Carlin 48245 User Manual

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Page 1

Model 48245 with Smart Ignition – CAD Cell Oil Primary Control Data Sheet

• Intermittent Duty when you need it, Ignitor-saving Interrupted Duty when you don’t

• Oil Pump Bleed Assist

• Recycle on Flame Failure

• Diagnostic LEDs

Status, lockout, ﬂame

Power input (from limit circuit) 120 VAC, 60 HZ

Motor load

Ignitor load

Operating temperature limits

10 FLA / 60 LRA

120 VAC, 60 HZ, 500 VA

+32°F to +140°F

60 seconds

Storage temperature limits

Thermostat anticipator current

CAD cell resistance (with ﬂame) R < 1500 OHMS

Agencies

• 45 or 15 second TFI

• Increased Flame Accuracy

• Thermostat/Aquastat Compatible

• Improved SMC Technology

zero bleed voltage during standby

• Works Well with Generators

Insensitive to frequency changes

-40°F to +185°F

0.1 A, AC

UL recognized (US & Canada)

Installing and Wiring

48245 control must be installed and serviced only by a qualiﬁed service technician.

1. Always disconnect power source before wiring to avoid electrical shock or damage to the control. All wiring must comply with applicable codes and ordinances.

2. Thermostat terminals (T-T) provide a current source. Never apply external power to these terminals under any circumstances.

Mounting

• The control may be mounted on a 4" x 4" junction box in any convenient location on the burner, furnace or wall. The location

must not exceed the ambient temperature limit, 140°F.

Wiring

• Wiring must comply with local and national electrical codes, and with the wiring diagram.

• Individual or bundled neutrals may be attached to any L2 terminal.

Field checks

1. Select preferred TFI by 1) leave jumper in for 45 seconds or 2) remove jumper for 15 seconds. IMPORTANT: TFI change oc- curs on next call for heat.

2. Safety timing (TFI) test – Remove one CAD cell wire (F-F). Start burner. The control should lockout within the TFI time limit. Replace CAD cell wire.

3. Flame failure test – Start burner. After ﬂame is established (after TFI period), close the oil supply hand valve. This will cause a ﬂame failure sequence as described in the Startup & Operation section of this data sheet. Under recycle, please read “Smart Ignition” on page 3.

4. If control does not operate as described, check the wiring.

Startup & Operation

Three wire or four wire conguration

• See Figure 1 for wiring diagram for four-wire conguration

(Smart Ignition)

• See Figure 2 for wiring diagram for three-wire conguration

Do not start the burner if the combustion chamber contains oil or oil vapor.

Per UL requirements, the control will not turn on if the CAD cell senses ﬂame during the self-test. If the CAD cell sees

Model 48245 Diagnostic LEDs

– Amber OFF – Amber ON – Amber FLASHING

– Green OFF – Green ON – Green FLASHING

– Red OFF – Red ON – Red FLASHING

light (ﬂame) at the beginning of a cycle, the control will remain in self-test mode until the CAD cell no longer senses light (ﬂame). The amber LED will blink momentarily

every 3 to 4 seconds and green LED will be on or ﬂashing.

Tech Support (800) 989-2275 www.carlincombustion.com

SEE WIRING DIAGRAM ON NEXT PAGE

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Wiring

Figure 1: 4-wire 48245 Oil Primary Control

(activates Smart Ignition)

Figure 2: 3-wire 48245 Oil Primary Control

(does not activate Smart Ignition)

Startup & Operation

Power ON Open all manual oil line valves. Close the line switch. (If Red LED turn on constant

Self-test 1 The control performs a “boot-up” test to verify internal operation each time power is applied to the L1 wire.

The amber LED turns on and the test continues for about 5 seconds. If the test fails, the control turns the

Stand-by (No call for heat) If Self-test 1 is successful, amber LED turns off and control waits for heat call.

Call for Set thermostat to call for heat. Thermostat circuit must be closed and power coming to black wire from heat limit circuit.

Self-test 2 If a failure occurs in this self-check, the control won’t start and the amber LED blinks 1 second on, 4 sec-

Burner ON After the self-test, amber LED turns off. The ignitor starts, followed 2 seconds later by the motor. Wired as

See next page to reset.)

amber LED off and repeats this test sequence until successful.

onds off, until serviced or the problem clears. These failures include CAD cell seeing light, internal failure, or line voltage <90V. See service section.

3-wire, the ignitor and motor come on at the same time.

Three wire or four wire conguration (continued)

, control is in lockout.

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Startup & Operation Four wire conguration

Do not start the burner if the combustion chamber contains oil or oil vapor.

Per UL requirements, the control will not turn on if the CAD cell senses ﬂame during the self-test. If the CAD cell sees light (ﬂame) at the beginning of a cycle, the control will remain in self-test mode until the CAD cell no longer senses light (ﬂame). The amber LED will blink momentarily

heat power from the limit circuit).

