Carlin 201CRD User manual

Instruction manual
™
70 Maple Street East Longmeadow, MA 01028
Ph 413-525-7700 Fx 413-525-8306
Carlin Combustion Technology, Inc.
TECH SUPPORT 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
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 ................................... 120V/60 Hz/1-Phase
Motor ...................Carlin PSC, 1/4 HP, 3450 RPM
Total current at 120V/60 Hz/1-Phase:
201CRD ............................Approx. 3.2 amps
301CRD ............................Approx. 3.2 amps
Ignition: . Carlin Model 41000 electronic — 14,000 volts
Control: .................................. U.L. primary safety control
Agencies: ..................................UL Listed (US and Canada)

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04
– 2 –
Before installing or servicing . . .
Contents
PLEASE read this first .............................................................2
General information ................................................................3
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 –
40200 primary control .....................................................16
50200 primary control .....................................................18
60200 primary control .....................................................20
5. Adjustment and verification .............................................22
6. Annual start-up and service ............................................23
7. Repair parts .....................................................................24
8. Maintenance/service procedures ....................................26
Warranty ...............................................................................27
User care and maintenance .................................... Rear cover
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.
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.
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 flammable 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.
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.
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 dam-
age.

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04 – 3 –
Codes and standards
Certification
201CRD and 301CRD burners are U.L. listed for the U.S. and Canada,
certified 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.
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
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.
Use the selections in Table 1 ONLY when heating appliance
manufacturer specific 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-specific nozzle data is not available from the
manufacturer or in the Carlin OEM Spec Guide. See
notes at end of table for application tips.
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 ap-
plicable 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.
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.

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04
– 4 –
2. Prepare site • assemble burner • mount burner
Vent system
General
Do not install this burner unless you have verified the
entire vent system and the appliance are in good condi-
tion 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 fireplace, 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 flue 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 manufac-
turer’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
specified 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 flue 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 find 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 finer than ¼-inch mesh, and must be accessible
for cleaning.
Residential installation air openings
Residential — Unconfined spaces (at least 7,000 cubic feet per GPH)
• An unconfined 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 classified as an unconfined 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
confined 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 infiltration, so special provisions will seldom be
required.
• If the building is tightly constructed, you will have to provide outside air open-
ings 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 — Confined spaces (less than 7,000 cubic feet per GPH)
• Air taken from inside building only —
• Provide two openings — one near the floor, 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 floor, 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 floor, 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).

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04 – 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 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 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:
• Gasoline or other flammable liquids or vapors.
• Combustible materials.
• Air contaminants and chemicals, such as laundry products, paint, thinner,
varnish, etc.
❏ Confirm 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.
2. Prepare site • assemble burner • mount burner (continued)
Verify clearances
Verify that the burner/appliance will maintain all required clearances:
❏ Verify clearance from combustible construction, as specified 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.
Table 2 Minimum combustion/ventilation air openings

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04
– 6 –
Verify combustion chamber
Chamber dimensions and construction
• If retrofitting the burner to an appliance, install the burner in accordance
with the appliance instruction manual, when available. If no specific
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 configurations, 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 fire the burner in a chamber with dimensions smaller
than shown in Table 3 unless the application has been specifically 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 flues and heating surfaces thoroughly, removing all
soot and scale.
• Seal all joints and gaps using furnace cement to prevent excess air
infiltration.
Read the WARNING on page 26 before handling or applying
ceramic fiber materials.
Using chamber linings
• When using refractory liners or lightweight chambers, use insulating-type
refractory rated 2600°F minimum, or as specified by the appliance manu-
facturer.
• You must install a target wall liner if flame length is close to the length of
the chamber.
• Use a floor liner when possible. The floor liner will improve firing in most
applications. Extend floor 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 flame corbel the top 1½ to 2½ inches deep.
• Use preformed chamber liners when available. Lining the floor and target
wall water-backed combustion chambers with lightweight insulating refrac-
tory will accomplish the same.
• When converting coal-fired units, install a combustion chamber in the ashpit
area, or fill the ashpit with sand up to 2 inches above the “mud ring” of the
boiler (firing through the door). Install a lightweight refractory liner on the
target wall as in Figure 2D.
Figure 1 Combustion chamber configurations, typical
2. Prepare site • assemble burner • mount burner (continued)

