Carlin EZGas Pro User manual

Contents
PLEASE read this rst......................................... 2
Codes and standards .......................................... 2
EZGas Pro burner at-a-glance ............................ 3
Prepare site • prepare burner • mount burner ..... 4
Install gas piping.................................................. 9
Wire burner........................................................ 10
Check system • start-up burner/appliance......... 11
Perform checkout procedure • ll out certicate 14
Maintenance and service procedures................ 15
Troubleshooting................................................. 17
Dimensions and mounting information .............. 19
Replacement parts ............................................ 20
Instruction manual
Ratings
Input: .................................. 50,000 to 275,000 Btuh
Fuels: ............................Natural gas or propane gas
Max. supply pressure...............14 inches w.c.
Min. supply pressure..................5 inches w.c.
Manifold pressure ...................3.5 inches w.c.
Electrical: Power............................ 120V/60 Hz/1-Phase
Motor.............1/15, 1/7, or 1/6 HP, 3450 RPM
Current.............. Approx. 2.0, 2.5 or 2.3 amps
Ignition: ............ Carlin Model 41800 solid state ignitor
Control: Carlin Model 60200FR microprocessor control
Agencies: ....UL Listed (US and Canada)
Installer/servicer — Except where specifically stated
otherwise, this manual must be used only by a qualied
service technician. (In the state of Massachusetts, this
product must be installed by a licensed Plumber or Gas
Fitter.) Failure to comply with this or other requirements in
this manual could result in severe personal injury, death
or substantial property damage.
User — Refer only to User’s Information manual for in-
formation regarding operation of this burner. The burner
Instruction Manual is intended only for your service techni-
cian. The burner and heat exchanger must be inspected
and started at least annually by your service technician.
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 2013 — Carlin Combustion Technology, Inc.
LISTED
™
Pro

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13
– 2 –
Where appliance instructions differ from this manual, follow the appliance instructions.
Codes and standards
General information
Burner applications
Follow all instructions in this manual and the appliance manual. Where ap-
pliance instructions differ from this manual, follow the appliance instructions.
Read the label attached to the burner air tube to verify the burner is correct
for the appliance being used. See page 7 for procedures.
Damage or shortage claims
The consignee of the shipment must le 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. Enter this information on the Installation
Certicate in this manual. The certicate information can be helpful when
troubleshooting or obtaining replacement parts.
Fill out burner adjustment label
Fill out the burner adjustment label, located on the front of the hinged
cover plate (or on French language plate) after completing installation and
burner setup.
Should overheating occur: (1) shut off the manual gas control
to the appliance, (2) do not shut off the control switch to the
pump or blower.
Follow the guidelines below to avoid potential severe
personal injury, death or substantial property damage.
The installer/servicer is solely responsible for compliance with all
applicable codes and standards.
Burner listing
Carlin EZGas Pro burners are C-UL listed, for use
in the US or Canada, per ANSI Z21.17/CSA2.7-
latest edition, for use with natural gas or propane
gas. Specify Canadian application when ordering
the burner to obtain proper labeling and manuals.
Codes
The installation must conform with local codes or, in the absence of local codes, with the Standard
for the Installation of Domestic Gas Conversion Burners, ANSI Z21.8, and the National Fuel Gas
Code, ANSI Z223.1, or the CAN/CGA-B149, Installation Codes. The electrical installation must also
conform with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/
NFPA 70, or the Canadian Electrical Code, CSA C22.1/CSA C22.2.
Special attention ags
Please pay particular attention to the following when you see them through-
out this manual.
Noties you of hazards that WILL cause severe personal
injury, death or substantial property damage.
Noties you of hazards that CAN cause severe personal
injury, death or substantial property damage.
Noties you of hazards that WILL or CAN cause minor per-
sonal injury or property damage.
Noties you of special instructions on installation, operation or
maintenance that are important, but are not normally related
to injury or property damage hazards.
PLEASE read this rst . . .
Installer/service technician . . .
• Read all instructions before proceeding. Perform all proce-
dures, and in the order given to avoid potential of severe
personal injury, death or substantial property damage.
• Before leaving the site after startup or service, review the
User’s information manual with the user. Make the user
aware of all potential hazards and perform the training
outlined below.
Train the user . . .
• To properly operate the burner/appliance per this manual,
the appliance instructions and the User’s information
manual.
• To keep this manual at or near the burner/appliance for
ready access by the user and service technician.
• To contact the service technician, gas supplier or re depart-
ment should the user smell gas.
• To keep the appliance space free of ammable liquids or
vapors and other combustible materials.
• Do not use laundry products, paints, varnishes or other
chemicals in the room occupied by the burner/appliance.
• To contact the service technician at least annually for startup
and burner/appliance service.
When servicing the burner . . .
• Disconnect electrical supply to burner before attempting
to service to avoid electrical shock or possible injury from
moving parts.
• Burner and appliance components can be extremely hot.
Allow all parts to cool before attempting to handle or
service to avoid potential of severe burns.

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13 – 3 –
Where appliance instructions differ from this manual, follow the appliance instructions.
EZGas Pro burner at-a-glance
12 Primary control (Carlin Model 60200FR microprocessor-based inter-
rupted ignition ame supervisory control, for use with ame rod ame
rectication)
13 Flame current test jack
14 Burner junction box
15 Motor (Carlin PSC motor, with permanently-lubricated bearings and
automatic thermal overload protection)
16 Blower housing (cast aluminum), with powder coat paint nish
17 Blower wheel
18 Air band with indicator — Only a single adjustment required for setting
combustion air; see page 7 for starting setting based on appliance
model and input)
19 Airow proving switch — Prevents burner from ring if air is not moving
20 Combination gas valve (with integral gas pressure regulation — set for
3½” w.c. outlet pressure) - 24V
21 Gas supply entrance — ¾” NPT; 5” w.c. min; 14” w.c. max
22 24V Transformer
1 Air tube (ange omitted for clarity), with powder coat paint nish
2 Diffuser plate (interchangeable hole or slot pattern)
3 Gas manifold (concentric cylinders swaged at ends) — Gas manifold
delivers gas to gas openings on inner wall of manifold near the dif-
fuser plate.
4 Ignitor electrode
5 Flame rod
6 Gas orice nipple — see pages 7 and 8 for orice sizing requirements
7 Gas inlet connection (gas entrance to gas manifold)
8 Gas manifold outer wall
9 Gas manifold inner wall
10 Hinged cover plate (for access to blower wheel & electrodes)
11 Ignitor — Carlin Model 41800 solid state electronic ignitor — 9,000
volts, continuous duty rated)
QUALITY CHARACTERISTICS
CRITICAL MAJOR
A
MAJOR
B
MINOR NO
SYMBOL
CRITICAL
STATISTICAL
SEE QAS 1000 FOR VENDORS QUALITY
ASSURANCE REQUIREMENTS
TOLERANCE UNLESS OTHERWISE SHOWN
FRACTIONAL `1/64 ANGLE `1/2~
DEC. .XX `.01 .XXX `.005
THIS DOCUMENT MAY NOT BE
REPRODUCED WITHOUT WRITTEN
PERMISSION FROM CARLIN
COMBUSTION TECHNOLOGY, INC.
REMOVE BURR AND FLASH FOR
PROPER OPERATION AND GOOD
APPEARANCE
THIRD ANGLE PROJECTION
DO NOT SCALE DRAWING
INTERPRET ALL DIMENSIONS
PER ANSI Y14.5 1994
CARLIN COMBUSTION TECHNOLOGY, INC.
EAST LONGMEADOW, MA U.S.A.
PART
NUMBER
MAT'L
NUMBER
PART
DESC.
MAT'L
DESC.
ITEM
CLASS
ITEM
CLASS
ECN #
REV SH
OF
DRAWING
NUMBER
DRAWN DATE
SCALE
EZ
GAS_RevA_FlippedElectrode_1
wmisiaszek 9/4/2013 ECN
BSIZE
ALL LINEAR DIMENSIONS
ARE IN INCHES
REVISION HISTORY
REV DESCRIPTION ECN BY DATE
.Released to Production ECN MPC 5/4/2009
12345
6
7
8
9
10
11
14
15
16
17
18
19
22
21
20
12
13

