Carlin 50200 User manual

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Model 50200 CAD Cell Oil
Primary Control Data Sheet
• Interrupted Duty Ignition
• Recycle on Flame Failure
• Serviceman Reset Protection
Latch-up after 3 consecutive lockouts
• Diagnostic LEDs
Status, lockout, ame
• 15-second, 30-second TFI
• Thermostat/Aquastat Compatible
• SMC Technology
• Pump Prime
• Alarm Contacts
Power input (from limit circuit) 120 VAC, 60 HZ, 9VA
Motor load 10 FLA / 60 LRA
Ignitor load 120 VAC, 60 HZ, 500 VA
Alarm contacts 24 V, AC/DC, 2A
Operating temperature limits +32°F to +140°F
Storage temperature limits -40°F to +185°F
Thermostat anticipator current 0.1 A, AC
CAD cell resistance (with flame) R < 1500 OHMS
Agencies UL recognized (US & Canada)
Installing and Wiring
50200 control must be installed and serviced only by a qualified service technician.
1. Always disconnect power source before wiring to avoid electrical shock or damage to the control. All wiring must comply with
applicable codes and ordinances.
2. Thermostat terminals (T-T) provide a current source. Never apply external power to these terminals under any circumstances.
3. Alarm terminals provide a 24 VAC/VDC-rated dry contact, suitable for use with security/fire alarm systems.
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 wiring diagram.
• Individual or bundled neutrals may be attached to any L2 terminal.
Field checks
1. Safety timing (TFI) test – Remove one CAD cell wire (F-F). Start burner. The control should lockout within the TFI time limit.
Replace CAD cell wire.
2. Flame failure test – Start burner. After ame is established (after TFI period), close the oil supply hand valve. This will cause a
flame failure sequence as described in the Startup & Operation section of this Data sheet. The control should recycle (restart
after 65 seconds).
3. If control does not operate as described, check the wiring.
SEE WIRING DIAGRAM ON NEXT PAGE

Wiring
Startup & 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 ame during the self-test. If the CAD cell sees light (ame) at the beginning of a cycle, the control will remain in
self-test mode until the CAD cell no longer senses light (flame). The amber LED will blink momentarily every 3 to 4 seconds and
green LED will be on or flashing.
Power ON Open all manual oil line valves. Close the line switch. (If Red LED turn 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 black
wire. The amber LED turns on and the test continues for about 5 seconds. If the test fails, the control turns
the amber LED off and repeats this test sequence until successful.
Stand-by (Thermostat circuit open and/or limit circuit open) If Self-test 1 is successful, amber LED turns off and
control waits for thermostat circuit to close and a limit input.
Call for Set thermostat to call for heat. Thermostat circuit must be closed and black wire must receive
heat power from the limit circuit.
Self-test 2 If a failure occurs in this self-check, the control won’t start and the amber LED blinks 1 second on, 4 sec-
onds off, until serviced or the problem clears. These failures include CAD cell seeing light, internal failure,
or line voltage <90V. See service section.
© Copyright 2015 - Carlin Combustion Technology, Inc. MN50200 022415
Bundled Neutrals Can Be Attached to Any L2 Terminal
Latch-Up: Prevents excessive resets by locking out after 3 consecutive resets during any one call for heat. To reset from Latch-Up: 1. Depress and hold the red button. Amber light will
blink after 10 seconds, red light will stay on solid.
2. After amber light stops blinking (approximately
20 seconds), release red button.
Releasing red button during step 1 and 2 will result in the control returning to latch-up
Model 50200 Diagnostic LEDs
– Amber OFF – Amber ON – Amber FLASHING
– Green OFF – Green ON – Green FLASHING
– Red OFF – Red ON – Red FLASHING

Startup & Operation (continued)
Burner ON After the self-test, amber LED turns off. The ignitor starts, followed 2 seconds later by the motor.
Pump To enter pump prime: 1. Start a CFH cycle. During Pre-Ignition, press Reset until motor turns
Prime off (10 seconds), then release the button. When motor turns back on, within 5 seconds, press the Reset button
until the amber LED starts to ash. You are in Pump Prime, release Reset button.
Optional Pump Prime notes: 1) If lost, press Reset for 1 second and release, then if the control is not in
Pump Prime, restart the sequence. 2) If Reset is released before end of rst 10 seconds, the control re-
turns to Standby and restarts another CFH cycle. 3) If reset is not pressed the second time, a normal CFH
cycle will continue. 4) If motor and igniter are on and amber LED is ashing, the control is in Pump Prime.
5) Pump Prime will exit standby if ame is detected, or 60 seconds has elapsed, or loss of TT or Limit, or
Reset button is pressed.
TFI The CAD cell must sense ame within the TFI time limit (trial for ignition). After CAD cell senses ame, the
ignitor stays on another 10 seconds (flame stabilization period).
Run The burner continues firing during call for heat if the CAD cell is sensing flame. Only the green LED is on
during normal running.
Lockout If CAD cell does not sense ame within the TFI time limit after the burner starts, lockout occurs. The con-
trol 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 LEDs 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 lockouts must be corrected before returning the burner to
normal operation.
Push in and hold the reset button for 10 seconds. The amber LED will begin to ash.
After the LED begins flashing, continue holding the reset button for 20 seconds. The LEDs will turn off.
Release the reset button and the control will restart (releasing the button before the LEDs 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 If the CAD cell loses ame signal during operation (after the TFI), the red LED ashes. The burner shuts off
Failure within 2 seconds.
Recycle: Control waits for 65 seconds (with red LED flashing), then begins again at Self-test 2. Red LED
goes off.
If the green LED is blinking during a run, the ame is weak or unstable and may go into recycle.
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 and thermostat circuit
closes (call for heat).
© Copyright 2015 - Carlin Combustion Technology, Inc. MN50200 022415

© Copyright 2015 - Carlin Combustion Technology, Inc. MN50200 022415
Service & Troubleshooting
Burner (control) will not come on
No power to control
• Check limit circuit 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 sec-
ond.
• 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
• Green LED on, and amber LED blinking 1 second
on, 4 seconds off. Remove one yellow lead from FF
terminals, and the flame test plug.
If the amber LED remains ashing and green LED on,
the control is defective.
If the amber and green LEDs go OFF, the 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:
• Attach multimeter to monitor CAD cell resistance.
Dark resistance should be over 50K ohms, and
room light resistance (control flipped open) should
be at most 10K ohms. Replace cell if necessary or
reinstall 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.
Repeated ame failures ( ashing red LED)
Check for:
• CAD cell is defective. Replace.
• Air leaking into oil line causing ame out.
Check oil line connections and filter gasket.
• Defective nozzle causing ame to be erratic.
Change nozzle.
• Excessive airow or draft causing ame to leave
burner head.
Check for proper air band setting and draft.
• Excessive back pressure causing ame to be er-
ratic. Check appliance and flue for sooting/plugging.
Control locks out after TFI ( red LED on)
Check for:
• No oil to burner. Check oil supply, filters, 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.
• Airow too high. Check air band setting.
• Ignitor module defective. Replace if no spark.
• CAD cell defective
• Oil valve (if used) stuck in closed position.
• Check wiring connections.
Blinking Green LED
• Weak or unstable ame.
• Check ohms.
• Check CO2level.
FROZEN PIPES/WATER DAMAGE: This is not a freeze protection device. Suitable freeze protection monitoring or
other precautions are recommended to protect against ruptured pipes/water damage caused by fuel outage, safety
related fault conditions, or equipment failures.