Carlin 102CRD 99FRD User manual
Instruction manual
™
Contents
PLEASE read this first.......................................................2
Codes and standards........................................................2
1. 99, 100, & 102 Oil nozzle selections............................3
2. Prepare site • assemble burner • mount burner 4
3. Prepare burner ............................................................9
4. Wire burner • start burner – 48245 primary control . 14
4. Wire burner • start burner – 40200 primary control . 16
4. Wire burner • start burner – 50200 primary control . 18
4. Wire burner • start burner – 60200 primary control . 20
5. Adjustment and verication.......................................22
6. Annual start-up and service ......................................23
7. Repair parts ...............................................................24
8. Maintenance procedures...........................................26
Warranty .........................................................................27
User care and maintenance...............................Rear cover
70 Maple Street East Longmeadow, MA 01028
Ph 413-525-7700 Fx 413-525-8306
Te c h s u p p o r t 800-989-2275 carlincombustion.com
©Copyright 2004 — Carlin Combustion Technology, Inc.
Installer/servicer — Except where specifically stated other-
wise, this manual must be used only by a qualified 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
Ratings
Input: 99FRD ..................................................0.50 to 3.00 GPH
100CRD............................................... 0.50 to 2.25 GPH
102CRD (2B\,’’ air cone).................... 2.00 to 3.50 GPH
102CRD (3’’ air cone) ....................... 3.00 to 4.50 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 p s i g nozzle pressure
Electrical: Power...........................................120V/60 Hz/1-Phase
Motor........................... Carlin PSC, 1/6 HP, 3450 RPM
Current
99FRD ..................................... Approx. 5.5 amps
100CRD ................................... Approx. 5.5 amps
102CRD ................................... Approx. 6.0 amps
Ignition: ..........Carlin Model 41000 electronic — 14,000 volts
Control: .................... U.L. Group I or II primary safety control
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08
– 2 –
PLEASE read this first . . .
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 personal injury,
death or substantial property damage.
Notifies you of hazards that CAN cause severe personal injury,
death or substantial property damage.
Notifies you of hazards that WILL or CAN cause minor personal
injury or property damage.
Notifies 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, 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 file damage or shortage claims im-
mediately 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.
Follow the guidelines below to avoid potential severe
personal injury, death or substantial property damage.
Installer/service technician . . .
• Readallinstructionsbeforeproceeding.Performallprocedures,
and in the order given to avoid potential of severe personal injury,
death or substantial property damage.
• Beforeleavingthesiteafterstartuporservice,reviewtheUser’s
information page with the user. Make the user aware of all potential
hazards and perform the training outlined below.
Train the user . . .
• Toproperlyoperatetheburner/applianceperthismanualandthe
appliance instructions see User’s information.
• Tokeepthismanualatorneartheburner/applianceforreadyac-
cess by the user and service technician.
• To contactthe service technicianor oil dealerif heencounters
problems with the burner/appliance.
• Tokeeptheappliancespacefreeofammableliquidsorvapors
and other combustible materials.
• Donotuselaundryproducts,paints,varnishesorotherchemicals
in the room occupied by the burner/appliance.
• Tocontacttheservicetechnicianatleastannuallyforstartupand
burner/appliance service.
When servicing the burner . . .
• Disconnectelectricalsupplytoburnerbeforeattemptingtoservice
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.
Should overheating occur:
(1) shut off the oil supply to the burner.
(2) do not shut off the control switch to the circulator or
Certification
99FRD, 100CRD,and102CRD burnersare U.L.listedfor theU.S. and
Canada,certiedtocomplywithANSI/UL296,forusewith#1or#2heating
oil(perstandardASTMD396).
Burnerlabelslistcompliance,whenrequired,withspeciallocal,stateor
provincial approvals.
in this manual.
United States installations
Burner/applianceinstallationsintheUnitedStatesmustcomplywiththe
latest editions of NFPA 31 (Standard for the Installation of Oil-Burning
Equipment),ANSI/NFPA70(NationalElectricalCode),andallapplicable
local codes.
Canadian installations
Burner/applianceinstallationsinCanadamustcomplywiththelatesteditions
ofCSAB139(InstallationCodeforOilBurningEquipment),CSAstandard
Codes and standards
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
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08 – 3 –
1. 99, 100, & 102 Oil nozzle selections (when appliance data is not available)
Table 1 Apply the guidelines below to select a nozzle when appliance-specific nozzle data is not avialable from the
manufacturer. See notes at end of table for application tips. 99FRD wrapped-shield air tubes are intended only for
approved applications in wet-base combustion chambers.
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08
– 4 –
2. Prepare site • assemble burner • mount burner
Inspect/repair/replace vent system
Donotinstallthisburnerunlessyouhaveveriedtheentire
vent system and the appliance are in good condition and
complywithallapplicablecodes.And...
•Theventandchimneymustbesizedandconstructedin
accordance with all applicable codes.
•Donotinstalloruseanexistingmanualdamperinthe
breeching (vent connector) or chimney.