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13
– 4 –
Where appliance instructions differ from this manual, follow the appliance instructions.
1. Prepare site • prepare burner • mount burner
Inspect installation site
Inspect, repair and/or replace vent system
Do not install this burner unless you have veried
the entire vent system and the appliance are in good
condition and comply with all applicable codes.
The vent and chimney must be sized and constructed
in accordance with all applicable codes. If intended for
use with an oil burner as well, the vent system must
comply with relevant codes for both gas and oil ring.
Appliances equipped with a gas conversion burner are
treated as fan-assisted appliances.
The vent system must not be pressurized unless the
vent piping and vent system are designed accordingly.
The vent must provide draft at all times (negative pres-
sure in vent).
Do not install or use an existing manual damper in the
vent connector or vent.
Do not connect the appliance vent connector to a
chimney or vent serving a replace, incinerator or
solid-fuel-burning apparatus.
In a cold climate, do not vent into a masonry
chimney that has one or more sides exposed to
the outside. Install a listed stainless steel liner to
vent the ue products.
A defective vent system could result in severe personal
injury, death or substantial property damage.
Vent/chimney sizing
• Follow all local codes when sizing the vent and chimney
• Refer to the appliance manufacturer’s manual, when available,
for venting recommendations.
Prepare vent/chimney
• Secure all metal vent joints with screws, following the vent
manufacturer’s instructions. Seal all joints in the vent system
and chimney. Repair masonry chimney lining and repair all
mortar joints as needed.
• Where draft uctuations are likely, install a double-acting baro-
metric draft regulator in the vent piping. (The damper must be
located in the same space as the appliance.) Install a manual
reset spill switch in the top of the draft regulator outlet. Wire the
switch into the appliance limit circuit to shut off the appliance/
burner if sustained downdraft should occur. Refer to the appli-
ance manufacturer’s instruction manual for recommendations
regarding the need for a barometric draft regulator.
• Provide support for the vent piping. Do not rest the weight of
any of the vent piping on the appliance ue outlet.
Figure 1 Vent and vent connector installation

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13 – 5 –
Where appliance instructions differ from this manual, follow the appliance instructions.
1. Prepare site • prepare burner • mount burner (continued)
Figure 2 Locating & sizing air openings
Inspect installation site
Verify combustion/ventilation air openings
Installing the burner/appliance in a space that does not provide
enough air for combustion and ventilation can result in severe
personal injury, death or substantial property damage. Follow
all applicable codes and guidelines below to ensure space
has sufcient air openings.
Large spaces
For appliances located in basements, ventilated crawl spaces or other
large areas, no additional air openings should be necessary. Exception: If
the building construction is unusually tight (see National Fuel Gas Code
for denition), you will need to provide air openings into the building if ap-
pliance air comes from inside. Provide one opening within 12 inches of the
ceiling, and one opening within 12 inches of the oor. Size each opening to
provide free area (after deduction for louvers) of 1 square inch per 1,000
Btuh input of all fuel-burning appliances in the building.
Conned spaces — air from inside building
If air openings connect to areas inside the building, provide two openings,
one within 12 inches of the ceiling, the other within 12 inches of the oor.
Each opening must have a free area (after deduction for louvers) of 1 square
inch per 1,000 Btuh of all appliances in the space. If the building construc-
tion is unusually tight (see National Fuel Gas Code for denition), you will
need to provide air openings into the building. Provide two openings sized
and located as for the openings into the boiler space.
Conned spaces — air from outside
If air openings connect directly to outside, provide two openings, one within
12 inches of the ceiling, the other within 12 inches of the oor. Each opening
must have a free area (after louver deduction) of:
• If directly through side wall: 1 square inch for each 4,000 Btuh of all
appliances in the space.
• If through vertical ducts: 1 square inch for each 4,000 Btuh of all appli-
ances in the space.
• If through horizontal ducts: 1 square inch for each 2,000 Btuh of all
appliances in the space.
Optional outside air connection
For spaces not tted with large enough air openings, you may be able to
apply the optional burner cover kit (RESCVR5S) with Outside Air/Direct Vent
kit (50433KIT) to provide outside combustion air to the burner. You must
use a vent outlet/air inlet termination approved by the appliance manufac-
turer. Refer to the appliance and outside air kit manuals for instructions.
You will also have to apply this option if the appliance space may contain
corrosive contaminants, such as laundry products, paints, varnishes or
other chemicals.
Even when using the optional outside air kit, make sure the
space provides enough ventilation to prevent overheating of
the appliance, burner and controls. If there is risk of over-
heating, you must install ventilation air openings sized large
enough to provide air for cooling the equipment. Failure to
provide ventilation can result in severe personal injury, death
or substantial property damage.

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13
– 6 –
Where appliance instructions differ from this manual, follow the appliance instructions.
1. Prepare site • prepare burner • mount burner (continued)
Inspect installation site
Verify combustion/ventilation air openings (continued)
When sizing air openings for combustion and ventilation,
include air required for exhaust fans and other appliances,
such as clothes driers, that require air for operation.
Check appliance manual and applicable codes for required sizing of com-
bustion and ventilation air openings.
• Verify that openings are unobstructed.
• Verify that appliance space and air source spaces are free of:
– Gasoline or other ammable liquids or vapors.
– Combustible materials.
– Air contaminants, such as laundry products, paint, thinner, varnish,
etc.
• Conrm with user that the area will be kept free of these materials at
all times.
Verify clearances
• Verify that the burner/appliance will maintain all clearances to combus-
tible walls or oor and all clearances required for service/maintenance
as required in the appliance manual and applicable codes.
Prepare the appliance
Burner input: Install a gas burner sized for the normal input
rating of the appliance. Do not install a burner with a higher
ring rate than the appliance rating. Do not install a burner
with a ring rate more than 10% lower than the appliance
rating. The appliance and vent system could be damaged
due to condensation.
Seal the appliance: Seal all ue-gas containing joints. Seal
all connections to the vent piping for breeching.
Clean the appliance: Clean the appliance thoroughly and
seal all joints. Test all electrical components and verify the
relief valve works (boilers only).
Verify combustion chamber dimensions comply with the
minimum dimensions shown in Figure 3, page 7. Install or
replace combustion chamber liner if required by the appliance
manufacturer. The burner must not extend into the combus-
tion chamber. The end of the burner air tube must be within
¼” of the inside face of the combustion chamber. If the space
around the burner air tube is more than ¼”, wrap the burner
air tube with minimum 2300-°F-rated ceramic ber blanket
to seal off the gap.
Repair or replace damaged appliance components.
Inspect the appliance thoroughly. Follow appliance manufac-
turer’s guidelines for repair or replacement of any component
found defective.
When cleaning the appliance or working with ceramic ber
refractories or berglass insulation, see WARNING on this
page. Failure to comply with the above could result in severe
personal injury, death or substantial property damage.
Prepare appliance for burner mounting
The universal ange supplied with EZGas Pro burners
is for ring chambers with negative or positive over-
re pressure. The ange should be sealed with high
temperature silicone. Failure to comply could result in
severe personal injury, death or substantial property
damage.
See page 19 for required dimensions and bolt locations.
Ceramic ber or
Fiberglass insulation
Ceramic ber materials, such as chamber liners,
may contain carcinogenic particles (chrysto-
balites) after exposure to heat. Airborne particles
from berglass or ceramic ber components have
been listed as potentially carcinogenic by the
State of California. Take the following precautions
when removing, replacing and handling these
items.
Avoid breathing dust and avoid contact with
skin or eyes. Wear long-sleeved, loose-tting
clothing, gloves and eye protection. Use a NIOSH
N95 certied respirator. This respirator meets
requirements for protection from chrystobalites.
Actual job requirements or NIOSH regulations
may require other or additional protection. For
information, refer to the NIOSH website, http://
www.cdc.gov/niosh/homepage.html.
Ceramic ber removal: To prevent airborne dust,
thoroughly wet ceramic ber with water before
handling. Place ceramic ber materials in a plastic
bag and seal to dispose.
Avoid blowing, tearing, sawing or spraying
berglass or ceramic ber materials. If such op-
erations are necessary, wear extra protection to
prevent breathing dust.
Wash work clothes separately from other laun-
dry. Rinse clothes washer thoroughly afterwards
to prevent contamination of other clothing.
NIOSH First aid procedures:
Eye exposure — irrigate immediately
Breathing — fresh air.

