Carlin 601CRD User manual

Model 601CRD
Oil Burner
Installation and
Operating Instructions
For Use By Qualified Service Technicians Only
126 Bailey Rd North Haven, CT 06473
Ph 203-680-9401 Fx 203-680-9403
Tech Support 800-989-2275 carlincombustion.com
©Copyright 2018 — Carlin Combustion Technology, Inc.
Carlin Combustion Technology, Inc.
“CRD” burners feature a combustion head
incorporating a new design concept which
provides a means to control the air pattern
to match the nozzle requirements. The aero-
dynamics for optimum combustion are easily
adjusted for any nozzle size without changing
the air-handling hardware. The flame front is
initiated inside the air tube so that no erratic re-
circulating gasses from the main chamber area
can quench the flame at the retention ring.
The letters “CRD” stand for “Controlled
Retention-Double Speed.”
Use of a small blower wheel (fan) operating
at 3450 rpm provides a more positive, yet quiet,
air flow which does not yield to normal draft
variations and therefore assures a more con-
stant air-fuel ratio for dependably clean com-
bustion day after day.
Fuel Specification................................... ASTM U396 No.2
Firing Range......................................................6.00-13.20*
Motor HP, rpm.................................................½, 3450 rpm
Motor Phase, Hz ............................................Single, 60 Hz
Motor Amps .................................................... 8.4 (approx.)
Motor Volts, Standard ................................................ 120V
Motor Volts, Optional .............................................. 230V**
Motor Contactor .......................................DPST-Optional**
Standard Control Type ............................................. 70200
Control Volts, Hz ............................................. 120 V, 60 Hz
Ignitor ....................................................................... 14,000
Burner Housing......................................... Rugged Casting
Blower Wheel Diam. x Width .............................. 61⁄4" X 4"
2-Stage Fuel Unit Pressure.................................... 150 psi
Oil.Valve Volts, Hz ........................................... 120 V, 60 Hz
Oil Nozzle Specs....................................................... 45° ss
Approximate Shipping Weight................................. 65 lbs
*The maximum high-fire capability shown is for natural draft. With forced draft, the maximum
firing rate is reduced.
**Motor contactor optional for Model 601CRD at an additional cost. Required when motor is
for 230 volts.

2
It is important that the installation of
the oil burner, piping and fittings, safety devices,
controls, electrical wiring and equipment be
done in accordance with national and/or local
regulations of the authorities having jurisdiction
over such installation.
Assembling the Burner (TWO-PAK)
1. Install air tuber assembly in housing using set
screws provided.
2. Install and tighten the proper nozzles. Be careful
not to damage the electrode insulators or to bend
the wires.
3. Check the electrode setting specified as follows:
1⁄8inch, 5⁄16 inch above the nozzle centerline and
¼ inch ahead of the nozzle tips. See Fig 1.
4. Swing open the ignitor assembly and slide the noz-
zle line assembly into the air tube.
5. Place the nozzle line yoke in the groove in the ad-
justing screw.
6. Fasten the high tension leads to the ignitor termi-
nals.
7. Swing the ignitor assembly to the closed position
and fasten.
8. Connect the flared fitting on the copper oil line to
the nozzle line and tighten.
About Combustion Chambers
The model 601CRD operates with superior efficiency
and cleanliness in properly designed refractory-type
combustion chambers. Very wide tolerance to burner
adjustments and other variables is found when these
chambers are used. Noise levels are also reduced.
Table 1, page 3 shows the recommended minimum
inside dimensions for refractory brick, refractory pre-
cast and pre-formed refractory fiber chambers. Due to
their quick warm-up properties, the lightweight insulat-
ing-type materials are slightly preferable although these
burners show less dependence upon refractory tem-
perature than previous models. Refractory materials in
boilers and furnaces should be capable of withstanding
2600°F (1427°C) or higher.
The notes accompanying Table 1 provides further de-
tails relative to variations in dimensions and geometry.
Refer to Fig. 3, page 3.
Firing Boilers without Refractory
Chambers
Depending upon the geometry of the combustion
space some units perform better than others without
refractory. When the back wall of the unit coincides
approximately with the end of the flame, a target of
refractory material is essential. Zero smoke readings
are made easier if a refractory fiber “rug” or fill material
is used on the base under the flame.
Table 1, page 3, together with its footnotes, gives
the essential dimensions and information needed to
provide conditions for satisfactory operation without
complete chambers. Refer to Figs. 4 and 5, page 3.
Installing the Burner:
Flange Mounted
1. Measure, in the burner opening, the distance from
the inside of the combustion chamber to the outside
of the mounting plate to find the insertion length of
air tube needed. Position flange on air tube at point
from end of burner corresponding to the measure-
ment. Tighten set screws to anchor flange. The
flange is now located so that the end of the burner
will be flush, or almost flush, with the inside of the
combustion chamber. See Fig. 3 (side view) page 3,
and Fig. 6, page 3.
2. Slide the end of the air tube into the opening and
secure the flange to the front plate.
Installing The Burner:
Pedestal Mounted
1. Adjust the pedestal so that the height of the air tube
matches the’ location of the burner opening.
2. Slide the end of the air tube into the opening so that
it is flush or nearly flush with the inside of the com-
bustion chamber. See Fig. 7.
3. From the outside of the unit, seal the space around
the air tube with refractory cement or equivalent.
Fig. 1
Electrode
Settings

