Carlin 301CRD User Manual
Instruction manual
™
Installer/servicer — Except where specifi cally stated other-
wise, this manual must be used only by a qualifi ed service
technician. Failure to comply with this or other requirements
in this manual could result in severe personal injury, death or
substantial property damage.
User — Refer only to User care and maintenance on back
page for information regarding operation of this burner. The
burner Instruction Manual is intended only for your service
technician. The burner and heat exchanger must be inspected
and started at least annually by your service technician.
Ratings
Input: 201CRD.......................................... 2.50 to 5.00 GPH
301CRD (3¼’’ air cone) ................. 3.00 to 6.00 GPH
301CRD (3½’’ air cone) ................. 4.00 to 7.00 GPH
Fuels: U.S. ........................................ No. 1 or No. 2 Fuel oil
Canada .............No. 1 Stove oil or No. 2 Heating oil
Fuel unit: ....................................................................... Suntec
.................................100 to 150 PSIG nozzle pressure
...............................................Factory set at 150 PSIG
Electrical: Power ................................240V, 50/60 Hz, 1-Phase
Motor........................ Carlin PSC, 1/4 HP, 3450 RPM
Total current at 240V, 50/60 Hz, 1-Phase:
201CRD ............................... Approx. 1.6 amps
301CRD ............................... Approx. 1.6 amps
Ignition: ....... Carlin Model 42000 electronic — 14,000 volts
Control: ........................................U.L. primary safety control
Agencies: ....................................... UL Listed (US and Canada)
© Copyright 2010 — Carlin Combustion Technology, Inc.
Carlin Combustion Technology, Inc.
70 Maple Street East Longmeadow, MA 01028
Ph 413-525-7700 Fx 413-525-8306
TECH SUPPORT 800-989-2275
carlincombustion.com
Model 201CRD & 301CRD 240-VAC Advanced oil burners — Instruction manual
PLEASE read this fi rst . . .
Contents
PLEASE read this fi rst .............................................................2
General information ................................................................3
Before installing or servicing . . .
Codes and standards ..............................................................3
1. 201 & 301 Oil nozzles ........................................................3
2. Prepare site • assemble burner • mount burner ......4
3. Prepare burner .................................................................10
4. Wire burner • start burner –
50240 primary control .....................................................16
60240 primary control .....................................................18
5. Adjustment and verifi cation .............................................20
6. Annual start-up and service ............................................21
7. Repair parts .....................................................................22
8. Maintenance/service procedures ....................................24
Warranty ...............................................................................27
User care and maintenance .................................... Rear cover
Special attention fl ags . . .
Please pay particular attention to the following when you see them throughout this manual.
Notifi es you of hazards that WILL cause severe personal injury,
death or substantial property damage.
Should overheating occur:
(1) Shut off the oil supply to the burner.
(2) Do not shut off the control switch to the circulator
or blower.
Follow the guidelines below to avoid potential severe
personal injury, death or substantial property damage.
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 fl ammable liquids or vapors and
other combustible materials.
• To never use laundry products, paints, varnishes or other chemicals in
the room occupied by the burner/appliance.
• To contact the service technician at least annually for startup and
burner/appliance service.
– 2 –
Notifi es you of hazards that CAN cause severe personal injury,
death or substantial property damage.
Notifi es you of hazards that WILL or CAN cause minor personal
injury or property damage.
Notifi es you of special instructions on installation, operation or
maintenance that are important, but are not normally related
to injury or property damage hazards.
When servicing the burner . . .
• Disconnect electrical supply to burner before attempting to service to
avoid electrical shock or possible injury from moving parts.
• 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.
Carlin part number MN2301A Rev. 10/21/10
Model 201CRD & 301CRD 240-VAC Advanced oil burners — Instruction manual
General information 1. 201 & 301 Oil nozzles
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 applicable codes/standards.
Damage or shortage claims
The consignee of the shipment must fi le damage or shortage claims immediately against the transportation company.
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
Certifi cation
201CRD and 301CRD burners are U.L. listed for the U.S. and Canada,
certifi ed to comply with ANSI/UL 296, for use with #1 or #2 heating oil
(per standard ASTM D396).
Burner labels list compliance, when required, with special local, state or
provincial approvals.
Use the selections in Table 1 ONLY when heating appliance
manufacturer specifi c nozzle selection data is not available,
either in the appliance manual or the Carlin OEM Spec Guide.
Follow all instructions provided with the appliance.
Table 1 Apply the guidelines below to select a nozzle when
appliance-specifi c nozzle data is not available from the
manufacturer or in the Carlin OEM Spec Guide. See
notes at end of table for application tips.