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04 – 7 –
Table 3 201CRD and 301CRD Minimum combustion chamber dimensions (all dimensions in inches) - See Figure 1 for combustion
chamber configurations
2. Prepare site • assemble burner • mount burner (continued)

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04
– 8 –
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 flange
Welded-flange burners
1. Verify the bolt pattern on the appliance chamber matches the flange pat-
tern.
2. Verify the insertion depth (UTL) matches the depth of the appliance open-
ing (so the end of the air tube is flush with, or slightly short of, the inside
surface of the combustion chamber).
Burners with adjustable flanges
1. See Figure 2 for standard adjustable flange (universal flange) dimensions.
See Figure 3 for adjustable forced draft flange dimensions.
Verify the flange mounting slots line up with the appliance bolts.
2. Slip the adjustable flange 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 flange at this distance from the end of the air
tube.
5. Tighten the locking screws finger tight.
6. Insert the air tube/flange assembly into the appliance opening and level
the air tube with a spirit level (see Figure 4). Adjust flange if needed.
7. The end of the air tube should be flush, or almost flush, 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 flange locking screws securely.
9. Remove the flange/air tube assembly from the opening.
10. Forced draft adjustable flanges: Use ¼-inch diameter fiberglass sealing
rope, as shown in Figure 3, to seal the flange to the air tube.
A forced draft adjustable flange must be sealed to the air
tube to prevent possible leakage of flue products. Failure
to comply could result in severe personal injury, death or
substantial property damage.
Figure 2 Standard adjustable flange (universal flange)
Figure 4 Mark insertion depth on air tube when using universal
flange mounting
2. Prepare site • assemble burner • mount burner (continued)
Figure 3 Adjustable forced draft flange

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04 – 9 –
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 flush 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
2. Prepare site • assemble burner • mount burner (continued)
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 flanges, you can bolt the air tube/
flange to the appliance first — then attach the housing to
air tube.
Figure 5 Attaching air tube to burner housing
Mount burner in appliance
Welded flange-mounted burner
1. Place gasket over burner air tube and insert burner into appliance opening.
Secure in place with hardware supplied with appliance.
Universal flange or pedestal mount — these insertion methods
are intended only for negative overfire pressure. For pressur-
ized firing, you must obtain a burner with a welded flange,
designed for use with the specific appliance. Failure to comply
could result in severe personal injury, death or substantial
property damage.
Adjustable flange-mounted burner
1. Place gasket over burner air tube.
2. Insert burner into appliance.
3. Verify burner is seated level and straight. Adjust flange slightly if neces-
sary.
4. Secure flange 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 as-
sembly.
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 flush 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).
Figure 6 Seal opening around burner air tube when pedestal
mounting (burner shown with tube attached to housing
and installed)

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04
– 10 –
Removing/installing head assembly
Use care when handling burner components after the burner
has been firing. Components can be hot and could cause
severe personal injury.
Removing the combustion head assembly
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 the screw on the left side of the burner housing that secures the
ignitor plate in place. Swing the ignitor plate open.
2. See Figure 7.
3. Unscrew the oil line fitting from the elbow at the end of the oil tube.
4. Remove the combustion head assembly by pulling the assembly up and
out of the housing.
7. Handle the assembly with care to avoid bending or moving the electrodes,
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. Inspect the ignitor contact clips. Clean or replace if necessary to ensure
reliable contact with the electrodes.
Replacing the combustion head assembly
To replace the combustion head assembly, reverse the sequence above.
• Make sure the oil line bracket seats into the slot on the adjusting screw.
• See Figure 8. You will have to lift the end of the assembly to guide it through
the throttle ring or air cone at the end of the air tube. DO NOT FORCE.
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
3. Prepare burner