Pump To enter pump prime: 1. Start a CFH cycle. During Pre-Ignition, press Reset until motor turns Prime off (10 seconds), then release the button. When motor turns back on, within 5 seconds, press the Reset button

Optional Pump Prime notes: 1) If Pump Prime is lost, press Reset for 1 second and release, then if the

To Reset Push in and hold reset button for 2 seconds, then release.

(Flame Failure) control waits for 65 seconds, Red LED goes off, then begins again at Self Test 2.

every 3 to 4 seconds and green LED will be on or ﬂashing.

Power ON Open all manual oil line valves. Close the line switch. (If Red LED turn on constant , control is in lockout.

Self-test 1 The control performs a “boot-up” test to verify internal operation each time power is applied to the black

Stand-by (No call for heat) If Self-test 1 is successful, amber LED turns off and control waits for heat call.

Call for Set thermostat to call for heat. Thermostat circuit must be closed (and black wire must receive

Self-test 2 If a failure occurs in this self-check, the control won’t start and the amber LED blinks 1 second on, 4 sec-

Burner ON After the self-test, amber LED turns off. The ignitor starts, followed 2 seconds later by the motor.

TFI The CAD cell must sense ﬂame within the TFI time limit (trial for ignition). Insufﬁcient ﬂame puts control into

Run The burner continues ﬁring during call for heat if the CAD cell is sensing ﬂame. Only the green LED is on

Lockout If CAD cell does not sense ﬂame within the TFI time limit after the burner starts, lockout occurs. The con-

Recycle If the CAD cell loses ﬂame signal during operation (after the TFI), the Red LED ﬂashes. Recycle:

Stand-by Control remains in stand-by mode until limit circuit sends power to the black wire and thermostat circuit

See below to reset.)

wire. The amber LED turns on and the test continues for about 5 seconds. If the test fails, the control turns the amber LED off and repeats this test sequence until successful.

onds off, until serviced or the problem clears. These failures include CAD cell seeing light, internal failure, or line voltage <90V. See service section.

until the amber LED starts to ﬂash. You are in Pump Prime, release Reset button.

control is not in Pump Prime, restart the sequence. 2) If Reset is released before end of ﬁrst 10 seconds, the control returns to Standby and restarts another CFH cycle. 3) If reset is not pressed the second time, a normal CFH cycle will continue. 4) If motor and igniter are on and amber LED is ﬂashing, the control is in Pump Prime. 5) Pump Prime will exit standby if ﬂame is detected, or 60 seconds has elapsed, or loss of TT or Limit, or Reset button is pressed.

lockout.

during normal running.

trol turns the red LED on constant and closes the alarm contact.

The 48245 control will retain lockout if power is interrupted.

If the green LED is blinking during a run, the ﬂame is weak or unstable and may go into recycle.

closes (call for heat).

IMPORTANT: All four wires provided must be used to activate the Smart Ignition feature. The ignitor must be wired to the control’s blue ignitor output terminal. See Figure 1 for Smart Ignition Wiring diagram

Smart Ignition runs in Intermittent Duty (aka “constant” duty) when needed to prevent loss of flame. But unlike any other primary control, Smart Ignition switches to Interrupted Duty when it can – to save wear and tear on the ignitor and electrodes.

How Smart Ignition Works:

The control initially works as an Interrupted Duty control. Following a 45-second Trial-for-Ignition period and a 45-second Flame Stabilization period, the ignitor output is turned off.

If flame is lost at any time after the Trial-for-Ignition period, the control will recycle (60 - 65 seconds). Following this recycle, the control will operate in Intermittent Duty mode for ten heat cycles. Following these ten cycles, the control will revert back to Interrupted Duty and will remain in Interrupted Duty until another recycle event occurs.

The Best of All Worlds:

The Model 48245 with Smart Ignition ensures flame retention by providing intermittent duty ignition when required to prevent flame loss and it dramatically increases the ignitor and electrode life and saves energy by switching to interrupted duty the remainder of the time.

To manually reset from Intermittent Mode: Open TT and depress the reset button until the amber LED turns on. Release the reset button; the control is reset from the intermittent mode.

Smart Ignition

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Service & Troubleshooting

Burner (control) will not come on

No power to control

• Check limit circuit to the control (at least 102 VAC).

• Check all electrical connections.

Control is in lockout

• Red LED will be on. Press the reset button for 2 sec-

• Green LED on, and amber LED blinking 1 second

If the amber LED goes OFF, the control is OK, and;

• light is leaking into the burner housing, or

• CAD cell is defective, or

• there is a problem with the CAD cell wiring or holder.

• If appliance was recently shut down, CAD cell may

To troubleshoot:

• Attach multimeter to monitor CAD cell resistance.

• Check for stray light by measuring the CAD cell

onds.

CAD cell seeing light

on, 4 seconds off. Remove one yellow lead from FF terminals. If the amber LED remains ﬂashing, the control is defective.

see residual hot spots in chamber.

Dark resistance should be over 50K ohms, and room light resistance (control ﬂipped open) should be at most 10K ohms Replace cell if necessary, or reinstall and close the burner housing.

resistance looking into the inactive combustion chamber. It should read at least 50 kohms.