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13 – 7 –
Where appliance instructions differ from this manual, follow the appliance instructions.
1. Prepare site • prepare burner • mount burner (continued)
Inspect burner and components
Do not install or operate the burner if any component is dam-
aged or if burner does not comply with the specications or
any other guidelines in this manual.
Air tube insertion length (UTL)
• Usable air tube length (UTL) is the distance from mounting ange to end of air
tube. Verify that the end of the air tube will be ush with, or no more than ¼ inch
short of, the inside of the appliance combustion chamber front wall when the
burner is mounted. See Figure 3 and Table 1 below for further information.
Diffuser plate
• Verify correct diffuser plate (item 2, page 3). Compare diffuser plate listed on air
tube label with diffuser plate listed in Table 1.
Gas orice drill size
• The gas orice is drilled through a plate in the end of the orice nipple (see item
6, page 3). Read the factory-drilled orice size on the label attached to the burner
air tube (see item 1, page 3) near the blower housing end. If the gas orice size
is not correct for your application, or if the label is illegible for any reason, check
the orice size directly and redrill orice or replace if necessary, as follows (next
page).
Figure 3 Combustion chamber dimensions (see Table 1)
Table 1 Burner specications for EZGas Pro burners
Appliance Diffuser Air Band
Input BTU Nat Gas Propane Plate Type C Diffuser B Diffuser A Diffuser 9-Slot Diff
Note 1 Note 3
50,000 - 75,000 5/32 1/8 C1-Slot 5%
75,000 - 100,000 3/16 9/64 B or 9-Slot 1-Slot 5% 15%
100,000 - 125,000 7/32 11/64 B or 9-Slot 1-Slot 20% 30%
125,000 - 150,000 1/4 13/64 B or 9-Slot 1-Slot 30% 40%
150,000 - 175,000 9/32 7/32 B or 9-Slot 1-Slot 45% 70%
175,000 - 200,000 5/16 1/4 A or 9-Slot 2-Slot 30% 45% Tube Length UTL min. UTL max.
200,000 - 225,000 5/16 1/4 A or 9-Slot 2-Slot 35% 60% 10" 1 3/4" 3 1/2"
225,000 - 250,000 11/32 9/32 A or 9-Slot 2-Slot 45% 75% 12 1 3/4" 5 1/2"
250,000 - 275,000 13/32 5/16 A2-Slot 55% 14 1 3/4" 7 1/2"
Note 2
Note 3
Note 4
C/L L W H VC
3 7687
3 7687
3 1/2 8798
3 1/2 9798 1/2
411 810 9 1/2
412 810 10
4 1/2 14 811 12
4 1/2 15 911 13
4 1/2 16 911 14
4 1/2 17 911 15
For BTU ranges that are covered by both the 9-Slot Diffuser Plate and the A or B Diffuser Plate, it is likely that either diffuser will work, but one may
provide better combustion. The 9-slot's short flame pattern favors appliances with shorter combustion chambers.
Use this as the starting setting only. Adjust air band setting, if necessary, after performing combustion testing (see page 13).
Minimum Chamber Dimensions
(in inches)
(VC= min. diam. Of vertical cylinder chamber)
Notes 3, 4, 5 Some tested appliances may operate satisfactorily with dimensions less than those
noted in the table.
Note 3
Horizontal cylindrical chambers - diameter must be no less than column W.
Horizontal stainless steel cylindrical chambers - diameter at least 1 to 4 inches
larger than column "W" above.
A corbel may help heat transfer in a larger boiler of furnace, provided it is
recommended by the appliance manufacturer.
Note 4
Note 5
Note 1
Firing rate should be within +/- 5% of rated input for the appliance. High altitude applications: The maximum burner input at sea level is 275,000 Btuh.
Reduce this capacity by 4% per 1,000 feet above sea level. Example- max. capacity at 5,000 feet is 220,000 Btuh (20% reduction). Pressurized firing:
Maximum burner input decreases with increasing overfire pressure. Assume a reduction in maximum burner input of approximately 5% at 0.1 w.c. and
10% at 0.2 inches w.c You will have to increase the air band opening to compensate for the increased pressure. Follow the procedures given in this
manual to check combustion with instruments to determine the correct air band setting. Do not fire into a chamber with pressure higher than 0.2 inches
w.c. and never fire at a higher pressure than recommended by the appliance manufacturer.
Burners with welded flange have fixed
insertion depths. Verify the insertion depth is
correct for the appliance. On burners with
adjustable flanges, the Usable Tube Length
(UTL) available for setting the insertion depth
varies with air tube length:
Once the orifice is drilled, minor adjustments to the firing rate can be achieved by adjusting the gas valve outlet pressure between 3.2" and 3.8" w.c. If
the rate remains too low, re-drill the orifice with a 1/64" larger bit (for details, see Make Final Burner Adjustments in Section 4 of this manual.)
Note 2
Note 4
Usable Tube Length
for Insertion Depth
Approx. Air Band SettingOrifice Drill Size