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04 – 11 –
Figure 10 Electrode settings
Install nozzle/check electrodes
1. Loosen the clamp screw on the retention ring assembly (see Figure 9,
step 1). Slide the retention ring assembly off of the nozzle adapter.
2. Install and tighten the nozzle listed in the appliance instruction manual or
Carlin OEM Spec Guide.
3. If nozzle information is not available, begin with the nozzle listed in Table 1,
page 3. (You may have to change the nozzle later if combustion results are
not acceptable.)
3. Hold the nozzle adapter securely as shown in Figure 9, steps 2 and 4, when
removing or replacing the nozzle. Take care not to damage the electrode
insulators or to bend the electrodes in the process.
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. Install the retention ring assembly by slipping one of the riveted arms
through the gap between the electrode tips. Align this arm straight up, with
the ring clamp firmly against the nozzle adapter shoulder (see Figure 10).
Then tighten the clamping screw.
5. Check the electrodes and reposition if necessary. Position the electrodes
as shown in Figure 10. These settings are critical in ensuring a reliable
ignition. Once the electrodes are set, check all clamps to be sure they are
securely tightened.
6. Insert the combustion head/nozzle assembly into the burner.
Figure 9 Replacing the oil nozzle —
1 – Remove retention ring from nozzle adapter
2 – Support the assembly carefully and remove the nozzle
using 5/8-inch and 3/4-inch open-end wrenches.
3 – Insert and finger-tighten the new nozzle.
4 – Support the assembly and tighten the nozzle using the
open-end wrenches.
NOTE: Do Not over tighten.
3. Prepare burner (continued)

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04
– 12 –
Figure 13 Combustion head/air tube combinations, typical
Set initial burner air settings
Combustion head (“A” dimension)
1. The combustion head adjusting screw is used to set the spacing between
the retention ring and throttle ring (or air cone), regulating how much air
passes around the retention ring.
2. See Figure 11.
3. Rotate the head adjusting screw until the distance from the housing detent
to the beginning of the scale equals the value given in Table 4, page 13
(“A” dimension).
Air band
1. See Figure 12. Loosen the air band locking screw and rotate the air band
until the opening equals the percent opening given in Table 4, page 13.
Final adjustments
1. The burner is now adjusted to the approximate air settings for the firing
rate chosen.
2. When you check combustion with instruments during start-up or servicing,
you may have to adjust the head and/or air band slightly to achieve the
desired efficiency.
• Increase the combustion head setting (“A” dimension) to increase air. If
additional adjustment is needed, open the air band slightly.
• Decrease the combustion head setting (“A” dimension) to decrease air. If
additional adjustment is needed, close the air band slightly.
3. See “Adjust burner using test instruments,” page 22.
4. Note that positive pressure overfire will reduce air flow, requiring more air
opening.
Figure 11 Combustion head setting
Figure 12 Air band setting
3. Prepare burner (continued)

