Carlin G3B User Manual
Instruction manual
Contents
PLEASE read this fi rst.......................................................... 2
Codes and standards........................................................... 2
G3B Gas burner at-a-glance .............................................. 3
Prepare site • prepare burner • mount burner ................ 4
Install gas piping .................................................................. 9
Wire burner .........................................................................10
Check system • start-up burner/appliance ....................12
Perform checkout procedure • fi ll out certifi cate ........ 14
Maintenance and service procedures ...........................17
Troubleshooting .................................................................. 19
Dimensions and mounting information .......................... 21
Replacement parts............................................................. 22
™
Ratings
Input: .................................................... 60,000 to 180,000 BTUH
Fuels: .........................................Natural gas or propane gas
Max. supply pressure .............................14 INCHES W.C.
Min. supply pressure ................................5 INCHES W.C.
Manifold pressure .................................3.5 INCHES W.C.
Electrical: Power ...................................120
Motor..................................................1/50 HP, 3450 RPM
Ignition: .................................. Norton hot surface ignitor, 120V
Control: .................................Honeywell S89C primary control
Agencies: ........................CSA certifi ed, U. S.
The G3B burner has been assigned
U. S. Patent No. 4397631
V/60HZ/1-PHASE, 8 AMPS
Installer/servicer — Except where specifi -
cally stated otherwise, this manual must be used only by
a qualifi ed service technician. In the state of MA, this
product must be installed by a licensed plumber or gas
fi tter. Failure to comply with this or other requirements
in this manual could result in severe personal injury, death
or substantial property damage.
Handling — Handle burner (and hot surface ignitor)
carefully to avoid cracking or breaking the ceramic ignitor.
Ignitor protrudes slightly beyond burner head. Do not set
burner on its end.
User — Refer only to User’s Information manual
for information regarding operation of this burner. The
remainder of this 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.
© Copyright 2008 — 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 G3B Gas burner — Instruction manual
PLEASE read this fi rst . . .
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.
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.
General information
Burner applications
Follow all instructions in this manual and the appliance manual. Where
appliance instructions differ from this manual, follow the appliance instructions. Read the label attached to the burner air tube to verify the burner is
correct for the appliance being used. See pages 6 and 7 for procedures.
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 burner serial number and burner model number
to assist us in locating information. Enter this information on the Installation
Certifi cate in this manual. The certifi cate information can be helpful when
troubleshooting or obtaining replacement parts.
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’s
information manual with the user. Make the user aware of all
potential hazards and perform the training outlined below.
Train the user . . .
• To properly operate the burner/appliance per this manual, the
appliance instructions and the User’s information manual.
• To keep this manual at or near the burner/appliance for ready
access by the user and service technician.
• To contact the service technician, gas supplier or fi re department
should the user smell gas.
• To keep the appliance space free of fl ammable liquids or vapors
and other combustible materials.
• Do not 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.
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.
• Handle the ceramic ignitor with care to avoid breaking or cracking
the ignitor. Do not handle ignitor when it is hot. NEVER touch
the surface of the ignitor with bare fi ngers. Body oils can cause
damage.
Codes and standards
The installer/servicer is solely responsible for compliance
with all applicable codes and standards.
Burner listings/approvals
Carlin G3B gas burners are CSA certifi ed for use with natural gas or propane
gas, United States installations only.
Burners are NYC/MEA approved. MEA-369-89-E.
2
Installation:
Burner/appliance installations 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.
• National Electrical Code, ANSI/NFPA 70.
• All additional applicable national, state and local codes.