•Donotconnecttheapplianceventconnectortoachimney
or vent serving a fireplace, incinerator or solid-fuel-burning
apparatus.
•Inacoldclimate,donotventintoamasonrychimneythat
has one or more sides exposed to the outside. Install a listed
stainlesssteellinertoventtheueproducts.
•Adefectiveventsystemcouldresultinseverepersonal
injury, death or substantial property damage.
Prepare vent/chimney
• Secureallmetalventjointswithscrews,followingtheventmanufacturer’s
instructions.Sealalljointsintheventsystemandchimney.Repairmasonry
chimney lining and repair all mortar joints as needed.
• Installadouble-actingbarometricdraftregulatorintheventpipingifspeci-
fied in the appliance manual. (The damper must be located in the same
space as the appliance.)
• Providesupportfortheventpiping.Donotresttheweightofanyofthe
ventpipingontheapplianceueoutlet.
Table 2 Minimum combustion/ventilation air openings
Combustion/ventilation air openings
Checkappliancemanualandapplicablecodesforrequiredsizing/design/
placement of combustion/ventilation air openings. You can use the follow-
inggeneralguidelines,takenfromNFPA31,providedtheymeetalllocal
requirements.
Louvers/screens
• Airopeningsizesarealwaysgiveninfreearea.Thismeansafterdeduction
forlouverobstruction.Ifyoucan’tndthelouverreductionforthegrilles
used,assumefreeareais20%oftotalforwoodlouvers,or60%oftotal
for metal louvers.
• Screenscanbenonerthan¼-inchmesh,andmustbeaccessiblefor
cleaning.
Residential installations
Unconnedspaces(atleast7,000cubicfeetperGPH)
• Anunconnedspacemeansaroomwithatleast7,000cubicfeetvolume
foreachGPHinput(or50cubicfeetperMBH)ofallappliancesintheroom.
Example:Foreach1GPHoilinput,theroommusthave7,000cubicfeet
(875squarefeetwithan8-footceilingheight.)
• Open basements and crawl spaces are usually large enough, and will
generally allow enough air infiltration so special provisions will seldom be
required.
• Ifthebuildingistightlyconstructed,youwillhavetoprovideoutsideair
openings into the building. The total free area of the openings must be
atleast1squareinchper5,000Btuh(28squareinchesperGPH)ofall
appliances in the space.
• SeeTable2forsummary.
Connedspaces(lessthan7,000cubicfeetperGPH)
• Airtakenfrominsidebuildingonly—
• Providetwoopenings—onenearoor,theothernearceiling.Providefree
areaof140squareinchesperGPHinput.Ifbuildingistightlyconstructed,
provideairopening(s)intobuildingproviding30squareinchesperGPHas
well.
• Airtakenfromoutside—
• Directthroughoutsidewallorverticalducts:Providetwoopenings—one
nearoor,theothernearceiling.Providefreeareaof35squareinchesper
GPHinput.
• Throughhorizontalducts:Providetwoopenings—onenearoor,theother
nearceiling.Providefreeareaof70squareinchesperGPHinput.
• Ventilationairfrominside/combustionairfromoutside
• Sizeopeningstointeriortoprovide140squareinchesfreeareaperGPH
input. Size outside air duct to provide 28 square inches free area per
GPH.
• SeeTable2forsummary.
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08 – 5 –
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
withexhaustfansorunsealedreturnairducts.Alwayscheck
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 sufficient 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:
• Gasolineorotherammableliquidsorvapors.
• Combustiblematerials.
• Aircontaminantsandchemicals,suchaslaundryproducts,paint,thinner,
varnish, etc.
❏ Conrmwiththebuildingownerthattheareawillbekeptfreeofthese
materials at all times and that air openings will be kept unobstructed.
2. Prepare site • assemble burner • mount burner (continued)
Verify combustion chamber
Chamber dimensions and construction
• Ifretrottingtheburnertoanappliance,installtheburnerinaccordance
with the appliance instruction manual, when available. If no specific
application data is available from the appliance manufacturer, read the
guidelinesinFigure1,page6,tocheckwhethertheburnerislikelyto
work acceptably in the application.
Verify clearances
Verify that the burner/appliance will maintain all clearances from combus-
tible construction and clearances for service/maintenance as required in
the appliance manual and applicable codes.
Verify that the vent system components maintain all necessary clearances
to combustible construction, including the correct design of thimbles and
insulation where penetrating combustible walls.
• IllustrationsAtoFinFigure1showdifferentchambercongurations
with and without refractory linings. The chamber dimensions listed in
Figure 1 depend on whether the chamber is lined or water-backed.
• Donotattempttoretheburnerinachamberwithdimensionssmaller
thanshowninFigure1,page6,unlesstheapplicationhasbeenspeci-
callytestedandlistedbytheappliancemanufacturerand/orCarlin.
• Chambers with dimensions larger than shown in Figure 1, page 6,
should not have much effect on combustion/performance.