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04 – 13 –
Table 4 Approximate air band and combustion head settings
3. Prepare burner (continued)
Inspect/install fuel supply
Inspect the oil supply system. Ensure that the fuel lines are
correctly sized and installed and that the fuel flow is unob-
structed, the oil tank is clean and only # 1 or # 2 heating oil
are supplied. Failure to supply a reliable oil flow could result
in loss of heat and potential severe equipment damage.
General guidelines:
• When installing oil lines, use continuous runs of heavy-wall copper tubing
if possible.
• Check fuel unit (oil pump) data sheet for recommended line sizing, lift
limitations and maximum length.
• Check all connections and joints to ensure they are air-tight.
• Use flare fittings. DO NOT use compression fittings.
• Never use pipe sealing tape. Fragments can break off and plug fuel line
components.
• Install a shut-off valve at the tank and one near the burner. (Use fusible
handle design valves when possible or when required by codes.)
• Install a large capacity fuel filter (rated for 50 microns or less) near the
burner.
Fuel supply to multiple burners
• When possible, use separate fuel supply lines for each oil burner. Using
manifolded oil supply lines can create problems. If the lines are undersized,
operating vacuum will exceed limits. If the lines are oversized, fuel units
may have difficulty priming. Because the lines must be sized to handle the
capacity of all the burners, the line size will almost always be too large
when only a single burner is running.
• If manifolding cannot be avoided, carefully size the lines following the fuel
units manufacturer’s instructions.
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 if connecting to a two-line oil system. Operating with
the plug in place on a one-line system will damage the fuel
unit and could lead to oil leakage and fire hazard.
If the fuel line or fuel supply is above the burner, never exceed
3 PSIG pressure at the fuel unit inlet. Install a suitable OSV to
reduce the pressure. Operating the fuel unit with higher inlet
pressure could result in fuel unit seal damage, oil leakage
and potential fire hazard.
Fuel unit vacuum limitations
• The sizing information in this manual applies only to the fuel units listed.
For other fuel units, refer to the manufacturer’s installation instructions.
• Attach a vacuum gauge to either of the fuel unit inlet ports, and verify the
vacuum does not exceed the limit below for all firing conditions.
• The vacuum at the fuel unit inlet port must not exceed the value below.
• One-line installations:
Model A2YA pump or B2YA pump 6 in. Hg
Model J pump or H pump 2 in. Hg
• Two-line installations:
Model A2YA pump or J pump 12 in. Hg
Model B2YA pump or H pump 17 in. Hg

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04
– 14 –
Figure 15 Two-line fuel system
Table 5 Two-line fuel system maximum lengths for copper tubing
distribution. Use only for burners equipped with the
Suntec fuel units listed. See fuel unit data sheet for any
other fuel unit.
Two-line fuel system requirements
• See Figure 15 and Table 5. Use Table 5 only for burners equipped with the
Suntec fuel units listed. For burners using other fuel units, follow the fuel
unit manufacturer’s instructions for line sizing.
• Follow the guidelines in this manual regarding maximum lift and maximum
operating vacuum. If the fuel system exceeds the limits given in this manual
or the fuel unit manufacturer’s instructions for a single-stage pump (stan-
dard), install a two-stage fuel unit. If limits are still exceeded, follow the
fuel unit manufacturer’s instructions for installation of transfer pump(s) if
necessary.
• Always size fuel lines using an oil flow rate based on the fuel unit gearset
capacity, not the burner firing rate. See fuel unit data sheet for informa-
tion.
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.
Figure 14 One-line fuel system
One-line fuel system requirements
• See Figure 14.
• The standard burner fuel unit is a single-stage, 3450-RPM oil pump. Apply
this fuel unit only on one-line systems where the fuel supply is on the same
level with, or higher than, the burner. This ensures oil flow by gravity.
• Also make sure the total lift does not exceed 8 feet (height difference from
bottom of oil tank to fuel unit) when the fuel unit is a Model A2YA or B2YA;
or 2 feet when the fuel unit is a Model J or H.
• 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.
One-line oil systems must be air-tight, to avoid air leaks into
the system or loss of prime. Use pipe dope where necessary,
but never use tape sealants. Verify the operating vacuum
does not exceed the limit given in this manual or the fuel
unit manufacturer’s instructions. Failure to comply could
result in sever personal injury, death or substantial property
damage.
3. Prepare burner (continued)

