Carlin EZGas Pro, Instruction Manual

Page 1: ...del 41800 solid state ignitor Control Carlin Model 60200FR microprocessor control Agencies UL Listed US and Canada Installer servicer Except where specifically stated otherwise this manual must be used only by a qualified service technician In the state of Massachusetts this product must be installed by a licensed Plumber or Gas Fitter Failure to comply with this or other requirements in this manu...

Page 2: ...3 1 or the CAN CGA B149 Installation Codes The electrical installation must also conform with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 CSA C22 2 Special attention flags Please pay particular attention to the following when you see them through out this manual Notifies you of hazards that WILL cause severe ...

Page 3: ...el and input 18 Airflow proving switch Prevents burner from firing if air is not moving 19 Combination gas valve with integral gas pressure regulation set for 3 w c outlet pressure 24V 20 Gas supply entrance NPT 5 w c min 14 w c max 21 24V Transformer 1 Air tube flange omitted for clarity with powder coat paint finish 2 Diffuser plate interchangeable hole or slot pattern 3 Gas manifold concentric ...

Page 4: ... vent system must be inspected and comply with all applicable local and national codes including National Fuel Gas Code NFPA54 ANSI Z223 1 ANSI Z21 8 or CAN CGA B 49 Canada Adefective 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 chimney Refer to the appliance manufacturer s manual when av...

Page 5: ...f the building construc tion is unusually tight see National Fuel Gas Code for definition you will need to provide air openings into the building Provide two openings sized and located as for the openings into the boiler space Confined 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 floor...

Page 6: ...e around the burner air tube is more than wrap the burner air tube with minimum 2300 F rated ceramic fiber blanket to seal off the gap Repair or replace damaged appliance components Inspect the appliance thoroughly Follow appliance manufac turer s guidelines for repair or replacement of any component found defective When cleaning the appliance or working with ceramic fiber refractories or fibergla...

Page 7: ... Diffuser Plate and the A or B Diffuser Plate it is likely that either diffuser will work but one may provide better combustion The 9 slot s short flame pattern favors appliances with shorter combustion chambers Use this as the star ng se ng only Adjust air band se ng if necessary a er performing combus on tes ng see page 13 Notes 3 4 5 Some tested appliances may operate sa sfactorily with dimensi...

Page 8: ...uired redrill the orifice to the correct size if necessary If gas orifice is larger than required obtain a replacement orifice nipple from Carlin If necessary drill the orifice hole in the replacement orifice nipple to the correct size Drill the orifice carefully avoiding drill wobble Wobble will cause the orifice to be over sized The orifice nipple should be secured in a vise if possible to ensur...

Page 9: ...fy it is large enough to handle the load of all connected appli ances 2 When branching from a common gas line do not tap off from the bottom of horizontal sections only from the side or top 3 Install a main manual shutoff valve sediment trap and ground joint union near the burner combination gas valve connection as shown in Figure 6 4 If the burner is installed inside the appliance jacket install ...

Page 10: ...nse flame and go into a lockout condition The minimum flame signal needed to satisfy the 60200FR sensing circuit is 0 8 microamps The control will register flame failure at any lower signal When the EZGas is properly set up the flame signal strength is typically 2 microamps or greater Code compliance The burner appliance installation must comply with codes listed on page 2 and any other locally ap...

Page 11: ...the gas meter dial For a one half cubic foot per revolution dial there should be no movement of the dial for at least 5 minutes For larger volumes per revolution increase this time proportionately 4 If you detect a gas leak locate the leak with a soap suds mixture and repair it Then test the system for leaks again Do not test for leaks with an open flame And do not use oxygen as a test gas Either ...

Page 12: ...rner if the combustion chamber contains gas Button Functions Reset 1 Return to Standby from other operating states Press for second 2 Reset control from Lockout Press for 1 second 3 Reset control from Latch up Press for 30 second Display Control ESC Display previous Operating State from Operating screen Exit Log or Setup screen to Operating screen with 3 second press Scroll through recent fault in...

Page 13: ...No flame detected at the end of TFI Flame is detected during Pre purge Pre ignition or Post purge CO input not detected during Pre purge Pre ignition TFI or Post purge BV input not detected after 30 second delay during Pre purge Pre ignition TFI or Post purge Motor ignitor or valve relay weld detected If the control is miswired causing voltage to be detected on the outputs terminals motor ignitor ...

