortheproper

nozzlepressure.

4. Install oil piping (continued)

Figure 10 702G/O fuel unit and ow diagram

(Low re pressure is 100 PSIG, adjusted by screw

on top of blocking valve; High re pressure is 300

PSIG, applied when blocking valve is powered)

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14

– 16 –

Where appliance instructions differ from this manual, follow the appliance instructions.

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.

5. Wire the burner — RM7897C primary control

Wire the burner (RM7895CorRM7897Cprimarycontrolonly)

1. Allwiringmustcomplywith:

• IntheU.S.—theNationalElectricalCode,ANSIZ223.1/NFPA54.

• InCanada—theCanadianElectricalCodePart1,CSAstandardC22.1.

• Allapplicablelocalcodes/standards.

2. ConnecttheburnerfollowingFigures13and14andanyspecialinstructions

orwiringdiagramsprovidedwiththeappliance,burnerorothercomponents.

3. Theburnerrequiresa120VAC/60hz/single-phasecontrolpowersupply,with

a10-ampfuse.Thecontrolcircuitcurrentdrawisapproximately1.2amps.An

additionalpowersourceisrequiredforthemotor(120VACor208-220VAC,

60hz),withfusesizedaccordingly.SeeFigure14foreldwiringconnections.

4. ReadtheHoneywellRM7897Cinstructionsforinformationonsettingaroom

thermostat,ifused.

5. Makesuretheburnerandappliancearecorrectlywiredandthelineswitch

isproperlyfusedfortheload.

 Turn off power to appliance when servicing burner.

Failure to comply could result in severe person-

al injury, death or substantial property damage.

Figure 12 Legend for Figures 13 and 14

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14 – 17 –

Where appliance instructions differ from this manual, follow the appliance instructions.

120 VAC

Appliance

high fire

control

(remove jumper)

Figure 14 702G/O eld wiring connections (RM7897C only) Low-High-Low step modulation

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ringcyclecanbemuchlongerusinglow-high-lowring,

becausetheburnercancycletolowreasdemanddecreases.This

keepstheburneronlonger,reducingcycliclosses.

2. Theappliancemustbeequippedwithahighrecontrol.Thiswouldbea

make-on-fallcontrol,eithertemperature(waterboiler)orpressure(steam

boiler)activated.Readtheappliancemanualforthelocationofthehigh

recontrol,whenused.

3. SeeFigure14toconnectthehighrecontroltotheburnerringrate

circuit.

4. Theburnerincludesapre-wiredmanualhigh-reswitch.Closethisswitch

toholdtheburnerinhighremode.Opentheswitchtoholdtheburner

inlowremode.

5. Wire the burner — RM7897C primary control (continued)

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14

– 18 –

Where appliance instructions differ from this manual, follow the appliance instructions.

6. Checkout procedure — before starting the burner

Before ﬁring the burner . . .

 Shouldoverheatingoranemergencyoccur,immediately

dothefollowing:

 • Shutoffoilsupplylineandgassupplyvalves.

 • Undersomecircumstancespowershouldremain

onforwaterpumpsorblowers.Determineproper

responsebeforeattemptingstart-up.

 • Ifburnerfailsignitiononseveralattempts,useburner

blowertopurgeappliancechamberbeforerestart.

Checklist before ﬁring . . .

❏Burnerandappliance installed per this manualandappliance

instructionmanual?

❏Burner/applianceinstalledperallapplicablecodes?

❏Installationsitehasadequatecombustion/ventilationairopenings

andventsystem?

❏Arevoltagescorrect?Burner,applianceandmotorcorrectlywired

perburnerandappliancemanualsandwiringdiagrams?

❏Gasmanifoldspudorices(ongasmanifold,item29,page5)sealed

withpipedopeandtight?

❏Burnernozzleveriedperappliancemanufacturer’sinstructions,

CarlinOEMSpecGuideorTable1,page4?

❏Gasandoil supply linesingood condition, sizedanddesigned

correctly?

❏Gasandoillineconnectionsandttingstight?

❏Oiltankhasoil,andoillinevalvesareopen.Oilsupplyandreturn

linespurged?

❏Burner, appliance and allcomponentsinspected and in good

condition?

❏Appliancelimitandoperatingcontrolsproperlyinstalled,wiredand

adjusted?

❏Boilerwatersupply,feedpumps,automaticfeeders,andlowwater

cut-offsproperlypipedandwired?

❏Breeching,draftregulator,draftinducer (if required)properly in-

stalledandoperational?

❏Gastrainpiping and components correctlyinstalled,tested and

veriedgastight?

❏Ventlinesinstalledwhenrequired?

❏Gaslinespurged?

❏Sufcientgaslinepressurepresent?

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14 – 19 –

Where appliance instructions differ from this manual, follow the appliance instructions.

Before ﬁring the burner . . .

Set combustion head (Dimension “A”)

1. Thecombustionheadadjustingscrewisusedtosetthespacingbetween

theretentionringandthrottlering(oraircone),regulatinghowmuchair

passesaroundtheretentionring.

2. SeeFigure16.Loosenthetwohousingcoverscrews.Thenrotatethe

headadjustingscrewuntilthedistancefromthehousingdetenttothe

beginningofthescaleequalsthevaluegiveninTable5(Dimension“A”).

Tightenthehousingcoverscrews.

Set air damper (low ﬁre position)

1. See Figure17. Loosentheairdamper adjusting screw and locknut.

Rotatetheadjustingscrewuntiltheairopeningbetweenthedamperand

thedamperhousingequalstheinitiallow-reopeninginTable5.Leave

screwandlocknutlooseuntilnaladjustment.