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04 – 15 –
3. Prepare burner (continued)
Perform checkout procedures
Verify before starting burner:
Should overheating or an emergency occur, immediately:
• Shut off oil supply line valve.
• Under some circumstances power should remain on for
water pumps or blowers. Determine proper response before
attempting start-up.
• If burner fails ignition on several attempts, use burner
blower to purge appliance chamber before restart.
Checklist
❏ Burner/appliance installed per appliance instruction manual?
❏ Burner nozzle verified per appliance manufacturer’s instructions,
Carlin OEM Spec Guide or Table 1, page 3?
❏ Burner/appliance installed per all applicable codes?
❏ Installation site has adequate combustion/ventilation air openings
and vent system?
❏ Fuel supply line in good condition and sized/designed cor-
rectly?
❏ Oil tank has oil and oil line valves are open.
❏ Wiring installed per burner manual and appliance instructions?
❏ Burner, appliance and all components inspected and in good
condition?
Oil flow schematics / fuel unit connections
• Figures 16, 17 and 18 show oil flow for Carlin 201 and 301 burners and
show port functions for Suntec Model A, B, J and H pumps.
• Figure 18 applies only for optional NYC-DAR pressure regulation kits.
Figure 16 201/301 burner with Suntec Model J or H fuel unit
Figure 17 201/301 burner with Suntec Model A or B fuel unit
Figure 18 201/301 burner with NYC-DAR pressure regulation kit
Obtain pressure regulator kits for New York City Department
of Air Resources. Kits must be set for the proper nozzle pres-
sure.

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04
– 16 –
Wire burner — 40200 primary control
1. All wiring must comply with:
• In the U.S — the National Electrical Code, ANSI Z223.1/NFPA 54.
• In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1.
• All applicable local codes/standards.
2. Wire the burner following Figure 19 and any special instructions or wiring
diagram provided with the appliance, burner or other components.
3. The burner requires a 120 VAC/60 hz/single-phase power supply, with a 5-amp
fuse. The current draw (equipped with Carlin PSC motor) will be approximately
3.2 amps.
4. The 40200 thermostat terminals provide a 200ma for thermostat power source.
Never apply external power to these terminals under any circumstances. To
avoid this problem when using zone valves, disconnect field wires from 40200
thermostat terminals. Then connect a voltmeter across wires. Operate all zones
and verify that there is never a voltage reading at the meter. A voltage reading
indicates incorrect wiring that must be corrected before attempting to operate
the burner.
5. Make sure the burner and appliance are correctly wired and the line switch is
properly fused for the load.
To start burner
Do not start the burner if the combustion chamber contains
oil or oil vapor.
1. Turn service switch OFF.
2. Perform inspections and checkouts on pages 16 and 17.
3. Slip one end of a 3/16-inch I.D. clear plastic hose over end of bleed valve, the
other end into a container. Then open bleed valve.
4. Set thermostat (operating controls) to call for heat.
5. Turn service switch ON.
6. Bleed oil line until plastic line is free of bubbles; then another 15 seconds longer.
(Should the primary control timing cause a lockout during purging, restart the
burner following the primary control data sheet instructions.)
7. Close bleed valve. The burner should cycle through the sequence given in the
primary control data sheet.
8. Perform primary control flame failure lockout and safety timing tests per instruc-
tions in primary control data sheet.
9. Should control/burner fail to operate correctly, see page 17 for suggestions in
troubleshooting.
4. Wire burner • start burner — 40200 primary control
Figure 19 201CRD and 301CRD burners wiring using Carlin 40200 primary control (see appliance manual or separate wiring information
for burner equipped with a primary control not covered in this manual)