Carlin part number MNG3B Gas Rev. 03/17/09
Model G3B Gas burner — Instruction manual
G3B Gas burner at-a-glance
1 Air tube, with powder coat paint fi nish
2 Flameholder
3 Hot surface ignitor
4 Adjustable fl ange
5 Rear ignitor assembly with terminal boots
6 Ignition tube assembly mounting plate
7 Pedestal legs
8 Burner gas inlet connection (see page 8)
9 Combination gas valve (with integral gas pressure regulation — set
for 3½” w.c. outlet pressure)
10 Control panel
11 Terminal strip
Carlin part number MNG3B Gas Rev. 03/17/09
12 Primary control (Honeywell Model S89C primary control, for use with
fl ame rectifi cation)
13 Control transformer, 120
14 Gas valve on indicator light
15 Motor relay
16 High-effi ciency motor
17 Blower housing (cast aluminum), with powder coat paint fi nish
18 Air inlet tube assembly
19 Air throttle indicator — Only a single adjustment required for setting
combustion air; see page 8 for starting setting based on appliance
model and input)
VAC / 24 VA C, 40 VA
3
Model G3B Gas burner — Instruction manual
1. Prepare site • prepare burner • mount burner
Inspect installation site
Inspect, repair and/or replace vent system
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. And . . .
The vent and chimney must be sized and constructed 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 fi ring.
The vent system must not be pressurized unless the vent
piping and vent system are designed accordingly. 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 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. Install a listed
stainless steel liner to vent the fl ue products.
Figure 1 Vent and vent connector installation
A defective vent system could result in severe personal injury,
death or substantial property damage.
Vent/chimney sizing
• Follow all local codes when sizing the vent and chimey
• Refer to the appliance manufacturer’s manual, when available, for
venting recommendations
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. (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.
• Provide support for the vent piping. Do not rest the weight of any of the
vent piping on the appliance fl ue outlet.
Verify clearances
• Verify that clearances required for service/maintenance comply with
the appliance manual and applicable codes. Provide at least 6 inches
around burner and 24 inches in front of burner panel for service
access.
4
Carlin part number MNG3B Gas Rev. 03/17/09
Model G3B Gas burner — Instruction manual
1. Prepare site • prepare burner • mount burner (continued)
Inspect installation site
Combustion/ventilation air openings
Installing the burner/appliance in a space that does not provide
enough air for combustion and ventilation can result in severe
personal injury, death or substantial property damage. Follow
all applicable codes and guidelines below to ensure space has
suffi cient air openings.
Large spaces
For appliances located in basements, ventilated crawl spaces or other large
areas, no additional air openings should be necessary.
Exception: If the building construction is unusually tight (see National Fuel
Gas Code or CSA B149.1 or .2 for defi nition), you will need to provide air
openings into the building if appliance air comes from inside. Provide one
opening within 12 inches of the ceiling, and one opening within 12
inches of the fl oor. Size each opening to provide free area (after deduction
for louvers) of 1 square inch per 1,000 Btuh input of all fuel-burning
appliances in the building.
Confi ned spaces — air from inside building
If air openings connect to areas inside the building, provide two openings,
one within 12 inches of the ceiling, the other within 12 inches of the fl oor.
Each opening must have a free area (after deduction for louvers) of 1 square
inch per 1,000 Btuh of all appliances in the space. If the building construction is unusually tight (see National Fuel Gas Code or CSA B149.1 or .2 for
defi nition), you will need to provide air openings into the building. Provide
two openings sized and located as for the openings into the boiler space.
Figure 2 Locating & sizing air openings
Confi ned spaces — air from outside
If air openings connect directly to outside, provide two openings, one within
12 inches of the ceiling, the other within 12 inches of the fl 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
appliances in the space.
• If through horizontal ducts: 1 square inch for each 2,000 Btuh of all
appliances in the space.
Verify openings
When sizing air openings for combustion and ventilation, include
air required for exhaust fans and other appliances, such as
clothes driers, that require air for operation.
Check appliance manual and applicable codes for required sizing of
combustion and ventilation air openings.
• 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, such as laundry products, paint, thinner, varnish, etc.
• Confi rm with user that the area will be kept free of these materials at
all times.
Carlin part number MNG3B Gas Rev. 03/17/09
5
Model G3B Gas burner — Instruction manual
1. Prepare site • prepare burner • mount burner (continued)
Prepare the appliance
Burner input: Install a gas burner sized for the normal input
rating of the appliance. Do not install a burner with a higher
fi ring rate than the appliance rating. Do not install a burner
with a fi ring rate more than 10% lower than the appliance
rating. The appliance and vent system could be damaged
due to condensation.