General guidelines
• Cleanallapplianceuesandheatingsurfacesthoroughly,removingall
soot and scale.
• Sealalljointsandgapsusingfurnacecementtopreventexcessair
infiltration.
The99FRDwrapped-shieldairtubemustbeusedonlyin
wet-base combustion chamber applications.
Using chamber linings and lightweight chambers
• Whenusingrefractorylinersorlightweightchambers,useinsulating-
typerefractoryrated2300°Fminimum.
• Youmustinstallatargetwalllinerifamelengthisclosetothelength
of the chamber.
• Useaoorlinerwhenpossible.Theoorlinerwillimproveringinmost
applications.Extendoorliner3to4inchesupsidewall.
• Targetwallliners—Corbelthetopoftargetwallliners1½to2½inches
deepandextendatleast3to4inchesabovethecenteroftheame.
• Usepre-formedchamberlinerswhenavailable.
• Forringratesbelow0.75GPH,itisbesttoapplyinarefractory-lined
orstainlesstube(designedforapplication)chamber.Liningtheoor
and target wall of the chamber with lightweight insulating refractory
will accomplish the same.
• Whenconversionringcoal-redunits,installacombustionchamberin
the ashpit area, or fill ashpit with sand up to 2 inches above the “mud
ring” of a boiler (firing through the door). Install a lightweight refractory
lineronthetargetwallasinFigure1F,page6.Makesuretheminimum
dimensions comply with those for Figure 1F.
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08
– 6 –
Figure 1 99FRD, 100CRD and 102CRD Minimum combustion chamber dimensions (all dimensions in inches)
2. Prepare site • assemble burner • mount burner (continued)
Chamber configurations
A Chamberwithwater-backedoorandtargetwall,withrefractoryliningson
oorandtargetwall.
B Chamberwith water-backedoorandtargetwall, with refractoryliningon
target wall only.
C Chamberwithwater-backedoorandtargetwall,withoutrefractorylinings.
D Refractorychamber,nowater-backedsurfaces(drybasedesign).
E Chamberwithrefractoryoorandwater-backedtargetwall(without target
refractory lining).
F Chamberwithrefractoryoorandwater-backedtargetwall(with target refrac-
tory lining).
Notes for dimension table
1 Some tested appliances operate well with dimensions other than shown
below.
2. Generally, applications should be acceptable with dimensions larger than
listed.
3. Horizontalcylinderchambersshouldhaveadiameteratleastaslargerasthe
minimum width listed. For steel cylinder chambers, increase this dimension
by from 1 to 4 inches.
4. Wingwallsarenotrecommended.Corbelscanbebenecialtoheatdistribution
in some applications.
5. DVistheminimumdiameterforverticalcylindricalchambers(refractoryor
refractory-lined chambers only).
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08 – 7 –
Inspect burner and components
• Checktheairtubelength.VerifytheusablelengthofthetubeUTLwill
be long enough (see “Mount burner in appliance”).
• Visuallyinspectallburnercomponentsandwiring.
• Verifythatwiringisintactandleadsaresecurelyconnected.
• Verifythatallburnercomponentsareingoodcondition.
Donotinstalloroperatetheburnerifanycomponentisdam-
aged or if burner does not comply with the specifications of
Table1,page3,andotherguidelinesofthismanualandthe
appliance manual.
Welded-flange burners
1. Verifytheboltpatternontheappliancechambermatchestheange
pattern.
2. Verify the insertion depth (UTL) matches the depth of the appliance
opening(sotheendoftheairtubeisushwith,orslightlyshortof,the
inside surface of the combustion chamber).
Assemble burner (when required)
Universal (adjustable) flange burners
1. Verifytheangemountingslotslineupwiththeappliancebolts.See
Figure 2.
2. Sliptheadjustableangeontotheairtube.
3. Measurethedistancefromtheinsideofthecombustionchamberto
the outside of the appliance mounting plate.
4. Positiontheuniversalangeatthisdistancefromtheendoftheair
tube.
5. Tightenthelockingscrewsngertight.
6. Inserttheairtube/angeassemblyintotheapplianceopeningandlevel
theairtubewithaspiritlevel.Adjustangeifneeded.
7. Theendoftheairtubeshouldbeush,oralmostush,withtheinside
of the combustion chamber wall.
8. Verify the air tube is level and inserted the correct depth. Adjust if
necessary.Thentightentheangelockingscrewssecurely.
9. Removetheange/airtubeassemblyfromtheopening.
Pedestal mount burners
1. Checkthediameteroftheapplianceopening.Iflargerthan4½inches,
rebuildtheopeningsotheopenisreducedto4½inchesmaximum.
2. InserttheairtubeintotheapplianceopeningasinFigure3.Donot
attach air tube to housing yet.
3. Slidethetubeinuntiltheendofthetubeisushwith,orupto¼inch
short of, the inside of the combustion chamber.