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13
– 8 –
Where appliance instructions differ from this manual, follow the appliance instructions.
1. Prepare site • prepare burner • mount burner (continued)
Inspect/redrill gas orice when required
• Turn off power to the burner/appliance before proceeding.
• Close main manual gas valve in gas line to burner. Then disconnect
the ground joint union to allow rotating burner combination gas valve.
You must disconnect power to burner and close main
manual gas valve before proceeding. Failure to do so
could result in severe personal injury, death or substantial
property damage.
• Unplug wire harness from combination gas valve.
• Remove the combination gas valve (item 20, page 3) and the orice
nipple (item 6, page 3). Remove the orice nipple from the gas valve.
• Read the correct orice drill size from Table 1, page 7. Then check
actual orice size using that size twist drill bit.
• If gas orice is smaller than required, redrill the orice to the cor-
rect size, if necessary.
• If gas orice is larger than required, obtain a replacement orice
nipple from Carlin. If necessary, drill the orice hole in the replace-
ment orice nipple to the correct size.
Drill the orice carefully, avoiding drill wobble. Wobble will
cause the orice to be over-sized. The orice nipple should
be secured in a vise, if possible, to ensure it is steady dur-
ing the drilling process.
• Write the orice size on the orice nipple label (or on the French
label attached to the burner for Canadian installations).
• Replace the gas valve and piping, using only pipe dope listed for use
with liqueed petroleum gases. Make sure the arrow on the orice
nipple label points in the direction of gas ow.
Flame rod and ignitor electrode
• Inspect the burner from air tube end. Flame rod should extend
through the diffuser plate as shown in Figure 4. Ignitor electrode
should be ush with inner face of diffuser plate as shown.
• The ame rod and ignitor electrode must not touch the diffuser or any
grounded metal surface at any point. The ame rod and electrode
should be as close as possible to the centers of the diffuser holes. If
either the ame rod or electrode is closer than 1/16” to the diffuser,
remove assembly (see page 15 for removal instructions and verify
dimensions per Figure 5). Bend the end of the ame rod or ignitor
electrode as required. Replace assembly and check spacing again.
Continue adjusting as necessary until neither rod nor electrode is
closer than 1/16” to the diffuser.
Figure 5 Flame rod/ ignitor electrode assembly
Install gas valve on burner
1. Read WARNING’s on page 9 before installing gas valve.
2. Apply a small amount of pipe dope (suitable for propane gas) to gas
valve outlet connection, gas line nipple and burner gas connection.
Assemble pipe nipple to gas valve. Install gas line nipple in burner
gas connection.
To avoid damage to gas valve, do not hold valve with a
pipe wrench or over-tighten. Use only a crescent wrench
or other means. Failure to comply could result in severe
personal injury, death or substantial property damage.
3. Connect wire harness to valve.
Inspect components and wiring
• Visually inspect all burner components and wiring.
• Verify that wiring is intact and connectors are securely connected.
• Verify that all burner components are in good condition.
Mount burner in appliance
• Verify appliance burner front plate dimensions per page 19.
• Slide gasket supplied with burner over end of air tube.
• Insert burner into appliance opening and bolt in place.
Verify and install diffuser plate
Each plate will be stamped on the face of the diffuser with a letter desig-
nating the diffuser type (Example A, B, C, 9S).
1. Install the diffuser on the air tube by placing the wide tab into the slot
at the end of the air tube with the 90obent tabs of the diffuser plate facing
into the air tube.
2. Fasten diffuser plate to the air tube with the two screws provided.
3. Make sure the ame rod and electrode are not touching the diffuser
plate.
4. If ame rod or electrode is making contact with the diffuser plate the
burner will not prove ame and will enter a lockout condition.
Air tube orientation for right side (motor side) gas supply (Burners
with Adjustable Flange only)
1. The air tube may be rotated from the left side gas inlet to the right side
gas inlet (motor side).
2. Remove the electrode/ame rod assembly as described in the Mainte-
nance section. It should look like Figure A.
3. Remove the four 5/16 screws that hold the air tube to the burner chas-
sis. Now the air tube can be rotated 180oso the gas inlet is on the right
side (motor side). Reinstall the four 5/16 screws, securing the tube back
onto the chassis.
4. Remove the screw holding the electrode/ame rod bracket to the alu-
minum rod. Reassemble the electrode/ame rod bracket to the aluminum
rod as shown in Figure B while positioning the ame rod and electrode as
shown in Figure 5.
5. Replace the electrode/ame rod assembly as described in the Main-
tenance section. Note that the aluminum rod must now sit on top of the
nylon washer.
Figure 4 Flame rod and Ignitor placement
QUALITY CHARACTERISTICS
CRITICAL MAJOR
A
MAJOR
B
MINOR NO
SYMBOL
CRITICAL
STATISTICAL
SEE QAS 1000 FOR VENDORS QUALITY
ASSURANCE REQUIREMENTS
TOLERANCE UNLESS OTHERWISE SHOWN
FRACTIONAL `1/64 ANGLE `1/2~
DEC. .XX `.01 .XXX `.005
THIS DOCUMENT MAY NOT BE
REPRODUCED WITHOUT WRITTEN
PERMISSION FROM CARLIN
COMBUSTION TECHNOLOGY, INC.
REMOVE BURR AND FLASH FOR
PROPER OPERATION AND GOOD
APPEARANCE
THIRD ANGLE PROJECTION
DO NOT SCALE DRAWING
INTERPRET ALL DIMENSIONS
PER ANSI Y14.5 1994
CARLIN COMBUSTION TECHNOLOGY, INC.
EAST LONGMEADOW, MA U.S.A.
PART
NUMBER
MAT'L
NUMBER
PART
DESC.
MAT'L
DESC.
ITEM
CLASS
ITEM
CLASS
ECN #
REV SH
OF
DRAWING
NUMBER
DRAWN DATE
SCALE
58572
wmisiaszek 9/4/2013 ECN
BSIZE
ALL LINEAR DIMENSIONS
ARE IN INCHES
REVISION HISTORY
REV DESCRIPTION ECN BY DATE
.Released to Production ECN MPC 5/4/2009
Ignitor electrode
Electrode bracket
Flame rod
Support rod
1.55" 1 3/4"
0.61"
1 3/8"
Flame rod
Ignitor electrode
Support rod flush at both ends
QUALITY CHARACTERISTICS
CRITICAL MAJOR
A
MAJOR
B
MINOR NO
SYMBOL
CRITICAL
STATISTICAL
SEE QAS 1000 FOR VENDORS QUALITY
ASSURANCE REQUIREMENTS
TOLERANCE UNLESS OTHERWISE SHOWN
FRACTIONAL ` 1/64 ANGLE ` 1/2 ~
DEC. .XX `
.01 .XXX ` .005
THIS DOCUMENT MAY NOT BE
REPRODUCED WITHOUT WRITTEN
PERMISSION FROM CARLIN
COMBUSTION TECHNOLOGY, INC.
REMOVE BURR AND FLASH FOR
PROPER OPERATION AND GOOD
APPEARANCE
THIRD ANGLE PROJECTION
DO NOT SCALE DRAWING
INTERPRET ALL DIMENSIONS
PER ANSI Y14.5 1994
CARLIN COMBUSTION TECHNOLOGY, INC.
EAST LONGMEADOW, MA U.S.A.
PART
NUMBER
MAT'L
NUMBER
PART
DESC.
MAT'L
DESC.
ITEM
CLASS
ITEM
CLASS
ECN #
REV SH
OF
DRAWING
NUMBER
DRAWN DATE
SCALE
wmisiaszek 9/4/2013
ALL LINEAR DIMENSIONS ARE IN INCHES
REVISION HISTORY
REV DESCRIPTION ECN BY DATE
.Released to Production W.M. 04-06-10
Flame rod
End of air tube
Ignitor electrode
*Tip should extend in front of diffuser by 1 1/4”.
(Tip should be ush with inside surface of diffuser).
*
QUALITY CHARACTERISTICS
CRITICAL MAJOR
A
MAJOR
B
MINOR NO
SYMBOL
CRITICAL
STATISTICAL
SEE QAS 1000 FOR VENDORS QUALITY
ASSURANCE REQUIREMENTS
TOLERANCE UNLESS OTHERWISE SHOWN
FRACTIONAL ` 1/64 ANGLE ` 1/2 ~
DEC. .XX `
.01 .XXX ` .005
THIS DOCUMENT MAY NOT BE
REPRODUCED WITHOUT WRITTEN
PERMISSION FROM CARLIN
COMBUSTION TECHNOLOGY, INC.
REMOVE BURR AND FLASH FOR
PROPER OPERATION AND GOOD
APPEARANCE
THIRD ANGLE PROJECTION
DO NOT SCALE DRAWING
INTERPRET ALL DIMENSIONS
PER ANSI Y14.5 1994
CARLIN COMBUSTION TECHNOLOGY, INC.
EAST LONGMEADOW, MA U.S.A.
PART
NUMBER
MAT'L
NUMBER
PART
DESC.
MAT'L
DESC.
ITEM
CLASS
ITEM
CLASS
ECN #
REV SH
OF
DRAWING
NUMBER
DRAWN DATE
SCALE
EZ
GAS_RevA_FlippedElectrode_Dims
wmisiaszek 9/4/2013 ECN
BSIZE
ALL LINEAR DIMENSIONS
ARE IN INCHES
REVISION HISTORY
REV DESCRIPTION ECN BY DATE
.Released to Production ECN MPC 5/4/2009
3 1/2"
7 3/8" Air tube length
(as needed for apliance) 5 7/8"
9 1/4"
11 3/4"
6 3/4"
10 3/4"
UTL
6
1
2
3
4
7
5
8
Figure A Figure B