Seal the appliance: Seal all fl ue-gas containing joints. Seal
all connections to the vent piping or breeching.
Clean and check the appliance: Clean the appliance
thoroughly. Test all electrical components and verify the
relief valve works (boilers only).
Verify combustion chamber dimensions comply with the
minimum dimensions shown in Figure 3. Install or replace
combustion chamber liner if required by the appliance
manufacturer. The burner air tube must not extend into the
combustion chamber. The end of the burner air tube must be
within ¼” of the inside face of the combustion chamber. If the
space around the burner air tube is more than ¼”, wrap the
burner air tube with minimum 2300-°F-rated ceramic fi ber
blanket to seal off the gap. Notice that the fl ameholder may
extend slightly into chamber as shown in Figure 3.
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 fi ber
refractories or fi berglass insulation, see WARNING on page
7.
Figure 3 Minimum combustion chamber dimensions
Input Minimum chamber dimensions, Inches
(Note 1)
Btuh
60,000 7 x 7 x 9 8 x 9
70,000 7½ x 7½ x 9 8½ x 9
100,000 8 x 8 x 9 9 x 9
120,000 9 x 9 x 9 10 x 9
140,000 10 x 10 x 9 11 x 9
160,000 11 x 11 x 9 12 x 9
180,000 12 x 12 x 9 13 x 9
Note 1: Rectangular chambers of similar fl oor area are equally acceptable, but the L/W ratio should not
exceed 2 and the width should be at least 5 inches.
(Using 2300ûF or higher refractories)
Square
L x W x H
Vertical cylinder
Diameter x H
Failure to comply with the above could result in severe
personal injury, death or substantial property damage.
6
Carlin part number MNG3B Gas Rev. 03/17/09
Model G3B Gas burner — Instruction manual
1. Prepare site • prepare burner • mount burner (continued)
Inspect burner and components
Do not install or operate the burner if any component is
damaged or if burner does not comply with the specifi cations
and guidelines in this manual and the appliance manual.
Air tube insertion length (UTL)
• Usable air tube length (UTL) is the distance from mounting fl ange to
end of air tube.
• Verify that the end of the air tube will be fl 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, page 6.
• Minimum UTL is 1¾ inches. Maximum UTL is tube length less 1¾
inches. Tubes are available in 6-inch, 9-inch and 12-inch lengths.
• Notice that the fl ameholder may extend slightly into chamber as
shown.
Prepare appliance for burner mounting
The universal fl ange supplied with G3B Gas burners is
intended only for fi ring chambers with negative overfi re
pressure. The G3B burner must not be installed on a product
that operates with a pressurized combustion chamber. Failure
to comply could result in severe personal injury, death or
substantial property damage.
Ceramic fi ber or
Fiberglass insulation
Ceramic fi ber materials, such as chamber liners, may
contain carcinogenic particles (chrystobalites) after
exposure to heat. Airborne particles from fi berglass or
ceramic fi 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-fi tting clothing,
gloves and eye protection. Use a NIOSH N95 certifi ed
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 fi ber removal: To prevent airborne dust, thor-
oughly wet ceramic fi ber with water before handling.
Place ceramic fi ber materials in a plastic bag and seal
to dispose.
• See page 21 for required dimensions and bolt locations.
Avoid blowing, tearing, sawing or spraying fi ber-
glass or ceramic fi ber materials. If such operations are
necessary, wear extra protection to prevent breathing
dust.
Wash work clothes separately from other laundry.
Rinse clothes washer thoroughly afterwards to prevent
contamination of other clothing.
NIOSH First aid procedures:
Eye exposure — irrigate immediately
Breathing — fresh air.
Carlin part number MNG3B Gas Rev. 03/17/09
7
Model G3B Gas burner — Instruction manual
1. Prepare site • prepare burner • mount burner (continued)
Inspect burner and components
Drill or ream gas orifi ce to size (initial installation)
You must disconnect power to burner and close main manual
gas valve before proceeding. Failure to do so could result
in severe personal injury, death or substantial property
damage.