Figure 2 Universal flange mounting dimensions
Figure 3 Mark insertion depth on air tube when using
universal flange mounting
2. Prepare site • assemble burner • mount burner (continued)
4. Level the air tube using a spirit level.
5. Marktheairtubepositionwithapenorpencilaroundthecircumference
of the tube.
6. Removeairtubefromtheopening.
NOTICE — 99FRD burners firing above 2.25 GPH
1. 99FRDburnersareshippedwiththeblankairshutter(behindfuelunit)
installed.Thisshutterissuitableonlyforringratesupto2.25GPH.
2. Forringratesover2.25GPH,obtainanopentypeairshutterfrom
yourCarlindealer.Removetheblankshutterandreplacewiththeopen
shutter.
3. Theoptionalopenairshutterissuitableforringratesfrom1.50to
3.00GPH.
4. To change air shutters, remove the burner fuel unit. (The fuel unit holds
the shutter in place.) Install the correct shutter and replace the fuel
unit.
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08
– 8 –
2. Prepare site • assemble burner • mount burner (continued)
Attach air tube to housing
1. SeeFigure4.Loosenairtubeholdingclamponthefrontoftheburner
chassis.
2. Openignitorcoverplatebylooseningthehold-downtabsandswinging
them away.
3. Spreadthehousingslightlyusingaatscrewdriverbetweenthetwo
halves of the housing on top at the air tube collar.
4. Insert the air tube into the housing, make sure the tube is inserted
completely, butting against the air tube collar legde. If necessary, tap
on the end of the air tube with a block of wood until properly seated.
5. Whenusing99FRDwrapped-shieldairtubeor102CRD“B”styleair
tube, locate the drip hole in the air cone. Rotate the air tube so the drip
hole is at the bottom before pressing into place.
6. Slideairtubeholdingclampontocollarandtighten.
Figure 4 Attaching air tube to burner chassis
Mount burner in appliance
Welded flange-mounted burner
1. Place gasket over burner air tube and insert burner into appliance
opening.Secureinplacewithhardwaresuppliedwithappliance.
Universalangeorpedestalmount—theseinsertionmethods
are intended only for negative overfire pressure. For pressur-
izedring,youmustobtainaburnerwithaweldedange,
designed for use with the specific appliance.Failure to comply
could result in severe personal injury, death or substantial
property damage.
Universal flange-mounted burner
1. Place gasket over burner air tube.
2. Insert burner into appliance.
3. Verifyburnerisseatedlevelandstraight.Adjustangeslightlyifneces-
sary.
4. Secureangetoappliancewithhardwaresuppliedwithappliance.
Pedestal-mounted burner
1. Assemblepedestaltothebottomoftheburnerbytighteningthetwo
¼-20slottedcapscrewsagainstthefrontfeetofthehousing.See
Figure5.Installthe fouradjusting legs(3/8-16 x 3”hex-head cap
screws).
2. Adjustthepedestallegssotheairtubeislevelandthecenterofthe
tube is at the same height as the center of the appliance opening.
3. Tightenthepedestallegjamnutstolocklegsinplace.
4. Insert the burner/air tube into the appliance opening until pen/pencil
lineisevenwithappliancefront(soendofairtubeisushwith,or
slightly short of, the inside of the chamber).
5. Sealthespacearoundtheairtubewithfurnacecementorequivalent
(Figure6).
Figure 6 Seal opening around burner air tube when
pedestal mounting (burner shown with tube
attached to housing and installed)
Figure 5 Attaching burner to pedestal (when used)
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08 – 9 –
3. Prepare burner
Removing/installing head assembly
Use care when handling burner components after the burner
hasbeenring.Componentscanbehotandcouldcause
severe personal injury.
You will need to remove the combustion head assembly for inspection of
the assembly, replacement of the oil nozzle or adjustment of electrodes.
To remove the assembly:
1. Loosen, and then rotate the two screw clamps securing the ignitor in
place.Swingtheignitorplateopen.
2. See Figure 7.Remove theblower shieldby loosening theretaining
screw on its front edge if needed for easier removal or insertion of the
combustion head assembly.
3. Unscrewtheoillinettingandthumbnutattheburnerhousing.
4. Pull the threaded end of the oil tube into the blower housing.
5. See Figure 7. Rotate the combustion head assembly 180° so the
electrodes are upside down. This places the electrode insulators out
of the way for easy removal.
6. Removethecombustionheadassemblybypullingtheassemblyup
and out of the housing.
7. Handletheassemblywithcaretoavoidbending/movingtheelectrodes,
or damaging the electrode ceramic insulators.
8. Inspect the gasket on the bottom of the ignitor plate.The gasket prevents
air from escaping from the housing. Replace the gasket if not in good
condition.
9. Inspecttheignitorcontactclips.Cleanorreplaceifnecessarytoensure
reliable contact with the electrodes.
Install nozzle/check electrodes
1. Loosentheclampscrewontheretentionringassembly(seeFigure10,
page10).Slidetheretentionringassemblyoffofthenozzleadapter.