Page 14: ...ond line contains the Value and Units if appropriate Lines starting with Total are not reset by Baseline Reset All other lines are reset using Reset Baseline setpoint Fault Cycles Number of fault cycles in log 50 max then oldest is discarded Total Cycles Total Number of CFH cycles since control was put into service Total Run Time Motor on Total Motor on time since control was put into service Tota...

Page 15: ...raft causing flame to leave burner head check for proper air band setting and draft Excessive back pressure causing flame to be erratic check appliance and flue for sooting plugging Defective flame rod assembly Control locks out at end of TFI Check for No gas to burner check gas supply Verify gas pressure is no higher than allowed for gas valve usually 1 2 psig or 14 water column Shorted electrode...

Page 16: ...s valve pressure regulator if necessary to obtain the correct firing rate Valve outlet pressure must not be lower than 3 2 inches w c nor higher than 3 8 inches w c M For propane gas contact your propane supply for procedure to verify firing rate Make final burner adjustments Check for leaks in gas piping M Smell around burner to make sure there is no gas leak in near burner piping Verify integrit...

Page 17: ...peration Verify correct operation of burner and control throughout Verify vent system operation M Verify vent is operating correctly and flue products are properly exhausted from building M Check operation of barometric damper and spill switch M If the building contains any exhaust fans or conditions that could affect vent performance check burner appliance vent operation with exhaust fans or othe...

Page 18: ...ut and nylon washer securing the housing end of the assembly support rod 3 Remove the access cover page 5 by loosening the screw securing it in place 4 Pull the electrode flame rod assembly straight back and out 5 Clean the assembly if necessary Replace any part that is damaged 6 Check the dimensions of the assembly against those shown in Figure 5 page 8 Adjust if necessary If the inside surface o...

Page 19: ... two bolts securing the motor to housing 2 Disconnect the motor wires in the burner junction box 3 Loosen the Allen screw securing the blower to the motor shaft and remove the wheel 4 When assembling the replacement assembly slide the wheel onto the motor shaft and use feeler gauges to set a space of 3 64 inch between the blower wheel and the motor face 5 Replace the motor wheel assembly in the ho...

Page 20: ...esetting the 60200FR control from Latch up be sure to investigate what caused the repeated failures Correct the condition Incorrect wiring Check wiring against appliance and burner wiring diagrams Verify all connections are secure Defective motor Remove motor leads from junction box and apply power directly If motor fails to operate then replace Defective primary control If control receives power ...

Page 21: ...Model EZGas Pro gas burner Instruction manual MNEZGas 011917 21 Where appliance instructions differ from this manual follow the appliance instructions 7 Troubleshooting continued ...

Page 22: ...d to meet appliance requirement 4 Carlin 41800 solid state ignitor 5 Combination gas valve 6 Carlin PSC motor 7 Cast aluminum blower housing 8 Transformer and Air flow proving switch QUALITY CHARACTERISTICS CRITICAL MAJOR A MAJOR B MINOR NO SYMBOL CRITICAL STATISTICAL SEE QAS 1000 FOR VENDORS QUALITY ASSURANCE REQUIREMENTS TOLERANCE UNLESS OTHERWISE SHOWN FRACTIONAL 1 64 ANGLE 1 2 DEC XX 01 XXX 00...

Page 23: ...Model EZGas Pro gas burner Instruction manual MNEZGas 011917 23 Where appliance instructions differ from this manual follow the appliance instructions ...

Page 24: ... Diffuser 2 Airbands 5 98522S Air Flow Switch 120 Volt 50806S Air Flow Switch 24 Volt 6 98554S Blower sensing lines kit Only used on EZGAS 120V version not shown 7 50824S Gas valve 24 volt 98523S Gas valve 120 volt 8 50819AS Gas valve power harness EZGas Pro only 9 9938440XX Field drilled orifice 10 77933S Blower wheel 11 98629S Motor PSC 1 15HP 98022S Motor PSC 1 6HP Can be used on gas same as oi...

Page 25: ...differ from this manual follow the appliance instructions 9 Replacement parts continued 17 4 5 14 15 13 12 16 10 11 20 2 2 1 9 8 7 Burner is shown with welded flange supplied only on burners ordered for specific appliance applications Other burners are supplied with the universal flange item 2 ...

Page 26: ...Model EZGas Pro gas burner Instruction manual MNEZGas 011917 26 Where appliance instructions differ from this manual follow the appliance instructions ...