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13 – 9 –
Where appliance instructions differ from this manual, follow the appliance instructions.
2. Install gas piping from meter to combination gas valve
Gas supply pressure — natural or propane
• Maximum supply pressure: 14 inches w.c.
• Minimum supply pressure: 5 inches w.c.
Do not expose the combination gas valve to gas pressure
in excess of 14 inches water column. Higher pressure could
damage the valve seat, resulting in potentially hazardous
condition. When pressure testing piping at higher pressures,
disconnect burner from gas line before testing.
If the gas supply pressure can exceed 14 inches water col-
umn at any time, you must install a lockup type gas pressure
regulator in the gas supply piping, ahead of the main manual
gas valve installed at the burner.
Test and purge gas line
Read WARNING above.
Pressure test and purge the line. Pressure testing should be done by the
gas supplier or utility, following all applicable codes.
Piping from meter to burner
Connect from the gas supply to the burner combination gas
valve inlet using new, clean black iron pipe and malleable iron
ttings only. Do not use copper, brass, cast iron or galvanized
pipe or ttings.
Provide support for gas piping. Do not rest weight of piping
on burner gas valve.
Apply pipe dope sparingly at all joints. Use only pipe dope
listed for use with propane gas. Do not use pipe sealing tape.
Do not hold gas valve with pipe wrench. Use crescent wrench
or other smooth-jawed device. Do not over-tighten.
Failure to comply with above could result in severe personal
injury, death or substantial property damage.
1. If possible, install a new gas line directly from the gas meter. If you are
using an existing gas line, verify it is clean and in good condition, and
verify it is large enough to handle the load of all connected appliances.
2. When branching from a common gas line, do not tap off from the bottom
of horizontal sections — only from the side or top.
3. Install a main manual shutoff valve, sediment trap and ground joint
union near the burner combination gas valve connection as shown in
Figure 6.
4. If the burner is installed inside the appliance jacket, install the main
manual gas valve and sediment trap external to the jacket.
5. Size piping (or verify size) using Table 2. You will nd additional informa-
tion on gas line sizing in the National Fuel Gas Code, ANSI Z223.1.
Figure 6 Connecting gas supply piping to burner
Table 2 Capacities of black iron pipe, cubic feet gas/hour
In the state of Massachusetts, when lever-type gas shutoffs
are used, they must be T-handle type only.
1 Pipe to meter or branch
2 Main manual gas shutoff valve
3 Use clean, burr-free black iron pipe
and malleable iron ttings
4 Ground joint union
5 Sediment leg
6 Burner combination gas valve
7 Upstream pressure tap, 1/8”
8 Outlet pressure tap, 1/8”
9 Gas regulator access screw
10 Gas valve electrical connection
QUALITY CHARACTERISTICS
CRITICAL MAJOR
A
MAJOR
B
MINOR NO
SYMBOL
CRITICAL
STATISTICAL
SEE QAS 1000 FOR VENDORS QUALITY
ASSURANCE REQUIREMENTS
TOLERANCE UNLESS OTHERWISE SHOWN
FRACTIONAL `1/64 ANGLE `1/2~
DEC. .XX `.01 .XXX `.005
THIS DOCUMENT MAY NOT BE
REPRODUCED WITHOUT WRITTEN
PERMISSION FROM CARLIN
COMBUSTION TECHNOLOGY, INC.
REMOVE BURR AND FLASH FOR
PROPER OPERATION AND GOOD
APPEARANCE
THIRD ANGLE PROJECTION
DO NOT SCALE DRAWING
INTERPRET ALL DIMENSIONS
PER ANSI Y14.5 1994
CARLIN COMBUSTION TECHNOLOGY, INC.
EAST LONGMEADOW, MA U.S.A.
PART
NUMBER
MAT'L
NUMBER
PART
DESC.
MAT'L
DESC.
ITEM
CLASS
ITEM
CLASS
ECN #
REV SH
OF
DRAWING
NUMBER
DRAWN DATE
SCALE
EZ
GAS_RevA_FlippedElectrode_Main
wmisiaszek 9/4/2013 ECN
BSIZE
ALL LINEAR DIMENSIONS
ARE IN INCHES
REVISION HISTORY
REV DESCRIPTION ECN BY DATE
.Released to Production ECN MPC 5/4/2009
9
7
10
8
12
3
4
5
6
7

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13
– 10 –
Where appliance instructions differ from this manual, follow the appliance instructions.
3. Wire burner
Figure 7 Wiring diagram — EZGas Pro burner with 60200FR primary control — typical wiring to appliance
Verify power supply
1. The burner requires a 120vac/60hz/single-phase power supply, with at least a 5-amp
fuse. The current draw will be (when equipped with Carlin motor and Carlin 41800
electronic ignitor):
2. The 120 vac power connections to the black and red/white wires of the 60200FR
must be the same polarity from the same power source. DO NOT attempt to supply
separate power sources. Check the power from the heat exchanger with a voltmeter.
Verify that the supply to the black and red/white wires are from the 120 vac HOT side
and that the power is no less than 102 vac nor more than 132 vac.
Checking burner ame signal
The 60200FR uses ame rectication to detect the ame. Because the grounded
metal surface area near the ame rod is much larger than the surface of the ame
rod, current ows through the ame more easily in one direction than the other. This
causes an AC voltage applied to the ame rod to result in a DC current. (Note that, if
the ame rod should touch a grounded metal part, the current would be AC, not DC,
and the control would not sense ame and go into a lockout condition).
The 60200FR control has a 3 mm ame signal test jack (item 13, page 3) that can
be used with a ame signal meter, such as the Honeywell W136. Or you can use a
standard 3 mm stereo plug tted with two leads. Connect these leads in series with
your ammeter leads to read DC microamps.
The minimum flame signal needed to satisfy the 60200FR sensing circuit is
0.8 microamps. The control will register ame failure at any lower signal.
Code compliance
The burner/appliance installation must comply with
codes listed on page 2 and any other locally appli-
cable codes.
General wiring requirements
Read and follow the guidelines below. Failure to comply
could result in severe personal injury, death or substantial
property damage.
Electrical shock hazard — Disconnect electrical supply
to the burner before attempting to service.
Electrically ground burner — The burner must be
grounded in accordance with local codes or, in the ab-
sence of local codes, with the National Electrical Code,
ANSI/NFPA 70 (in Canada, per Canadian Electrical Code,
CSA C22.1/CSA C22.2).
Label all wires before removing for servicing. Wiring
errors could result in unsafe appliance/burner operation.
Read appliance manufacturer’s instructions completely
before wiring burner.
The 60200FR control requires a constant 120 vac power
source from the appliance as well as power from the
appliance limit circuit. See Figure 7. Check polarity
carefully. If hot and neutral wires are reversed at
appliance power source, the control will lockout on
ame failure.
If replacing any of the wire supplied with the burner, use
minimum #18 AWG 125°C or better.
Air ow
switch
Yellow
24VAC
Transformer
Yellow
White
White
Approximate amp draw of EZGas Pro burners
Motor--> 1/15 HP 1/7 HP 1/6 HP
During ignition 2.5 AMPS 2.8 AMPS 3.0 AMPS
Steady operation 2.0 AMPS 2.3 AMPS 2.5 AMPS