Then loosen electrodes to rotate out of the way.
2. Install and tighten the nozzle shown inTable 1, page 3, for retrot
applications. Install the nozzle given in the appliance manual when
applicationinformationforthe99FRD,100CRD,and102CRDoilburner
is given.
3. Holdthenozzleadaptersecurelywhenremovingorreplacingthenozzle
(Figure 9). Take care not to damage the electrode insulators or to bend
the electrodes in the process.
To replace the combustion head assembly, reverse the sequence.
• Remember to put the assembly in upside down, so the electrode
insulators are out of the way. Remove, then replace, the blower shield
if necessary for easier removal/insertion of the assembly.
• SeeFigure8.For99FRDor100CRDburners,youwillhavetoliftthe
end of the assembly to guide it through the throttle at the end of the
airtube.DONOTFORCE.
Use care when tightening the oil line fitting to oil tube extension.
Tighten securely, but do not cross-thread or over-tighten.
Figure 8 Inserting combustion head assembly
Figure 7 Removing/inserting combustion head assembly
Figure 9 Carefully support the nozzle adapter when
installing or removing nozzle
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08
– 10 –
3. Prepare burner (continued)
Inspect the nozzle adapter before replacing the nozzle. If the
threads have been damaged or show score marks, replace
the nozzle line/adapter assembly.
4. Replace the retention ring assembly by slipping one of the riveted arms
throughthegapbetweentheelectrodetips.Alignthisarmstraightup,
with the ring clamp firmly against the nozzle adapter shoulder (see
Figure10).Thentightentheclampingscrew.
5. Repositionandchecktheelectrodesettings.Positiontheelectrodesas
showninFigure10.Thesesettingsarecriticalinensuringareliable
ignition.Oncetheelectrodesareset,checkallclampstobesurethey
are securely tightened.
6. Insertthecombustionhead/nozzleassemblyintheburner.
Check zero position (99FRD & 100CRD only)
1. SeeFigures11,12and13.Loosentheoillinethumbnutandadjusting
slide locking screw. Use a B\cx"Allenwrenchtorotatetheadjusting
screwuntiltheleadedgeoftheslidealignsto“0”onthescale.The
retentionringshould be ush, ornearlyush, with the edgeofthe
throttling ring.
2. Iftheretentionringisnotclosetoushwiththethrottlering,make
sure the air tube is completely inserted into the housing collar and the
Set initial burner air settings
Combustionhead
1. The combustion head adjusting slide controls the spacing between the
retention ring and throttle ring (or air cone), regulating how much air
passes around the retention ring.
2. Loosen the oil line thumb nut and adjusting slide locking screw. Use a
B\cx"Allenwrenchtorotatetheadjustingscrewuntiltheleadedgeof
theslidealignstothenumbergiveninTable3,page11.Lockinplace
by first tightening the oil line thumbnut, then tightening the locking
screw.
Airshutter
1. Theairshutterisxedforall99FRD,100CRDand102CRDburners.
Seepage7forthecorrectairshuttertype.(Some102CRDburners
maybeequippedwith3-slotairshutters.)
Airband
1. The air band is marked in percent opening. Loosen the air band locking
screw and move the air band until the pointer lines up with the percent
openinggiveninTable3,page11.
Final adjustments
1. The burner is now adjusted to the approximate air settings for the firing
ratechosen.Whenyoucheckcombustionwithinstrumentsduringstart-
up or servicing, you may have to adjust the head slightly to achieve the
desiredefciency.See“Adjustburnerusingtestinstruments,”page22.
(Notethatpressureoverrewillreduceairow,requiringmoreair
opening.)
Figure 11 Check zero position — 99FRD & 100CRD only
Figure 10 Combustion head/nozzle/electrode settings Figure 12 Combustion head and air band adjutsments
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08 – 11 –
3. Prepare burner (continued)
Figure 13 Combustion head/air tube combinations, typical
Table 3 Approximate air band and combustion head settings
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08
– 12 –
3. Prepare burner (continued)
• Thenozzlelineheaterneedspowerwhentheburnerisinstandby(no
call for heat from the appliance). Make sure the nozzle line heater is
powereddirectlyfromthe120VACHOTline,notthroughtheappliance
operating control circuit. The nozzle line heater wiring should be shown
on the wiring diagram supplied with the appliance/burner unit.
• Thenozzlelineheaterissuppliedwithanelectricaldisconnectharness,
allowing removal of the combustion head assembly without discon-
necting wires. Position the heater harness disconnect in the rear of
the blower housing, above the blower access cover. The wire leads to
the disconnect route through the side of the housing into the junction
box.
Whenrststartingtheburner,oraftertheserviceswitchhas
beenoffforsometime,theheaterrequiresabout15minutes
to bring the oil to operating temperature.