3
Minimum Inside Dimensions In Refractory
Type Combustion Chambers (Ins.)
Minimum Dimensions In Boilers Fired
Without Refractory Chambers (Ins.)
1
Nozzle
Size
2
Firing
Rate
(GPH) at
150 psi
3
Length
(L)
4
Width
(W)
5
Dimen-
sion (C)
6
Height
(H)
7
Vertical
CYL.
8
Length (L)
with
Target
9
Length (L)
without
Target
10
Width
(W)
11
Dimen-
sion
(C)
12
Dimen-
sion
(D)
5.00
5.50
6.00
6.50
7.00
7.50
6.00
6.60
7.20
7.80
8.40
9.00
18
19
20
22
24
27
16
16
17
17
17
17
7.5
7.5
8.0
8.0
8.0
8.0
15
15
16
16
16
16
16
17
18
20
22
25
18
19
20
22
24
27
22
23
24
27
29
33
18
18
19
19
19
19
8.5
8.5
9.0
9.0
9.0
9.0
10.5
10.5
11.0
11.0
11.0
11.0
8.00
8.50
9.00
9.50
10.00
11.00
9.60
10.20
10.80
11.40
12 00
13.20
30
31
33
35
38
42
17
17
17
17
18
18
8.0
8.0
8.0
8.0
8.5
8.5
16
16
16
16
17
17
28
29
31
33
36
40
30
31
33
35
38
42
36
38
40
42
46
50
19
19
19
19
20
20
9.0
9.0
9.0
9.0
9.5
9.5
11.0
11.0
11.0
11.0
11.5
11.5
Table 1. Recommended Minimum Dimensions of Combustion Chamber for Model 601CRD (inches)
1. Flame lengths are approximately as shown in column (3) when using 45° semi-solid nozzles. Flames approximately 10% shorter are attainable with 45° hollow nozzles. Often, tested boilers or
furnaces will operate well with chamber shorter han the lengths shown in column (3).
2. As a general practice any of these dimensions can be exceeded without much effect on combustion.
3. Chambers in the form of horizontal cylinders should be at least as large in diameter as the dimension in column (4). Horizontal stainless steel cylindrical chambers should be 1 to 4 inches larger
in diameter than the figures in column (4).
4. Wing walls are not recommended. Corbels are not necessary although they might be of benelit to good heat distribution in certain boiler or furnace designs.
5. A fiber-type refractory “rug” or fill material to cover the floor area of the combustion space in boilers fired without refractory chambers is recommended for cleaner combustion and to protect
the base.
6. When a refractory or refractory fiber target is used, the lengths in column (8) apply. If the lengths are equal to or longer than in column (9), no target material is needed unless recommended by
the boiler manufacturer.
Fig. 2
Fig. 3
Fig. 5 Fig. 6 Fig. 7
Fig. 4
Brick combustion chamber, side view.
Scotch Marine boliler. No combustion chamber.
Wet leg boiler. No combustion chamber, side view.

4
Installing and Wiring
The 70200 control must be installed and serviced only by a qualified service technician.
Always disconnect power source before wiring to avoid electrical shock or damage to the control. All wiring must
comply with applicable codes and ordinances.
Mounting
The control may be mounted on a 4" x 4" junction box in any convenient location on the burner, furnace or wall. The
location must not exceed the ambient temperature limit, 140°F.
Wiring
Wiring must comply with local and national electrical codes, and with the following wiring diagrams.
6-Wire
Recommended
Wiring
3-Wire
Replacement
Wiring
When con-
necting to BLACK power
harness wire, without
constant L1 power, wire
nut together L1 (RED)
and Limit In (BLACK)
from control.
M
OV
OIL
VALVE
IGNITION
NOZZLE
LINE HTR
(OPTIONAL)
WHT
WHT
WHT
WHT
BLACK
BLUE
ORANGE
VIOLET
BURNER
MOTOR
GN
WHT
RED/WHT
BLACK
WHT
WHT
M
IGNITION
ORANGE
BLUE
BURNER
MOTOR
WHT
RED
WHT
BLK
GN