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13 – 11 –
Where appliance instructions differ from this manual, follow the appliance instructions.
4. Check system • start-up burner/appliance
Figure 8 Air band adjustment
Verify ame failure lockout of 60200FR control
1. Install a hose barb tting in the combination gas valve outlet pressure
tap and connect with a hose to a U-tube manometer.
2. Close the main manual gas valve and turn the combination gas valve
knob to ON.
3. Turn on power to appliance and set appliance limit(s) to call for heat.
4. Burner motor will start. The 60200FR will run for its prepurge timing,
then start the ignitor. Approximately one second later, the combination
gas valve will open. (The manometer should show almost no pressure,
because the main manual gas valve is closed.)
5. After the Trial for Ignition Period, (TFI) the 60200FR will lockout and
turn on the red LED. The ignitor will shut off and the gas valve will close.
Turn off power and set controls to stop call for heat.
6. If lockout does not occur, replace the 60200FR control.
Inspect/check system
Before starting the burner and appliance, verify the system has been in-
stalled as directed by this manual and the appliance instructions.
Check gas piping for leaks
Disconnect the burner from the gas supply line if gas line
test pressure will exceed 14 inches w.c. Exposing the burner
combination gas valve to pressure higher than 14 inches w.c.
can damage the valve seat, resulting in potentially unsafe
operation.
You can usually test the gas piping by allowing the line to ll with gas to
main regulator outlet pressure.
1. Shut off gas ow to all appliances connected to the meter.
2. If test pressure will be less than 14 inches w.c., turn the burner com-
bination gas valve knob to OFF. If test pressure will be higher than 14
inches, remove the burner from the gas line by shutting off the main
manual gas valve installed near the burner (per Figure 6, page 9) and
disconnecting the ground joint union. See warning above.
3. Watch the gas meter dial. For a one half cubic foot per revolution dial,
there should be no movement of the dial for at least 5 minutes. For
larger volumes per revolution, increase this time proportionately.
4. If you detect a gas leak, locate the leak with a soap suds mixture and
repair it. Then test the system for leaks again.
Do not test for leaks with an open ame. And do not use
oxygen as a test gas. Either of these could cause an explo-
sion, resulting in severe personal injury, death or substantial
property damage.
Bleed gas line
Purge all air from the gas line. Purge to outside of the building, NEVER
into the appliance or burner.
Leak test near-burner gas piping
If piping near burner has not already been pressure tested, open main
manual gas valve on supply to burner and smell around area for any signs
of gas. Apply a soap suds mixture to all gas piping joints near burner and
check for any leaks. If any leaks appear, repair before proceeding and retest.
Set burner air band
See Figure 8. Loosen air band locking screw. Then rotate band until indicator
points to setting given in Table 1, page 7. Tighten air band locking screw.
The Table 1 setting will probably be satisfactory without change. If the
combustion test indicates a need for more or less air, however, you will
have to adjust the band accordingly.
Check burner and primary control
Inspect burner thoroughly. Verify hinged cover is in place and in good
condition, cover is closed and clamps are tightened. Verify all wiring is in
place and all components are secure and in position.
If the burner fails to ignite, NEVER attempt to manually bypass
the normal sequence of the control, which provides purging
of the combustion chamber.
Do not start the burner if you smell gas or if there may be
gas present in the appliance combustion chamber, heat
exchanger or the vent system. An explosion could occur,
causing severe personal injury, death or substantial property
damage.
During initial start-up, you must be constantly alert for emer-
gency conditions such as fuel leaks, electrical malfunctions,
etc. Familiarize yourself with the location of manual shutoff
valves and switches so you can quickly use them if needed.
Indicator
Locking screw

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13
– 12 –
Where appliance instructions differ from this manual, follow the appliance instructions.
4. Check system • start-up burner/appliance (continued)
Should overheating or an emergency occur, immediately:
• Shut off main manual gas valve.
• Shut off control switch to burner.
Under some circumstances power should remain on for water
pumps or circulating blowers. Determine proper response
before attempting start-up.
If burner fails ignition on several attempts, close gas valve
and use burner blower to purge appliance before restart.
Model 60200FR diagnostic LED’s
– Amber OFF – Red OFF – Green OFF
– Amber ON – Red ON – Green ON
– Amber FLASHING – Red FLASHING
– Amber BLINKING (blinks off momentarily every 3 to 4 seconds)
Please see 60200FR control label for trial for
ignition (TFI) and purge timings.
Start-up & operation
Do not start the burner if the combustion chamber
contains residual gas. Allow gas to disperse.
Per UL requirements, the control will not turn on if
the ame rod senses ame during the self-test. If the
ame rod senses ame, the green LED turns on. The
control will remain in self-test mode until the ame rod
no longer senses ame. The amber LED will remain
on, but blink off momentarily every 3 to 4 seconds.
LED turns on at the end of the TFI if the ame rod
senses ame.
Run The burner continues ring during call for heat if the
ame rod senses ame. Amber and red LED’s are off
and green LED is on during normal running.
Lockout If the ame rod does not sense ame within the TFI
time limit after gas valve activation, lockout occurs.
The control turns the red LED on constant, and closes
the alarm contact. Green LED is off.
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 from latch-up — Only a qualied service
technician should attempt to reset the control
after latch-up. The problem that caused the re-
peated burner problems must be corrected before
returning the burner to normal operation.
Push in and hold the reset button for about 10 seconds.
The red and amber LED’s will ash alternately.
After the LED’s begin ashing, continue to hold 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 60200FR control will not reset from lockout or
latch-up if power is interrupted.
Flame failure If the ame rod loses ame signal during operation
(after the TFI), the red LED ashes. The gas valve
closes within 2 seconds. The motor remains on for the
post-purge period, then shuts off. Recycle: Control
waits for 65 seconds (with red LED ashing), then
begins again at Self-test 2. Red LED goes off .
(NOTE: Controls with non-recycle feature will lock out
on ame failure.)
Post-purge Set operating control(s) and limit(s) to stop call for
heat. The gas valve will turn off within 2 seconds.
The motor remains on for the post-purge period, then
turns off.
Stand-by Control remains in stand-by mode until limit circuit
sends power to the black wire and thermostat circuit
closes (or jumpered) — (call for heat).
Power ON Open all manual gas line valves. Close the line switch.
(If Red LED turns on constant , control is in lockout.
See below to reset.)
Self-test 1 The control performs a “boot-up” test to verify internal
operation each time power is applied to the red/white
wire. 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.
Stand-by (No call for heat) If Self-test 1 is successful, amber
LeD turns off and control waits for heat call.
Call for heat Set operating control and all limit controls to call for
heat. The 60200FR thermostat circuit must be closed
(jumpered) and power coming to black wire from
limits.
Self-test 2 The amber LED turns on. For the rst 3 to 4 seconds,
the control performs a self-test. If the ame rod senses
ame, the green LED turns on. The control repeats
the self-test until ame is no longer detected (green
LED would turn off). During this time, the amber LED
will remain on, but blink off momentarily every 3
to 4 seconds. If the control detects motor contacts
closed or power to the gas valve, lockout occurs.
Burner on After the self-test, the amber LED turns off. The motor
starts.
Pre-purge The ignitor starts after the pre-purge period. Two
seconds later, the gas valve opens. The 2-second
delay (ignition establishment period) helps ensure a
stable spark is in place when the gas valve opens
(to compensate for sluggish response of some AC
ignition transformers).
TFI After gas valve opens, the ame rod must sense ame
within the TFI time limit (trial for ignition). The green