Figure 14 One-line fuel system
One-line fuel system requirements
SeeFigure14.Thestandardburnerfuelunitisasingle-stage,3450-RPM
oilpump.Applythisfuelunitonlyonone-linesystemswherethefuelsup-
ply is on the same level with, or higher than, the burner. This ensures oil
owbygravity.Alsomakesurethetotalliftdoesnotexceed8feet(height
difference from bottom of oil tank to fuel unit). For other conditions, you
must provide a two-line fuel system. You may also have to change the fuel
unit to a two-stage type.
Inspect/install fuel supply
Inspect the oil supply system. Ensure that the fuel lines are
correctlysizedandinstalledandthatthefuelowisunob-
structed,theoiltankiscleanandonly#1or#2heatingoil
aresupplied.Failuretosupplyareliableoilowcouldresult
in loss of heat and potential severe equipment damage.
Nozzle line heater
• Oilburnersoftenoperateinspaceswhere temperatures tendtobe
cool,typically60°Forlower.Cooloilhashigherviscosity,whichcan
affect atomization, ignition, combustion and fuel consumption. The
nozzle line heater avoids this problem by heating the nozzle line oil to
between120°Fand130°F,resultinginsmootherignitionandimproved
combustion.
General guidelines:
• Wheninstalling oillines, usecontinuous runs ofheavy-wall copper
tubing if possible.
• Checkfuelunit(oilpump)datasheetforrecommendedlinesizing,lift
limitations and maximum length.
• Checkallconnectionsandjointstoensuretheyareair-tight.
• Usearettings.DoNOTusecompressionttings.
• Neverusepipesealingtape.Fragmentscanbreakoffandplugfuelline
components.
• Installashut-offvalveatthetankandoneneartheburner.(Usefusible
handle design valves when possible or when required by codes.)
• Installalargecapacityfuellter(ratedfor50micronsorless)nearthe
burner.
Fuel unit bypass plug
The fuel unit is shipped with its bypass plug not installed,
intended for a one-line oil system. Install the bypass plug only
ifconnectingtoatwo-lineoilsystem.Operatingwiththeplug
in place on a one-line system will damage the fuel unit and
could lead to oil leakage and fire hazard.
Ifthefuellineorfuelsupplyisaboveburner,neverexceed3
PSIGpressureatthefuelunitinlet.InstallasuitableOSVto
reducethepressure.Operatingthefuelunitwithhigherinlet
pressure could result in fuel unit seal damage, oil leakage
and potential fire hazard.
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08 – 13 –
Figure 15 Two-line fuel system
Table 4 Two-line fuel system maximum lengths for 3/8”
and 1/2” OD copper tubing distribution. Use only
for burners equipped with Suntec fuel units. See
fuel unit data sheet for any other fuel unit.
Perform checkout procedures
Verify before starting burner:
Shouldoverheatingoranemergencyoccur,immediately:
•Shutoffoilsupplylinevalve.
•Undersomecircumstancespowershouldremainonfor
waterpumpsorblowers.Determineproperresponsebefore
attempting start-up.
• Ifburnerfails ignitiononseveral attempts, useburner
blower to purge appliance chamber before restart.
Checklist
❏ Burner/applianceinstalledperapplianceinstructionmanual?
❏ BurnernozzleandheadpositioningbarveriedagainstTable1,page
3,orappliancemanufacturer’sinstructions?
❏ Burner/applianceinstalledperallapplicablecodes?
❏ Installation site has adequate combustion/ventilation air openings and
ventsystem?
❏ Fuelsupplylineingoodconditionandsized/designedcorrectly?
❏ Oiltankhasoilandoillinevalvesareopen.
❏ Wiringinstalledperburner/applianceinstructions?
❏ Burner,applianceandallcomponentsinspectedandingoodcondi-
tion?
3. Prepare burner (continued)
Two-line fuel system requirements
SeeFigure15andTable4.UseTable4onlyforburnersequippedwith
Suntecfuel units.Forburners using otherfuel units,readthe fuel unit
manufacturer’sdatasheettodeterminemaximumlengthsandlifts.
Thestandardburnerfuelunitisasingle-stage,3450-RPMoilpump.Use
this fuel unit only on two-line oil systems that do not exceed the total
tubinglengthsallowedinTable4(forSuntecfuleunitsonly).Forlonger
systems(orwhereliftexceeds10feet),replacetheone-stagefuelunit
with a two-stage unit.
Alwayssizefuellinesusinganoilowratebasedonthefuelunitgearsetca-
pacity,nottheburnerringrate.Seefuelunitdatasheetforinformation.
Install the fuel unit bypass plug when connecting to a two-line
system.The plug is shipped in a bag attached to the fuel unit,
along with a fuel unit data sheet.
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08
– 14 –
Wire burner — 48245 primary control
1. Allwiringmustcomplywith:
• IntheU.S—theNationalElectricalCode,ANSIZ223.1/NFPA54.
• InCanada—theCanadianElectricalCodePart1,CSAstandardC22.1.
• Allapplicablelocalcodes/standards.
2. Wire the burner following Figure 16 and any special instructions or wiring
diagram provided with the appliance, burner or other components.