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04 – 17 –
Start-up & operation
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 wait until
it no longer senses the problem.
Service & Troubleshooting
Burner (control) will not come on
No power to control
• Check line voltage to the control (at least 102 VAC).
• Check all electrical connections.
Control is in lockout
• Press the reset button for 3 seconds.
CAD cell seeing light
• Remove one lead from FF terminal on the control. Press and hold
the reset button for 3 seconds. If voltmeter shows power between
control white and black wires, and T-T circuit is closed, but control
does not start, replace the control.
If control starts when receiving power on the black wire and T-T
circuit is closed, check for:
• 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 see residual
hot spots in chamber.
To troubleshoot:
• Check CAD cell by unplugging it and measuring the resis-
tance across its pins: dark resistance at least 50 KOHMS; room
light resistance less than 10 KOHMS. Replace if necessary. If
the CAD cell functions properly, reinstall the cell and close the
burner housing.
• Check for stray light by measuring the CAD cell resistance
looking into the inactive combustion chamber. It should read
at least 50 KOHMS.
Control will not reset
• If the control will not reset, the Safety Monitoring Circuit may be
detecting an internal control problem. Replace the control.
Repeated flame failures (burner lights, but shuts
down)
Check for:
• CAD cell is defective.
• Air leaking into oil line causing flame out — Check oil line con-
nections and filter gasket.
• Defective nozzle causing flame to be erratic — Change nozzle.
• Excessive airflow or draft causing flame to leave burner head
Check for proper air shutter setting and draft.
• Excessive back pressure causing flame to be erratic — Check
appliance and flue for sooting/plugging.
Control locks out after TFI
Check for:
• No oil to burner — Check oil supply, filter, lines.
• Shorted electrodes — Inspect for cracked porcelain and replace
as needed.
• Poor spark — Check electrode spacing and condition per burner
manual. Replace or realign if necessary.
• Nozzle clogged — Replace nozzle.
• Airflow too high — Check air shutter setting.
• Ignitor module defective — Replace if no spark.
• CAD cell defective.
• Oil valve stuck in closed position.
• Check wiring connections.
Power ON Open all manual oil line valves. Close the line
switch.
Reset Press and hold the reset button for 3 seconds,
then release. This will reset the control at any
time during its operation.
Stand-by (No call for heat) Control waits for power to be
applied to the black wire (from appliance limit
circuit).
Call for heat Set thermostat (or limit) to call for heat. Thermo-
stat circuit must be closed and power coming to
black wire from limit circuit.
Burner on The ignitor and motor start. Four seconds later,
the electronic time delay relay allows the oil valve
to open.
TFI The cad cell must sense flame within the control’s
trial for ignition (TFI) timing — 15 seconds for
40200 control. After cad cell senses flame, the
ignitor stays on another 10 seconds (flame sta-
bilization period).
Run The burner continues firing during call for heat
if the cad cell is sensing flame.
Lockout If cad cell does not sense flame within the TFI
timing (15 seconds), lockout occurs.
To Reset Push in and hold reset button for 3 seconds, then
release. This will reset control at any time during
operation.
Flame failure If the cad cell loses flame signal during operation
(after the TFI), the burner shuts off within 1.3
seconds. Recycle: After 60 to 90 seconds the
control will restart (Burner on mode).
Burner off Set thermostat (or aquastat) to stop call for heat.
The burner shuts off within 2 seconds after end
of call for heat.
Stand-by Control remains in stand-by mode until limit
circuit sends power to the black wire and T-T
circuit closes (call for heat).
Power loss If power to control/burner is interrupted during a
normal run cycle, the control will begin a normal
cycle again after power is restored.