Install this burner in accordance with all local codes and
authorities having jurisdiction. Regulations of these authorities 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 NFPA 31 (Standard for the Installation of Oil-Burning
Equipment), ANSI/NFPA 70 (National Electrical Code), and all applicable
local codes.
Canadian installations
Burner/appliance installations in Canada must comply with the latest editions
of CSA B139 (Installation Code for Oil Burning Equipment), CSA standard
C22, Part 1 (Canadian Electrical Code), and all applicable local codes.
The fuel unit is factory-set at 150 PSIG. The
nozzle selected must consider the fuel unit pressure. See
nozzle sizing in Table 4, page 13.
Carlin part number MN2301A Rev. 10/21/10
– 3 –
Model 201CRD & 301CRD 240-VAC Advanced oil burners — Instruction manual
2. Prepare site • assemble burner • mount burner
Vent system
General
Do not install this burner unless you have verifi ed the
entire vent system and the appliance are in good condition and comply with all applicable codes.
• The vent and chimney must be sized and constructed
in accordance with all applicable codes.
• Do not install or use an existing manual damper in
the breeching (vent connector) or chimney.
• Do not connect the appliance vent connector to a
chimney or vent serving a fi 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.
You must install a listed stainless steel liner in the
chimney to vent the fl ue products.
• A defective vent system could result in severe personal
injury, death or substantial property damage.
Prepare vent/chimney
• Secure all metal vent joints with screws, following the vent manufacturer’s instructions.
• Seal all joints in the vent system and chimney.
• Repair masonry chimney lining and repair all mortar joints as
needed.
• Install a double-acting barometric draft regulator in the vent piping if
specifi ed in the appliance manual. (The damper must be located in
the same space as the appliance.)
• Provide support for the vent piping. Do not rest the weight of any of
the vent piping on the appliance fl ue outlet.
Combustion and ventilation air
openings
General
Check appliance manual and applicable codes for required sizing,
design and placement of combustion/ventilation air openings. You can
use the following general guidelines, taken from NFPA 31, provided
they meet all local requirements.
Free area — Louvers and screens
• Air opening sizes are always given in free area. This means after
deduction for louver obstruction. If you can’t fi nd the louver reduction
for the grilles used, assume free area is 20% of total for wood louvers,
or 60% of total for metal louvers.
• Screens can be no fi ner than ¼-inch mesh, and must be accessible
for cleaning.
Residential installation air openings
Residential — Unconfi ned spaces (at least 7,000 cubic feet per GPH)
• An unconfi ned space means a room with at least 7,000 cubic feet volume for
each GPH input (or 50 cubic feet per MBH) of all appliances in the room.
Example: For a boiler room housing a 6.00 GPH input burner/appliance, multiply
6 times 7,000 cubic feet, equals 42,000 cubic feet. The room must have a
volume of 42,000 cubic feet to be classifi ed as an unconfi ned space. (If the
boiler room has an 8-foot ceiling height, the room would have to have 5,250
square feet, or about 73 feet square.)
• Most boiler rooms do not provide this much volume, and must be treated as
confi ned spaces, requiring dedicated combustion air openings, sized as in the
following.
• Open residential basements and crawl spaces are often large enough, and
will generally allow enough air infi ltration, so special provisions will seldom be
required.
• If the building is tightly constructed, you will have to provide outside air openings into the building regardless of the boiler room volume. The total free area
of these openings must be at least 1 square inch per 5,000 Btuh (28 square
inches per GPH) of all appliances in the space.
• See Table 2 for a summary.
Residential — Confi ned spaces (less than 7,000 cubic feet per GPH)
• Air taken from inside building only —
• Provide two openings — one near the fl oor, the other near the ceiling. Provide
free area of 140 square inches per GPH input.
• If the building is tightly constructed, provide dedicated air opening(s) into the
building with at least 30 square inches free area per GPH.
• Air taken from outside —
• Direct through outside wall or vertical ducts:
Provide two openings — one near the fl oor, the other near the ceiling. Provide
free area of at least 35 square inches per GPH input.
• Through horizontal ducts:
Provide two openings — one near the fl oor, the other near the ceiling. Provide
free area of at least 70 square inches per GPH input.
• Ventilation air from inside, with combustion air from outside
• Size openings to interior to provide 140 square inches free area per GPH
input.
• Size the outside combustion air duct to provide 28 square inches free area per
GPH.
• See Table 2 for a summary.
Commercial installation air openings
Commercial — Air openings directly from outside to boiler room
• Provide one opening that provides a free area of at least 28 square inches
per GPH input.
Example: For a boiler room housing boilers totalling 10 GPH fuel oil input,
the area opening must have a free area of no less than 10 times 28, or
280 square inches. If the opening is wood louvered, divide by 20%, or the
opening must be 1400 square inches (about 38 inches by 38 inches). If
the opening is metal louvered, divide by 60%, or the opening must be 467
square inches (about 22 inches by 22 inches).