3. Theburnerrequiresa120VAC/60hz/single-phasepowersupply,withatleast
a5-ampfuse.Thecurrentdraw(equippedwithCarlinPSCmotor)willbeap-
proximately2.5amps.
4. The48245thermostatterminalsprovideapowersource.Neverapplyexternal
power to these terminals under any circumstances.To avoid this problem when
usingzonevalves,disconnecteldwiresfrom48245thermostatterminals.
Thenconnectavoltmeteracrosswires.Operateallzonesandverifythatthere
isneveravoltagereadingatthemeter.Avoltagereadingindicatesincorrect
wiring that must be corrected before attempting to operate the burner.
5. Makesuretheburnerandappliancearecorrectlywiredandthelineswitchis
properly fused for the load.
To start burner
Donotstarttheburnerifthecombustionchambercontains
oil or oil vapor.
1. TurnserviceswitchOFF.
2. Performinspectionsandcheckoutsonpages14and15.
3. Sliponeendofa3/16-inchI.D.clearplastichoseoverendofbleedvalve,the
other end into a container. Then open bleed valve.
4. Setthermostat(operatingcontrols)tocallforheat.
5. TurnserviceswitchON.
6. Bleedoillineuntilplasticlineisfreeofbubbles;thenanother15secondslonger.
(Shouldtheprimarycontroltimingcausealockoutduringpurging,restartthe
burner following the primary control data sheet instructions.)
7. Closebleedvalve.Theburnershouldcyclethroughthesequencegiveninthe
primary control data sheet.
8. Performprimarycontrolamefailurelockoutandsafetytimingtestsperinstruc-
tions in primary control data sheet.
9. Shouldcontrol/burnerfailtooperatecorrectly,seepage15forsuggestionsin
troubleshooting.
Figure 16 Burners up to 3.0 GPH only, wiring using Carlin 48245 primary control (see appliance manual or separate wiring
information for burner equipped with a primary control not covered in this manual)
4. Wire burner • start burner — 48245 primary control
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08 – 15 –
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08
– 16 –
Wire burner — 40200 primary control
42230 primary control
1. Allwiringmustcomplywith:
• IntheU.S—theNationalElectricalCode,ANSIZ223.1/NFPA54.
• InCanada—theCanadianElectricalCodePart1,CSAstandardC22.1.
• Allapplicablelocalcodes/standards.
2. Wire the burner following Figure 17 and any special instructions or wiring
diagram provided with the appliance, burner or other components.
3. Theburnerrequiresa120VAC/60hz/single-phasepowersupply,withatleast
a5-ampfuse.Thecurrentdraw(equippedwithCarlinPSCmotor)willbeap-
proximately2.5amps.
4. The40200or42230thermostatterminalsprovideapowersource.Neverap-
ply external power to these terminals under any circumstances. To avoid this
problemwhenusingzonevalves,disconnecteldwiresfrom40200or42230
thermostatterminals.Thenconnectavoltmeteracrosswires.Operateallzones
andverifythatthereisneveravoltagereadingatthemeter.Avoltagereading
indicates incorrect wiring that must be corrected before attempting to operate
the burner.
5. Makesuretheburnerandappliancearecorrectlywiredandthelineswitchis
properly fused for the load.
To start burner
Donotstarttheburnerifthecombustionchambercontains
oil or oil vapor.
1. TurnserviceswitchOFF.
2. Performinspectionsandcheckoutsonpages16and17.
3. Sliponeendofa3/16-inchI.D.clearplastichoseoverendofbleedvalve,the
other end into a container. Then open bleed valve.
4. Setthermostat(operatingcontrols)tocallforheat.
5. TurnserviceswitchON.
6. Bleedoillineuntilplasticlineisfreeofbubbles;thenanother15secondslonger.
(Shouldtheprimarycontroltimingcausealockoutduringpurging,restartthe
burner following the primary control data sheet instructions.)
7. Closebleedvalve.Theburnershouldcyclethroughthesequencegiveninthe
primary control data sheet.
8. Performprimarycontrolamefailurelockoutandsafetytimingtestsperinstruc-
tions in primary control data sheet.
9. Shouldcontrol/burnerfailtooperatecorrectly,seepage17forsuggestionsin
troubleshooting.
4. Wire burner • start burner — 40200 or 42230 primary control
Figure 17 99FRD, 100CRD, and 102CRD burners wiring using Carlin 40200 or 42230 primary control (see appliance
manual or separate wiring information for burner equipped with a primary control not covered in this manual)
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08 – 17 –
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08
– 18 –
Wire burner — 50200 primary control
1. Allwiringmustcomplywith:
• IntheU.S—theNationalElectricalCode,ANSIZ223.1/NFPA54.
• InCanada—theCanadianElectricalCodePart1,CSAstandardC22.1.
• Allapplicablelocalcodes/standards.
2. Wire the burner following Figure 18 and any special instructions or wiring
diagram provided with the appliance, burner or other components.