5
How to Adjust the Combustion Head
The retention ring position ahead of the throttle ring is
adjustable from the zero (flush) to 11⁄8inches (Dimen-
sion “A”, Figs. 8 and 9). Turning the adjustable screw
in (clockwise) increases the distance “A” ahead. This
distance is indicated by reading the scale of the nozzle
line across the corners on sides of the channel guiding
the nozzle line. Each division is 1/16 inch.
Low Voltage Wiring
Nozzle Specifications: 45° Semi-Solid or 45° Hollow
45° hollow cone nozzles provide approximately 10%
shorter flame than 45° semi-solid nozzles.
Other nozzle configurations may not prove satisfactory.
Always use the nozzle size and spray pattern recom-
mended by Carlin.
Retention Ring and Air Shutter
Adjustments
Table 2 shows for each firing rate the approximate
recommended positions of the flame retention ring with
the corresponding amount of air shutter opening.
Table 2 is provided as a guide only. Final adjustments
must be made using a combustion analyzer.
Table 2. Approximate Settings for Model 601CRD
(61⁄4" x 4" Blower Wheel)
Nozzle
Size
Firing Rate
(GPH)
at 150 psi
Retention Ring
Setting,
Inches on Scale,
Dimension “A”
Initial
Air Shutter
Opening
(percent)
5.00
5.50
6.00
6.50
7.00
7.50
8.00
6.00
6.60
7.20
7.80
8.40
9.00
9.60
1/8
3/16
1/4
5/16
3/8
7/16
1/2
35
45
50
55
60
65
70
8.50
9.00
9.50
10.00
11.00
10.20
10.80
11.40
12.00
13.20
9/16
5/8
3/4
7/8
11⁄4
85
100
100
100
100
Fig. 8
Fig. 9

6
Light-Off and Adjustment
Before re-starting the burner, preset the air shutter and
the retention ring position for the particular firing rate
according to Table 2, page 5.
Adjust draft to 0.02 to 0.04 inches W. C. over the fire for
natural draft units.
Run a smoke test. Strive for zero or a trace. Each time
further adjustment of air or retention ring is made, reset
the draft to 0.02 to 0.04 inches W.C. over the fire.
Check C02. This should be set between 11% and 12%.
Check for good ignition and clean cut-off. If cut-off
continues to be poor, look for air leaks in the suction
line and correct them.
Forced Draft Firing
Due to the back pressure in forced draft units the
maximum firing rate of a burner is reduced. The greater
the pressure, the lower the maximum GPH capability
becomes. Note that the graph at the right stops at 0.30
inches W.C. for Model 601CRD; the maximum recom-
mended back pressure for this model.
The combustion head settings for forced draft firing
would be somewhat greater than those shown in Table
2, page 5, which are for zero pressure or natural draft.
MN00000 111017© Copyright 2018 — Carlin Combustion Technology, Inc.
TECH SUPPORT HOTLINE [phone]
Carlin Combustion Technology, Inc.
126 Bailey Road North Haven, CT 06473 Phone [phone] Fax [phone]
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Fuel Units and Oil Lines
Standard burners are provided with a two-stage
3450 rpm fuel unit set at 150 psi.
A single-pipe system is recommended whenever the
bottom of the fuel tank is above the burner or is at the
same level as the burner. This includes outdoor fuel
tanks that are at such levels.
A two-pipe system is recommended when the fuel tank
is below the level of the burner, and the fuel unit must
pull (lift) the fuel up to the burner. For two-pipe instal-
lations, the by-pass plug must be installed. Maximum
recommended vacuum is 12 inches of mercury.
Table 3 shows, for the standard two-stage fuel unit, the
allowable lift and lengths of 1/2" and 5/8" OD tubing for
both suction and return lines in two-pipe systems.
Be sure that all oil line connections are absolutely
airtight. Check all connections and joints. Flared fittings
are recommended. Do not use compression fittings
or teflon tape.
Open the air-bleed valve and start the burner. For clean
bleed, slip a 3/16" ID hose over the end of the bleed
valve and bleed into a container. Continue to bleed
for 15 seconds after oil is free of air bubbles. Stop the
burner and close the bleed valve.
Table 3. Two-Stage Units – Two Pipe Systems
Lift
(feet)
Length of Tubing (feet)
1/2" OD 5/8" OD
0
2
4
6
8
10
12
14
15
100
88
78
69
59
49
39
29
24
100
100
100
100
100
100
100
82
68