– 4 –
Carlin part number MN2301A Rev. 10/21/10
Model 201CRD & 301CRD 240-VAC Advanced oil burners — Instruction manual
2. Prepare site • assemble burner • mount burner (continued)
Table 2 Minimum combustion/ventilation air openings
Combustion/ventilation air checklist
The burner may operate successfully under momentary
downdraft conditions, but sustained downdraft is unsafe.
• This can occur with an inadequate or incorrectly installed
chimney/vent.
• It can also occur in rooms/buildings equipped with exhaust
fans or unsealed return air ducts.
• Always check operation of the burner under all conditions
to verify vent system operates correctly.
• You may have to interlock the burner with exhaust fans to
shut burner off when fan operates; or provide make-up air
to the appliance room suffi cient to prevent any negative
pressure in the space.
• Failure to correct downdraft or negative room pressure
operation could result in severe personal injury, death or
substantial property damage.
Verify that openings are unobstructed.
Verify that appliance space and air source spaces are free of:
• Gasoline or other fl ammable liquids or vapors.
• Combustible materials.
• Air contaminants and chemicals, such as laundry products, paint, thinner,
varnish, etc.
Confi rm with the building owner that the area will be kept free of these
materials at all times and that air openings will be kept unobstructed.
Verify clearances
Verify that the burner/appliance will maintain all required clearances:
Verify clearance from combustible construction, as specifi ed by appliance
manufacturer and local codes.
Verify clearances for service and maintenance as required in the appliance
manual and applicable codes.
Vent system components must maintain all necessary clearances to
combustible construction, including the correct design of thimbles and
insulation where penetrating combustible walls.
Carlin part number MN2301A Rev. 10/21/10
– 5 –
Model 201CRD & 301CRD 240-VAC Advanced oil burners — Instruction manual
2. Prepare site • assemble burner • mount burner (continued)
Verify combustion chamber
Chamber dimensions and construction
• If retrofi tting the burner to an appliance, install the burner in accordance
with the appliance instruction manual, when available. If no specifi c
application data is available from the appliance manufacturer, read the
guidelines below to check whether the burner is likely to work acceptably
in the application.
• Illustrations A to E in Figure 1 show different chamber confi gurations, with
and without refractory linings. The chamber dimensions listed in Table 3
depend on whether the chamber is lined or water-backed, as shown.
• Do not attempt to fi re the burner in a chamber with dimensions smaller
than shown in Table 3 unless the application has been specifi cally tested
and listed by the appliance manufacturer and/or Carlin.
• Chambers with dimensions larger than shown in Table 3 should not have
much effect on combustion/performance.
General guidelines
• Clean all appliance fl ues and heating surfaces thoroughly, removing all
soot and scale.
• Seal all joints and gaps using furnace cement to prevent excess air
infi ltration.
Read the WARNING on page 26 before handling or applying
ceramic fi ber materials.
Figure 1 Combustion chamber confi gurations, typical
Using chamber linings
• When using refractory liners or lightweight chambers, use insulating-type
refractory rated 2600°F minimum, or as specifi ed by the appliance manufacturer.
• You must install a target wall liner if fl ame length is close to the length of
the chamber.
• Use a fl oor liner when possible. The fl oor liner will improve fi ring in most
applications. Extend fl oor liner 3 to 4 inches up the side walls.
• Target wall liners — Extend target wall liners at least 3 to 4 inches above
the center of the fl ame corbel the top 1½ to 2½ inches deep.
• Use preformed chamber liners when available. Lining the fl oor and target
wall water-backed combustion chambers with lightweight insulating refractory will accomplish the same.
• When converting coal-fi red units, install a combustion chamber in the ashpit
area, or fi ll the ashpit with sand up to 2 inches above the “mud ring” of the
boiler (fi ring through the door). Install a lightweight refractory liner on the
target wall as in Figure 2D.
– 6 –
Carlin part number MN2301A Rev. 10/21/10
Model 201CRD & 301CRD 240-VAC Advanced oil burners — Instruction manual
2. Prepare site • assemble burner • mount burner (continued)
Table 3 201CRD and 301CRD Minimum combustion chamber dimensions (all dimensions in inches) - See Figure 1 for combustion
chamber confi gurations
Carlin part number MN2301A Rev. 10/21/10
– 7 –
Model 201CRD & 301CRD 240-VAC Advanced oil burners — Instruction manual
2. Prepare site • assemble burner • mount burner (continued)
Inspect burner and components
General
• 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.