3. Theburnerrequiresa120VAC/60hz/single-phasepowersupply,withatleast
a5-ampfuse.Thecurrentdraw(equippedwithCarlinPSCmotor)willbeap-
proximately2.5amps.
4. The50200thermostatterminalsprovideapowersource.Neverapplyexternal
power to these terminals under any circumstances.To avoid this problem when
usingzonevalves,disconnecteldwiresfrom50200thermostatterminals.Then
connectavoltmeteracrossterminals.Operateallzonesandverifythatthere
isneveravoltagereadingatthemeter.Avoltagereadingindicatesincorrect
wiring that must be corrected before attempting to operate the burner.
5. Alarmterminalsprovidea24vac-rateddrycontact,suitableforusewithsecurity/
realarmsystemssuchasCarlinSecureHeat™.
6. Makesuretheburnerandappliancearecorrectlywiredandthelineswitchis
properly fused for the load.
To start burner
Donotstarttheburnerifthecombustionchambercontains
oil or oil vapor.
1. TurnserviceswitchOFF.
2. Perform inspections and checkouts on pages 18 and 19.
3. Sliponeendofa3/16-inchI.D.clearplastichoseoverendofbleedvalve,the
other end into a container. Then open bleed valve.
4. Setthermostat(operatingcontrols)tocallforheat.
5. TurnserviceswitchON.
6. Bleedoillineuntilplasticlineisfreeofbubbles;thenanother15secondslonger.
(Shouldtheprimarycontroltimingcausealockoutduringpurging,restartthe
burner following the primary control data sheet instructions.)
7. Closebleedvalve.Theburnershouldcyclethroughthesequencegiveninthe
primary control data sheet.
8. Performprimarycontrolamefailurelockoutandsafetytimingtestsperinstruc-
tions in primary control data sheet.
9. Shouldcontrol/burnerfailtooperatecorrectly,seepage19forsuggestionsin
troubleshooting.
4. Wire burner • start burner — 50200 primary control
Figure 18 99FRD, 100CRD, and 102CRD burners wiring using Carlin 50200 primary control (see appliance manual or
separate wiring information for burner equipped with a primary control not covered in this manual)
Model 99FRD, 100CRD, & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08 – 19 –
Model 99FRD, 100CRD & 102CRD oil burners — Instruction manual
Carlin part number MN99102 Rev. 08/20/08
– 20 –
Figure 19 99FRD, 100CRD, and 102CRD burners wiring using Carlin 60200 primary control (see appliance manual or
separate wiring information for burner equipped with a primary control not covered in this manual)
4. Wire burner • start burner — 60200 primary control
Wire burner — 60200 primary control
1. Allwiringmustcomplywith:
• IntheU.S—theNationalElectricalCode,ANSIZ223.1/NFPA54.
• InCanada—theCanadianElectricalCodePart1,CSAstandardC22.1.
• Allapplicablelocalcodes/standards.
2. Wire the burner following Figure 19 and any special instructions or wiring
diagram provided with the appliance, burner or other components.
3. Theburnerrequiresa120VAC/60hz/single-phasepowersupply,withatleast
a5-ampfuse.Thecurrentdraw(equippedwithCarlinPSCmotor)willbeap-
proximately2.5amps.
4. The60200thermostatterminalsprovideapowersource.Neverapplyexternal
power to these terminals under any circumstances.To avoid this problem when
usingzonevalves,disconnecteldwiresfrom60200thermostatterminals.Then
connectavoltmeteracrossterminals.Operateallzonesandverifythatthere
isneveravoltagereadingatthemeter.Avoltagereadingindicatesincorrect
wiring that must be corrected before attempting to operate the burner.
5. Alarmterminalsprovidea24vac-rateddrycontact,suitableforusewithsecurity/
realarmsystemssuchasCarlinSecureHeat™.
6. Makesuretheburnerandappliancearecorrectlywiredandthelineswitchis
properly fused for the load.
To start burner
Donotstarttheburnerifthecombustionchambercontains
oil or oil vapor.
1. TurnserviceswitchOFF.
2. Performinspectionsandcheckoutsonpages20and21.
3. Sliponeendofa3/16-inchI.D.clearplastichoseoverendofbleedvalve,the
other end into a container. Then open bleed valve.
4. Setthermostat(operatingcontrols)tocallforheat.
5. TurnserviceswitchON.
6. Bleedoillineuntilplasticlineisfreeofbubbles;thenanother15secondslonger.
(Shouldtheprimarycontroltimingcausealockoutduringpurging,restartthe
burner following the primary control data sheet instructions.)
7. Closebleedvalve.Theburnershouldcyclethroughthesequencegiveninthe
primary control data sheet.
8. Performprimarycontrolamefailurelockoutandsafetytimingtestsperinstruc-
tions in primary control data sheet.
9. Shouldcontrol/burnerfailtooperatecorrectly,seepage21forsuggestionsin
troubleshooting.
This manual suits for next models
1
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