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13 – 13 –
Where appliance instructions differ from this manual, follow the appliance instructions.
4. Check system • start-up burner/appliance (continued)
Installer/servicer
Please check off and ll in certicate
Should overheating or an emergency occur, immediately:
• Shut off main manual gas valve.
• Shut off control switch to burner.
Under some circumstances power should remain on for water
pumps or circulating blowers. Determine proper response
before attempting start-up. If appliance fails ignition on several
attempts, close gas valve and use burner blower to purge
appliance before restart.
Check combustion using instruments
Do not attempt to conrm combustion simply by inspecting
the ame visually. You must use combustion test instruments.
Failure to properly verify/adjust combustion could allow
unsafe operation of the burner, resulting in severe personal
injury, death or substantial property damage.
Make nal burner adjustments (continued)
Inspect ame
❏ Look at ame through appliance observation port. The ame should be
a soft blue with well-dened orange and yellow tips for natural gas, or
well-dened yellow tips for propane gas. (If you make air or gas pres-
sure changes later, inspect the ame again). See instrument warning
below.
Check the ring rate
❏ Natural gas only — Turn off all other gas appliances connected to the
gas meter. Use a stopwatch to time the number of seconds for a ow
of one cubic foot of gas (two revolutions for a one half cubic foot per
revolution dial, for example). You will also need to know the gas heat
content in Btu per cubic foot. Determine the actual input from: INPUT
= (3600 x Btu per cubic foot) ÷ (number of seconds for one cubic foot),
for ring rate in Btuh. For example, for 1050 Btu per cubic foot natural
gas, with meter timed at 30.2 seconds for one cubic foot of gas: INPUT
example = (3600 x 1050) ÷ (30.2) = 125,200 Btuh. Firing rate should
be within ± 5% of rated input for the appliance. Adjust the combination
gas valve pressure regulator if necessary to obtain the correct ring
rate. Valve outlet pressure must not be lower than 3.2 inches w.c. nor
higher than 3.8 inches w.c.
❏ For propane gas, contact your propane supply for procedure to verify
ring rate.
Make nal burner adjustments
Check for leaks in gas piping
❏ Smell around burner to make sure there is no gas leak in near-burner
piping. Verify integrity of gas line joints between combination gas valve
and burner gas inlet tapping using soap suds mixture.
Check/adjust gas valve outlet pressure
❏ With burner running, check manometer reading for combination gas
valve outlet pressure. Adjust valve regulator if necessary so the reading
is 3.5 inches w.c. for either natural gas or propane gas (an LP conver-
sion kit is not required when ring propane).
Preparation before checkout
❏ Burner/appliance installed per appliance instruction manual?
❏ Burner components veried against Table 1, page 7?
❏ Burner/appliance installed per all applicable codes?
❏ Installation site has adequate ventilation openings and vent system?
❏ Gas supply line in good condition and sized correctly?
❏ All gas line joints sealed with pipe dope listed for use with liqueed
petroleum gases?
❏ Gas supply pressure to combination gas valve checked?
❏ Regulator installed if pressure can exceed 14 inches w.c.?
❏ Air purged from gas line?
❏ Gas piping checked for leaks?
❏ Wiring installed per burner and appliance instruction manuals?
❏ Burner inspected and primary control ame failure lockout checked?
❏ Start-up sequence performed (page 12)?
❏Insert test probe into vent above appliance to sample ue products.
The results should show CO2 or O2as follows:
❏ If the combustion results are outside the range above, and the ring
rate of the burner is within 5% of rated input, open or close the air band
until the CO2 (or O2) are acceptable.
After CO2 (O2) tests are completed satisfactorily, measure
ue products for carbon monoxide (CO) concentration. The
CO must not exceed 50 ppm adjust to “air free”, or other if
specied by local codes.
❏ Check pressure overre in appliance. Refer to appliance manual for
recommended reading and barometric damper instructions for proper
setting of damper.

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13
– 14 –
Where appliance instructions differ from this manual, follow the appliance instructions.
5. Perform checkout procedures • ll out certicate
Prepare burner for normal operation
❏Cycle burner off with appliance controls. Then turn off
power to the appliance.
❏ Close the main manual gas valve.
❏ Remove the U-tube manometer line from the combination
gas valve outlet pressure tap hose barb. Remove hose
barb and replace 1/8" NPT pipe plug in tapping.
❏ Verify all components and wires are in place and burner
is ready for operation.
Train the user
❏Train the user to operate the burner and appliance un-
der normal conditions. Explain procedure to shut down
burner/appliance when required.
❏ Review the user’s information manual (and the appliance
manual) with the user.
❏ Verify the user is aware of all procedures specied in the
manual.
❏ Verify user will not store or use combustible liquids or
materials or contaminants in the vicinity of the burner/
appliance.
Fill out the certicate
❏ Fill out the Installation/Service certicate on the back
page of this manual.
Verify burner/appliance operation
Check burner/appliance/controls operation
❏ Test operating and limit controls on appliance as specied
in appliance instruction manual.
❏ Check operation of the 60200FR primary control by forc-
ing Latch-up (three consecutive lockouts during the same
call for heat) by closing the main manual gas cock and
cycling the burner. Press the reset button to reset when
the control locks out on ame failure. Do this two times
and the control should enter Latch-up. See page 12 to
reset control.
❏ Check operation of airow switch.
❏ Remove cover from left side of burner. Remove two ag
terminals from pressure switch. Before initiating call-for-
heat, measuring resistance across the two airow switch
connections should indicate innity (overload). During
prepurge, zero ohms should be measured.
Verify burner operation
❏ Start and stop the burner several times, allowing the
primary control to sequence through normal operation.
Verify correct operation of burner and control throughout.
Verify burner/appliance operation (cont.)
Verify vent system operation
❏ Verify vent is operating correctly and ue products are
properly exhausted from building.
❏ Check operation of barometric damper and spill switch.
❏If the building contains any exhaust fans or conditions that
could affect vent performance, check burner/appliance/
vent operation with exhaust fans (or other conditions)
operating.

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13 – 15 –
Where appliance instructions differ from this manual, follow the appliance instructions.
6. Maintenance and service procedures
This burner should be started and serviced at least annually by a
qualied service technician. Failure to properly maintain and service
the burner could result in severe personal injury, death or substantial
property damage.
Turn off power to appliance and close main manual gas valve when
servicing burner. See warnings on page 2 and elsewhere in this manual
regarding correct procedures. Failure to comply could result in severe
personal injury, death or substantial property damage.
Annual start-up & service
Annual start-up and service procedures
❏ Discuss burner/appliance operation with user to determine any problems that may have
occurred during the previous season and to verify user is aware of proper operation
and care of the burner/appliance.
❏ Turn off power to appliance and close main manual gas valve.
❏ Remove burner from appliance and inspect diffuser plate, ignitor electrode and ame
rod (see Figure 4, page 8).
❏ Remove ignitor electrode/ame rod assembly to clean and adjust if necessary.
❏ To remove assembly:
1. Remove the connector wires from the ame rod and ignitor electrode.
2. Remove the lock nut and nylon washer securing the housing end of the assembly
support rod.
3. Remove the access cover (item 14, page 21) by loosening the screw securing it in
place.
4. Pull the electrode/ame rod assembly straight back and out.
5. Clean the assembly if necessary. Replace any part that is damaged.
6. Check the dimensions of the assembly against those shown in Figure 5, page 8.
Adjust if necessary.
If the inside surface of the air tube and/or diffuser plate need to be cleaned,
clean them with a vacuum cleaner with brush attachment before replacing
the electrode/ame rod assembly.
7. Replace the electrode/ame rod assembly:
• Insert the electrode/ame rod assembly into the air tube, with support legs down
(electrode/ame rod up).
• Place the support rod slot over support rod mounting stud. Slide the assembly
forward. When back of slot reaches mounting stud, replace the nylon washer
and locking nut on the mounting stud and tighten.
See Section 1 if the gas inlet connection is on the motor side of the burner.
• Replace the access cover (item 14, page 21) and tighten its retainer screw.
After replacing the electrode/ame rod assembly, follow the inspection proce-
dure on page 8 to verify the electrode and ame rod are correctly positioned.
Failure to properly install them can result in equipment failure.
❏ Close the ignitor cover plate and secure in place.
❏ Check the burner ange gasket. It must be in good condition. Replace gasket on burner
ange and mount burner in appliance, securing to mounting studs.
❏ Perform the complete checkout procedures of pages 11 through 14, including system
inspection and checks.