Determining ﬁnal adjustments

1. Theburnerisnowadjustedtotheapproximateairsettingsforthering

rateused. Follow theprocedureson thefollowingpages touse test

instrumentsandmakenalburneradjustments.

Figure 17 Set initial low re air damper setting

Figure 16 Set initial combustion head position

Low-fire input High-fire input Combustion

head position

Dimension “A”

Air damper

low-fire

opening

Butterfly valve

open – low fire

(factory set)

#2 Fuel oil Natural gas #2 Fuel oil Natural gas

GPH @ 100 PSIG

(Nozzle rating) MBH GPH @ 300 PSIG MBH Inches

(approximately)

Inches

(approximately)

3.50 490 6.00 840 03/8 50

3.75 525 6.50 910 1/16 3/8 50

4.00 560 6.90 966 1/8 7/16 50

4.50 630 7.80 1092 3/16 7/16 50

5.00 700 8.70 1218 3/8 1/2 50

5.50 770 9.50 1330 5/8 1/2 50

6.00 840 10.40 1456 1-1/8 9/16 50

6.50 910 11.20 1568 1-3/8 9/16 50

Nozzle specifications:

Standard Hago 45° SS

Alternates Hago 45° P

Monarch 45° PLP

Table 5 Initial burner settings (see the pages 20 through 21 for nal adjustments using test instruments)

7. Set burner initial head and damper positions

 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.

 Failuretofollowthecorrectprocedurescouldre-

sultinseverepersonalinjury,deathorsubstantial

propertydamage.

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14

– 20 –

Where appliance instructions differ from this manual, follow the appliance instructions.

Adjustment procedure, summary

Step 1: Sethigh-reoilairowby adjustingthecombustion head.See

detailsfollowing.

Step 2: Adjusttheairdamperforlow-reoil.Seedetailsfollowing.

Step 3: Adjustthedampermotorendswitch(onlyifnecessary).Seedetails

following.

Step 4: Setgaspilotoperation.Seedetailsfollowing.

Step 5: Sethigh-regasowtomatchhigh-reair.Seedetailsfollowing.

Step 6: Adjustthebutteryvalvelinkagetomatchlow-regastolow-re

air.Seedetailsfollowing.

Step 7: 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.

2. Overrepressuremustnotexceedtheappliancemanufacturer’srecom-

mendations.Theburnermustneverberedatanoverrepressuremore

than0.60inchesw.c.

 Whentheoverrepressureispositive,themaximumburner

ringrateisreduced. Theringrateis also reduced for

altitudeshigherthan2000feetabovesealevel.Seepage3

forratinginformation.Ensurethattheoilnozzleselectedis

correcttherequiredringrate.

3. Adjusttheburnerfuelandairsettingsusingthefollowingprocedures.

Whenadjustmenthasbeencompleted,theCO2(orO2)shouldbewithin

therangesinTable6,atbothlowreandhighre.

Table 6 Allowable values of CO2 and O2

Fuel

CO2O2

Minimum Maximum Maximum Minimum

#2 Fuel Oil 10.5 % 12.5 % 6.6 % 3.9 %

Natural Gas 8.5 % 10.0 % 6.2 % 3.6 %

Propane 9.5 % 11. 2 % 6.0 % 3.5 %

8. Adjust the burner using test instruments

 ThesettingsgiveninSection7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.

Start the burner (ringonoil)

 Donotstarttheburnerifthecombustionchambercontains

oiloroilvapor.

1. TurnserviceswitchOFF.

2. Performinspectionsandcheckoutsonpage18.

3. Verifyburnerissetaccordingtopage19.

4. Sliponeendofa3/16-inchI.D.clearplastichoseovertheendofthefuel

unitbleedvalve,theotherendintoacontainer.Thenopenbleedvalve.

5. SetburnerfuelselectorswitchtoOIL.

6. Setthermostat(operatingcontrols)tocallforheat.

7. TurnserviceswitchON.

8. Burnermotor,fuelunitandblowershouldturnon.

9. Bleedtheoillineuntiltheplasticlineisfreeofbubbles;thenanother15

secondslonger.(Shouldtheprimarycontroltimingcausealockoutdur-

ingpurging,restarttheburnerfollowingtheprimarycontroldatasheet

instructions.)

10.Closethebleedvalve.Theburnershouldcyclethroughthesequence

givenintheprimarycontroldatasheet.

11.Shouldcontrol/burnerfailtooperatecorrectly,shutburneroffimmediately

andcheckburnersettingsandfuelsupplies.

12.Operateburnerfor15minutesbeforemakingnaladjustmentsusing

testequipment.

13.Checkforleaksinfuelpiping.

 Inspectfuelpipingsystemforleaks.Repairanyleaksto

avoidrehazardfromoilleakageorcombustionproblems

duetoairinltrationintooil.

14.Inspecttheame

• Lookattheamethroughtheappliancecombustionchamberobserva-

tionport,ifavailable.Theameshouldbewell-denedandshouldnot

impingeonanyappliancesurface.(Ifyoumakeairchangeslater,inspect

theameagain.)

Do not attempt to conrm combustion simply by inspect-

ing the ame visually. You must use combustion test

instruments.Failuretoproperlyverify/adjustcombustion

couldallowunsafeoperationoftheburner,resultinginsevere

personalinjury,deathorsubstantialpropertydamage.

15.Insertthecombustionequipmenttestprobeintoaventsampleopening

tosampleueproducts.

 Allinstallationsshouldbecheckedafteronetotwoweeksof

operationtoensuretheappliance/burnerunitsareoperating

correctly.

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Carlin Combustion Technology 702 Installation guide

Brand: Carlin Combustion Technology

Model: 702

Type: Installation guide

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Carlin Combustion Technology 702 Installation guide

Carlin Combustion Technology 702 Installation guide

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