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04
– 18 –
Wire burner — 50200 primary control
1. All wiring must comply with:
• In the U.S — the National Electrical Code, ANSI Z223.1/NFPA 54.
• In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1.
• All applicable local codes/standards.
2. Wire the burner following Figure 20 and any special instructions or wiring
diagram provided with the appliance, burner or other components.
3. The burner requires a 120 VAC/60 hz/single-phase power supply, with a 5-amp
fuse. The current draw (equipped with Carlin PSC motor) will be approximately
3.2 amps.
4. The 50200 thermostat terminals provide a 200ma for thermostat power source.
Never apply external power to these terminals under any circumstances. To
avoid this problem when using zone valves, disconnect field wires from 50200
thermostat terminals. Then connect a voltmeter across terminals. Operate all
zones and verify that there is never a voltage reading at the meter. A voltage
reading indicates incorrect wiring that must be corrected before attempting to
operate the burner.
5. Alarm terminals provide a 24 vac-rated dry contact, suitable for use with
security/fire alarm systems such as Carlin SecureHeat™.
6. Make sure the burner and appliance are correctly wired and the line switch is
properly fused for the load.
To start burner
Do not start the burner if the combustion chamber contains
oil or oil vapor.
1. Turn service switch OFF.
2. Perform inspections and checkouts on pages 18 and 19.
3. Slip one end of a 3/16-inch I.D. clear plastic hose over end of bleed valve, the
other end into a container. Then open bleed valve.
4. Set thermostat (operating controls) to call for heat.
5. Turn service switch ON.
6. Bleed oil line until plastic line is free of bubbles; then another 15 seconds longer.
(Should the primary control timing cause a lockout during purging, restart the
burner following the primary control data sheet instructions.)
7. Close bleed valve. The burner should cycle through the sequence given in the
primary control data sheet.
8. Perform primary control flame failure lockout and safety timing tests per instruc-
tions in primary control data sheet.
9. Should control/burner fail to operate correctly, see page 19 for suggestions in
troubleshooting.
4. Wire burner • start burner — 50200 primary control
Figure 20 201CRD and 301CRD 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 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04 – 19 –
Start-up & operation
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, the
control will remain in self-test mode until the cad cell no longer
senses light (flame). The amber LED will remain on, but blink off
momentarily every 3 to 4 seconds.
Model 50200 diagnostic LED’s
– Red OFF – Red ON – Red FLASHING
– Amber OFF – Amber ON – Amber FLASHING
– Amber BLINKING (blinks off momentarily every 3 to 4 seconds)
Service & Troubleshooting
Burner (control) will not come on
No power to control
• Check line voltage 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 1 second.
• If the control returns immediately to lockout, The Safety
Monitoring Circuit may have detected an internal control
problem. Replace the control.
CAD cell seeing light
• Amber LED blinks off each 3 to 4 seconds. Remove one
yellow lead from FF terminal on the control.
If the amber LED remains on with a wire detached, the
control is defective.
If amber LED goes off , 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 see
residual hot spots in chamber.
To troubleshoot:
• Check CAD cell by unplugging it and measuring the
resistance across its pins: dark resistance at least 50
KOHMS; room light resistance less than 10 KOHMS. Re-
place if necessary. If the CAD cell functions properly,
reinstall the cell and close the burner housing.
• Check for stray light by measuring the CAD cell resis-
tance looking into the inactive combustion chamber.
It should read at least 50 KOHMS.
Repeated flame failures ( flashing red LED)
Check for:
• CAD cell is defective.
• Air leaking into oil line causing flame out — Check oil line
connections and filter gasket.
• Defective nozzle causing flame to be erratic — Change
nozzle.
• Excessive airflow or draft causing flame to leave burner head
— Check for proper air shutter setting and draft.
• Excessive back pressure causing flame to be erratic — Check
appliance and flue for sooting/plugging.
Control locks out after TFI ( red LED on)
Check for:
• No oil to burner — Check oil supply, filter, lines.
• Shorted electrodes — Inspect for cracked porcelain and
replace as needed.
• Poor spark — Check electrode spacing and condition per
burner manual. Replace or realign if necessary.
• Nozzle clogged — Replace nozzle.
• Airflow too high — Check air shutter setting.
• Ignitor module defective — Replace if no spark.
• CAD cell defective.
• Oil valve stuck in closed position.
• Check wiring connections.
Power ON Open all manual oil line valves. Close the line switch. (If Red light
turns on constant , control is in lockout. See below to reset.)
Self-test 1 Each time the limit circuit sends power to the black wire, the
control performs a “boot-up” test to verify internal operation.
About 4 seconds after power application, the amber LED turns on.
The test continues for about 6 more seconds. If the test fails, the
control turns the amber LED off and repeats this test sequence until
successful. (This test occurs on every call for heat cycle if burner is
operated by a limit control (terminals “T-T” jumpered).
Stand-by (Thermostat circuit open, limit circuit closed) If Self-test 1 is
successful, amber LED turns off and control waits for thermostat
circuit to close.
Call for heat Set thermostat to call for heat. Thermostat circuit must close (and
black wire must receive power from the limit circuit).
Self-test 2 The amber LED turns on. For the first 3 to 4 seconds, the control
performs a self-test. If the cad cell senses flame, the control
repeats this test until flame is no longer detected. During this time,
the amber LED remains on, but blinks off momentarily every 3
to 4 seconds. If the control detects motor contacts closed, lockout
occurs.
Burner on After the self-test, amber LED turns off. The ignitor starts, followed
1 second later by the motor. The electronic time delay relay allows
the oil valve to open 4 seconds later.
TFI The cad cell must sense flame within the TFI time limit (trial for
ignition). After cad cell senses flame, the ignitor stays on another
10 seconds (flame stabilization period).
Run The burner continues firing during call for heat if the cad cell
senses flame. LED’s are off during normal running.
Lockout If cad cell does not sense flame within 15 seconds after burner
starts, lockout occurs. The control turns the red LED on constant,
and closes the alarm contact.
To Reset Push in and hold reset button for 1 second, then release.
Latch-up If the control locks out 3 times during a single call for heat, latch-
up occurs. The control turns on both the amber and red LED’s
constant. You must use the special procedure below to reset the
control after latch-up.
Reset after latch-up — Only a qualified service technician should
attempt to reset the control after latch-up. The problem that
caused the repeated burner problems must be corrected before
returning the burner to normal operation.
Push in and hold the reset button for about 10 seconds. The amber
and red LED’s will begin to flash alternately.
After the LED’s begin flashing, continue holding the reset button for
about another 20 seconds. The LED’s will turn off. Release the reset
button and the control will restart. (Releasing the button before the
LED’s turn off will cause the control to remain in latch-up.)
The 50200 control will not reset from lockout or latch-up if power
is interrupted.
Flame failure If the cad cell loses flame signal during operation (after the TFI),
the red LED flashes. The burner shuts off within 2 seconds. Re-
cycle: Control waits for 65 seconds (with red LED flashing), then
begins again at Self-test 2. Red LED goes off .
End cycle Set thermostat (or aquastat) to stop call for heat. The burner shuts
off within 2 seconds after end of call for heat.
Stand-by Control remains in stand-by mode until limit circuit sends power to
the black wire (call for heat).