You must drill or ream the burner orifi ce to the size given in
Figure 4. The orifi ce is shipped with a pilot hole only. Firing the
burner with the orifi ce as shipped can result in damage to the
burner. Never fi re the G3B burner below 60,000 Btuh input.
The fl ameholder can overheat, resulting in potential severe
personal injury, death or substantial property damage.
1. After drilling or reaming orifi ce to correct size, thread orifi ce fi tting into
orifi ce nipple as shown in Figure 4.
Install gas valve on burner
1. Read WARNING’s on page 9 before installing gas valve.
2. Apply a small amount of pipe dope (suitable for propane gas) to gas
valve outlet connection, gas line elbow and orifi ce nipple. Assemble
elbow and orifi ce nipple to gas valve.
To avoid damage to gas valve, do not hold valve with a pipe
wrench or over-tighten. Use only a crescent wrench or other
means. Failure to comply could result in severe personal
injury, death or substantial property damage.
3. Insert orifi ce nipple into burner gas connection and secure in place
using the two Allen screws.
4. Connect gas valve wires to gas valve.
Inspect/redrill gas orifi ce when required
1. Turn off power to the burner/appliance before proceeding.
2. Close main manual gas valve in gas line to burner. Then disconnect the
ground joint union to allow rotating burner combination gas valve.
You must disconnect power to burner and close main manual
gas valve before proceeding. Failure to do so could result
in severe personal injury, death or substantial property
damage.
3. Loosen Allen screws securing gas line to burner gas connection.
4. Remove combination gas valve (item 9, page 3) and gas piping to burner
gas connection (item 8, page 3) on burner air tube.
5. Read correct orifi ce drill size from Figure 4. Then check actual orifi ce
size using that size twist drill bit.
• If gas orifi ce is smaller than required, redrill orifi ce to correct size,
if necessary. Replace gas valve and piping, using only pipe dope listed
for use with liquefi ed petroleum gases.
• If gas orifi ce is larger than required, obtain a replacement gas orifi ce
fi tting. Drill orifi ce hole in replacement orifi ce fi tting.
Figure 4 Orifi ce and gas valve installation
Input
Btuh
Note 1 Natural Gas Propane Gas
60,000 #28 (0.141) #33 (0.113) 0
70,000 #24 (0.152) ¹⁄₈ (0.125) ½
80,000 #20 (0.161) #30 (0.129) ¾
90,000 #17 (0.173) #28 (0.141) 1
100,000 #14 (0.182) #25 (0.150) 1½
110,000 #11 (0.191) #22 (0.157) 1¾
120,000 #7 (0.201) #20 (0.161) 2¼
140,000 #3 (0.213) #16 (0.177) 3
160,000 A (0.234) #12 (0.189) 4¼
180,000 D (0.246) #7 (0.201) 9
Note 1: High altitude applications: The maximum burner input at sea level is 180,000 Btuh.
Note 2: Use this as the starting setting only. Adjust air throttle, if necessary, after performing
Burner orifi ce drill size
Diameter, inches
Reduce this capacity by 4% per 1,000 feet above sea level. Example — max.
capacity at 5,000 feet is 144,000 Btuh (20% reduction).
combustion testing (see page 14).
Air throttle
turns (appr.)
Notes 1 & 2
Hot surface ignitor
• Inspect the burner from air tube end. The hot surface ignitor must extend
slightly past the end of the burner.
• Carefully inspect the ignitor, ensuring it is intact, with no cracks or visual
signs of degradation.
• Do not touch the ignitor with bare hands. Body oils can cause deterioration
of the silicon carbide.
• Replace ignitor if there are any signs of damage.
You must allow ignitor to cool before attempting to handle.
Failure to do so could result in severe personal injury or
damage to the ignitor.
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.
Mount burner in appliance
• Verify appliance burner front plate dimensions per page 21.
• Slide gasket supplied with burner over end of air tube.
• Insert burner into appliance opening and bolt in place.
8
Carlin part number MNG3B Gas Rev. 03/17/09
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