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13
– 16 –
Where appliance instructions differ from this manual, follow the appliance instructions.
6. Maintenance and service procedures (continued)
Maintenance/service procedures
Cleaning blower wheel
1. The blower wheel accumulates dust and debris from normal operation. You
will need to clean the wheel blades periodically to prevent reduction in airow.
To clean blades, remove the two bolts securing the motor to blower housing.
2. Slide the motor out and rotate to remove and access blower wheel.
3. Use a brush and vacuum to clean each blade and the blower housing interior.
4. Replace motor/wheel in blower housing and secure with the two bolts.
5. Push wire slack back into junction box.
Replacing blower motor or wheel
1. If either the blower wheel or motor must be replaced, remove the two bolts
securing the motor to housing.
2. Disconnect the motor wires in the burner junction box.
3. Loosen the Allen screw securing the blower to the motor shaft and remove
the wheel.
4. When assembling the replacement assembly, slide the wheel onto the motor
shaft and use feeler gauges to set a space of 3/64 inch between the blower
wheel and the motor face.
5. Replace the motor/wheel assembly in the housing, wire the motor leads and
secure the motor with the two bolts.
Motor maintenance
The Carlin PSC motor is constructed with permanently-lubricated bearings,
and requires no oiling. Should you replace the original motor with another type
of motor, occasional oiling may be required, depending on motor design and
manufacturer’s recommendations.
Any time you replace a component or disassemble any part of the
burner for service/maintenance, perform a complete operational test
after reassembly to verify the burner operates correctly. Failure to verify
operation could result in severe personal injury, death or substantial
property damage.

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13 – 17 –
Where appliance instructions differ from this manual, follow the appliance instructions.
7. Troubleshooting
If switch is correctly connected, but won’t close, replace airow switch.

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13
– 18 –
Where appliance instructions differ from this manual, follow the appliance instructions.
7. Troubleshooting (continued)

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13 – 19 –
Where appliance instructions differ from this manual, follow the appliance instructions.
8. Dimensions and mounting information
Figure 9 Dimensional data
Mounting burner to appliance
The universal ange can be used as supplied for
ring chambers with negative overre pressure.
For pressurized ring, the entire space where
the airtube meets the ange must be sealed
with a high temperature silicone sealant rated
for at least 400°F. Failure to comply could result
in severe personal injury, death or substantial
property damage.
Prepare the burner opening on the front of the appliance as
shown in Figure 10 if not already supplied. See page 7 to
determine the location of the ange on the burner air tube.
Tighten the ange locking screws rmly.
Figure 10 Universal mounting ange
1- Carlin 60200FR microprocessor control
2- Air tube
3- Flange (selected to meet appliance requirement)
4- Carlin 41800 solid state ignitor
5- Combination gas valve
6- Carlin PSC motor
7- Cast aluminum blower housing
8- Transformer and Air ow proving switch








 




 


QUALITY CHARACTERISTICS
CRITICAL MAJOR
A
MAJOR
B
MINOR NO
SYMBOL
CRITICAL
STATISTICAL
SEE QAS 1000 FOR VENDORS QUALITY
ASSURANCE REQUIREMENTS
TOLERANCE UNLESS OTHERWISE SHOWN
FRACTIONAL ` 1/64 ANGLE ` 1/2 ~
DEC. .XX `
.01 .XXX ` .005
THIS DOCUMENT MAY NOT BE
REPRODUCED WITHOUT WRITTEN
PERMISSION FROM CARLIN
COMBUSTION TECHNOLOGY, INC.
REMOVE BURR AND FLASH FOR
PROPER OPERATION AND GOOD
APPEARANCE
THIRD ANGLE PROJECTION
DO NOT SCALE DRAWING
INTERPRET ALL DIMENSIONS
PER ANSI Y14.5 1994
CARLIN COMBUSTION TECHNOLOGY, INC.
EAST LONGMEADOW, MA U.S.A.
PART
NUMBER
MAT'L
NUMBER
PART
DESC.
MAT'L
DESC.
ITEM
CLASS
ITEM
CLASS
ECN #
REV SH
OF
DRAWING
NUMBER
DRAWN DATE
SCALE
EZ
GAS_RevA_FlippedElectrode_Dims
wmisiaszek 9/4/2013 ECN
BSIZE
ALL LINEAR DIMENSIONS
ARE IN INCHES
REVISION HISTORY
REV DESCRIPTION ECN BY DATE
.Released to Production ECN MPC 5/4/2009
3 1/2"
7 3/8" Air tube length
(as needed for apliance) 5 7/8"
9 1/4"
11 3/4"
6 3/4"
10 3/4"
UTL
6
1
2
3
4
7
5
8

Model EZGas Pro gas burner — Instruction manual
Carlin part number MNEZGas Rev. 10/28/13
– 20 –
Where appliance instructions differ from this manual, follow the appliance instructions.
9. Replacement parts
Item Number Description Part Number
1Air tube used with universal ange
*Consult Carlin for welded ange airtubes
10” air tube 50877A
12” air tube 50877B
14” air tube 50877C
16” air tube 50877D
18” air tube 50877E
2Gasket, mounting ange 50821
3 Blower housing contact factory
4 Air band, 1-slot 50866
4a Air band, 2-slot 50867
5Airow switch 50806
6 24VAC transformer 50822
7Air ow switch cover 50837
8 Gas valve, VR8305M4009 50824
9Gas orice nipple, 3/4” NPT both ends 4” Starter hole orice 9983440XX
Drilled to size Contact factory
10 Escutchean plate 98548A
11 Blower wheel 77933
12 Motor, Carlin PSC, 1/15 HP 98629
13 Junction box, 4” x 4”, with grommet and lock washer contact factory
14 Access cover 98281A (without tab)
98282A (with tab)
15 Hinged cover plate for Carlin ignitor 98498
16 Ignitor, Carlin electronic Model 41800 4180002
17 Primary control, Carlin 60200FR microprocessor ame
rod control
6020002FR
18 Ignitor electrode/ame rod assembly for 10-inch air tube 50875A
for 12-inch air tube 50875B
for 14-inch air tube 50875C
for 16-inch air tube 50875D
for 18-inch air tube 50875E
19 Electrode bracket with screw 50868S
20 Flame rod for 10-inch air tube 50874A
for 12-inch air tube 50874B
for 14-inch air tube 50874C
for 16-inch air tube 50874D
for 18-inch air tube 50874E
21 Ignitor electrode for 10-inch air tube 50873A
for 12-inch air tube 50873B
for 14-inch air tube 50873C
for 16-inch air tube 50873D
for 18-inch air tube 50873E