Install/check burner fl ange
Welded-fl ange burners
1. Verify the bolt pattern on the appliance chamber matches the fl ange pattern.
2. Verify the insertion depth (UTL) matches the depth of the appliance opening (so the end of the air tube is fl ush with, or slightly short of, the inside
surface of the combustion chamber).
Figure 2 Standard adjustable fl ange (universal fl ange)
Figure 3 Adjustable forced draft fl ange
Burners with adjustable fl anges
1. See Figure 2 for standard adjustable fl ange (universal fl ange) dimensions.
See Figure 3 for adjustable forced draft fl ange dimensions.
Verify the fl ange mounting slots line up with the appliance bolts.
2. Slip the adjustable fl ange onto the air tube.
3. Measure the distance from the inside of the combustion chamber to the
outside of the appliance mounting plate.
4. Position the adjustable fl ange at this distance from the end of the air
tube.
5. Tighten the locking screws fi nger tight.
6. Insert the air tube/fl ange assembly into the appliance opening and level
the air tube with a spirit level (see Figure 4). Adjust fl ange if needed.
7. The end of the air tube should be fl ush, or almost fl ush, with the inside of
the combustion chamber wall.
8. Verify the air tube is level and inserted the correct depth. Adjust if necessary.
Then tighten the fl ange locking screws securely.
9. Remove the fl ange/air tube assembly from the opening.
10. Forced draft adjustable fl anges: Use ¼-inch diameter fi berglass sealing
rope, as shown in Figure 3, to seal the fl ange to the air tube.
A forced draft adjustable fl ange must be sealed to the air
tube to prevent possible leakage of fl ue products. Failure
to comply could result in severe personal injury, death or
substantial property damage.
Figure 4 Mark insertion depth on air tube when using universal
fl ange mounting
– 8 –
Carlin part number MN2301A Rev. 10/21/10
Model 201CRD & 301CRD 240-VAC Advanced oil burners — Instruction manual
2. Prepare site • assemble burner • mount burner (continued)
Pedestal-mounted burners
1. Check the diameter of the appliance opening. If larger than 4½ inches,
rebuild the opening so the open is reduced to 4½ inches maximum.
2. Insert the air tube into the appliance opening as in Figure 4. Do not attach
air tube to housing yet.
3. Slide the tube in until the end of the tube is fl ush with, or up to ¼ inch short
of, the inside of the combustion chamber.
4. Level the air tube using a spirit level.
5. Mark the air tube position with a pen or pencil around the circumference
of the tube.
6. Remove air tube from the opening
Attach air tube to housing
1. See Figure 5. Loosen the four hex set screws on the top front of the burner
chassis.
2. Open the ignitor cover plate by loosening the retainer screw on the left side
of the burner housing.
3. Swing the ignitor plate open.
4. Locate the drip hole in the burner air cone (301 burners) or throttle ring
(201 burners). Rotate the air tube so the drip hole is at the bottom.
5. Insert the air tube into the housing.
6. Make sure the air tube is inserted completely, butting against the air tube
socket ledge. If necessary, tap on the end of the air tube with a block of
wood until properly seated.
7. Secure the air tube by tightening the four hex set screws on the top front
of the burner housing.
On burners with welded fl anges, you can bolt the air tube/
fl ange to the appliance fi rst — then attach the housing to
air tube.
Figure 5 Attaching air tube to burner housing
Mount burner in appliance
Welded fl ange-mounted burner
1. Place gasket over burner air tube and insert burner into appliance opening.
Secure in place with hardware supplied with appliance.
Universal fl ange or pedestal mount — these insertion methods
are intended only for negative overfi re pressure. For pressurized fi ring, you must obtain a burner with a welded fl ange,
designed for use with the specifi c appliance. Failure to comply
could result in severe personal injury, death or substantial
property damage.
Adjustable fl ange-mounted burner
1. Place gasket over burner air tube.
2. Insert burner into appliance.
3. Verify burner is seated level and straight. Adjust fl ange slightly if necessary.
4. Secure fl ange to appliance with hardware supplied with appliance.
Pedestal-mounted burner
1. Assemble the pedestal to the burner and tighten the bolt. Insert a screw
into each of the two holes in the pedestal feet if needed to level the assembly.
2. Adjust the pedestal so the air tube is level and the center of the tube is at
the same height as the center of the appliance opening.
3. Tighten the pedestal bolt.
4. Insert the burner/air tube into the appliance opening until pen/pencil line is
even with appliance front (so end of air tube is fl ush with, or slightly short
of, the inside of the chamber).
5. Seal the space around the air tube with furnace cement or equivalent
(Figure 6).
Carlin part number MN2301A Rev. 10/21/10
Figure 6 Seal opening around burner air tube when pedestal
mounting (burner shown with tube attached to housing
and installed)
– 9 –
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