Model 201CRD & 301CRD Advanced oil burners — Instruction manual
Carlin part number MN2301 Rev. 04/12/04
– 20 –
Figure 21 201CRD and 301CRD 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. All wiring must comply with:
• In the U.S — the National Electrical Code, ANSI Z223.1/NFPA 54.
• In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1.
• All applicable local codes/standards.
2. Wire the burner following Figure 21 and any special instructions or wiring
diagram provided with the appliance, burner or other components.
3. The burner requires a 120 VAC/60 hz/single-phase power supply, with a 5-amp
fuse. The current draw (equipped with Carlin PSC motor) will be approximately
3.2 amps.
4. The 60200 thermostat terminals provide a 200ma for thermostat power source.
Never apply external power to these terminals under any circumstances. To
avoid this problem when using zone valves, disconnect field wires from 60200
thermostat terminals. Then connect a voltmeter across terminals. Operate all
zones and verify that there is never a voltage reading at the meter. A voltage
reading indicates incorrect wiring that must be corrected before attempting to
operate the burner.
5. Alarm terminals provide a 24 vac-rated dry contact, suitable for use with
security/fire alarm systems such as Carlin SecureHeat™.
6. Make sure the burner and appliance are correctly wired and the line switch is
properly fused for the load.
To start burner
Do not start the burner if the combustion chamber contains
oil or oil vapor.
1. Turn service switch OFF.
2. Perform inspections and checkouts on pages 20 and 21.
3. Slip one end of a 3/16-inch I.D. clear plastic hose over end of bleed valve, the
other end into a container. Then open bleed valve.
4. Set thermostat (operating controls) to call for heat.
5. Turn service switch ON.
6. Bleed oil line until plastic line is free of bubbles; then another 15 seconds longer.
(Should the primary control timing cause a lockout during purging, restart the
burner following the primary control data sheet instructions.)
7. Close bleed valve. The burner should cycle through the sequence given in the
primary control data sheet.
8. Perform primary control flame failure lockout and safety timing tests per instruc-
tions in primary control data sheet.
9. Should control/burner fail to operate correctly, see page 21 for suggestions in
troubleshooting.