Carlin 40200 User manual

Model 40200/42230
CAD Cell Oil Primary Control
Data Sheet
• Oil Pump Bleed Assist
Up to 1 min.
• Recycle on Flame Failure
• Serviceman Reset Protection
Latch-up after 3 consecutive lockouts
• Diagnostic LEDs
Status, lockout, ame
• 15-second, 30-second TFI
• Increased Flame Accuracy
• Thermostat/Aquastat Compatible
• Improved SMC Technology
Zero bleed voltage during standby
• Works Well with Generators
Insensitive to frequency changes
• Flame Stabilize
Tech Support [phone] www.carlincombustion.com
Power input (from limit circuit) 120 VAC, 60 HZ, 10 VA
Motor load 10 FLA / 60 LRA
Ignitor load 120 VAC, 60 HZ, 500 VA
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
40200 and 42230 controls 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.
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
© Copyright 2014 - Carlin Combustion Technology, Inc. MN40200E 111214

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 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.
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 (No call for heat) If Self-test 1 is successful, amber LED turns off and control waits for heat call.
Call for heat Set thermostat and limit to call for heat. Thermostat circuit must be closed and power coming to black
wire from 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 fault, or
line voltage <90V. See service section.
Burner on After the self-test, amber LED turns off. The ignitor starts, followed 2 seconds later by the motor.
Pump Prime To enter pump prime: 1. Start a CFH cycle. During Pre-Ignition, press Reset. Motor turns 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 ignitor 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). Insufcient ame puts control into
lockout.
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 2 seconds, 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 latchup.
The problem that caused the repeated burner lockouts must be corrected before returning the burner to
normal operation.
To Reset 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. Re-
lease 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 40200 & 42230 controls will retain lockout or latchup if power is interrpted.
Flame If the CAD cell loses ame signal during operation (after the TFI), the red LED ashes. Recycle: Control
Failure 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 which may cause recycle.
Stand-by Control remains in stand-by mode until limit circuit sends power to the black wire and thermostat circuit
closes (call for heat).
Model 40200 & 42230 Diagnostic LEDs
– Amber OFF – Amber ON – Amber FLASHING
– Green OFF – Green ON – Green FLASHING
– Red OFF – Red ON – Red FLASHING
© Copyright 2014 - Carlin Combustion Technology, Inc. MN40200E 111214

© Copyright 2014 - Carlin Combustion Technology, Inc. MN40200E 111214
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 2 sec-
onds.
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 ame test plug. If the amber LED
remains flashing, the control is defective.
If the amber LED goes 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.
Other no start problems
If the CAD cell is OK, and the amber LED still blinks
1 second on, 4 seconds off, the other possible failures
include:
• Line voltage <90 VAC (amber LED ashes uniquely,
1 second on, 1/2 second off, 1 second on, 3 sec-
onds off, then repeats). Check line voltage.
• Internal fault. CAD cell and line voltage OK. The is-
sue may be an internal fault. Replace the control.
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 at end of 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.