Carlin 60200FR User manual

Model 60200FR
Gas Burner
Primary Control
Installation and
Operating Instructions
For Use By Qualified Service Technicians Only
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.
126 Bailey Rd North Haven, CT 06473
Ph 203-680-9401 Fx 203-680-9403
Tech Support 800-989-2275 carlincombustion.com
©Copyright 2019 — Carlin Combustion Technology, Inc.
Carlin Combustion Technology, Inc.
• On-Board LCD Screen
• Fully Programmable Settings
• 32 Cycle Fault History
• Alarm Contacts
• Serviceman Reset Protection
• Blocked Vent Protection
• Provides Flame Signal in Microamps
• Low Voltage Terminals
Power input
(red/white wire) ................................ 120 VAC, 60 HZ, 9 VA
Limit circuit input
(black wire) .............................................. 120 VAC, 60 HZ
Motor load
(orange wire).........10 FLA / 60 LRA (reduce by valve load)
Ignitor load
(blue wire) .................................... 120 VAC, 60 HZ, 500 VA
Valve load
(violet wire).......................................... 120 VAC, 60 HZ, 2A
Auxiliary..................................................... 120 VAC, 1 amp
Alarm contacts (dry contacts)....................24V, AC/DC, 2A
Operating temperature limits ..................+32°F to +140°F
Thermostat..................................................... 24 VAC, 0.1A
Blocked Vent ................................................. 12 VDC, 2mA
CO .................................................................. 12 VDC, 2mA
Agencies.............................. UL recognized (US & Canada)

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Carlin Combustion Technology, Inc. MN60200FR1 070319
WARNINGS
1. Warning – Do not attempt to confirm combustion simply by inspecting the flame visually. You must use combustion test instru-
ments. Failure to properly verify/adjust combustion could allow unsafe operation of the burner, resulting in severe personal injury,
death or substantial property damage. Refer to the burner manual for proper setup instructions.
2. Warning – Never test an ignitor by placing a screwdriver (or other metallic object) across the high voltage clips. Check ignitors only
by observing spark at appliance ignition electrodes, with fuel supply OFF. Using any other method could cause ignitor damage and
severe personal injury.
3. Danger – Fire, explosion, or carbon monoxide hazard. Water damage can lead to unreliable operation or cause the control to
malfunction which could lead to severe personal injury or death. Do not install the control module where it can get wet. Always
replace the control if it gets wet or if it has any signs of water residue.
4. Warning – Electrical shock hazard. To prevent electrical shock, death, or equipment damage, disconnect power supply before
installing or servicing control. Only qualified personnel may install or service this control in accordance with local codes and ordi-
nances. Read instructions completely before proceeding.
5. Warning – Electrical shock hazard. The ignition circuit of the control can produce over 10,000 volts which can cause severe injury
or death.
6. Warning – Frozen pipes/water damage. This is not a freeze protection device. Central heating systems are prone to shut down as
a result of power or fuel outages, safety related fault conditions or equipment failure. Installation of freeze protection monitoring or
other precautions are recommended for unattended dwellings in climates subject to sustain below-freezing temperatures.
7. Warning – All work must be performed by a qualified and licensed professional in accordance with all applicable codes and ordi-
nances.
8. Notice – Read these instructions completely before proceeding with the installation.
9. Notice – Retain these instructions for future reference.
10. Notice – All wiring must comply with the National Electric Code or any other state or local codes or regulations.
11. Danger – Carbon Monoxide Hazard. Improper application or use can result in dangerous flue products, such as carbon monox-
ide, which can escape into the living space causing severe injury or death. All venting must be checked for proper operation before
allowing the burner to run.
Hazard Definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product.
Indicates presence of hazards that will cause
severe personal injury, death or substantial
property damage.
Indicates presence of hazards that will cause
severe personal injury, death or substantial
property damage.
Indicates presence of hazards that will cause
minor personal injury or property damage.
Indicates special instructions on installation,
operation or maintenance that are important
but not related to personal injury or property
damage.
Installing
The 60200FR 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.

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Carlin Combustion Technology, Inc. MN60200FR1 070319
Wiring
Commercial
Gas Train
120V
EZGas Pro
24V
EZGas
120V
Wiring must comply with local and national electrical codes, and with the wiring diagram.

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View or Change Control Settings
NOTE: The settings mode cannot be accessed during a run
cycle, the burner must be in standby mode (or lockout) to
enter setup.
To enter the Settings Mode:Press the Gand Ebuttons
simultaneously for 2 seconds. The display will show –
To View Current Settings: Press the Ebutton to scroll
through all Setting Modes (see table at the top of page 5 for
Setting Mode options). The second line of the screen will
display the current setting for each Setting Mode –
Pressing the Ebutton again will leave the setting as is and
move to the next option –
Carlin Combustion Technology, Inc. MN60200FR1 070319
Trial for Ign
4 Seconds
Blocked Vent/
Spill Switch*
Jumper
or
Thermostat
N.O.
Dry
Contacts
CO Sensor
Do not start the burner if the combustion chamber contains gas.
To Change a Setting: Scroll to the desired Setting Mode
option using the Ebutton (as described in table on page
5), then press the or Hbutton to scroll through the avail-
able Settings. When the desired setting is displayed on the
screen press the E/ ENTER button. The display will briefly
indicate that the new setting has been “Entered” and the new
setting will replace the previous setting on the second line of
the screen. Continue pressing the Ebutton to view the cur-
rent setting for all options or Hbutton to make any desired
changes.
To Exit the Setup Menu: Press the F/ ESCAPE button for 3
seconds. NOTE: The control will automatically exit the Setup
menu after 30 seconds of inactivity or by a call for heat.
Trial for Ign
6 Seconds
Settings Press
To Exit Hold
Pre-Purge
30 Seconds
*Blocked Vent/Spill Switch Operation: During each run cycle, the BV contacts will be checked beginning
30 seconds after ignition. If the BV contacts open (indicating the spill switch has detected a blocked vent),
the control will shut down the burner. The control will either recycle the burner or will go immediately into
Lockout dependent on the Allowed Recycle setting. The spill switch must be closed within 2 seconds on a
call for heat. If not, it will retry 2 times before control goes into lockout.
NOTE: If using a manual reset blocked vent spill switch, the control will lock out with the display reading BV
Switch Open.

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Carlin Combustion Technology, Inc. MN60200FR1 070319
Shaded box = default setting.
**MA Code (“N” models) are non-recycling and will lock out on flame failure.
**Changing this setting to ‘Yes’, with limits powered will exit Settings mode and result in immediate ‘Call For Heat’.
*†
If flame is sensed during Pre-Purge, control will lockout immediately (except when Pre-Purge is set to 0 seconds).
AVAILABLE SETTINGS
Setup Menu Definitions
•Pre-Purge: Time period motor and ignitor are on prior to Trial
for Ignition. Note: If flame is sensed during Pre-Purge, control
will lockout immediately (except when Pre-Purge is set to 0 or 3
seconds).
• Trial for Ignition: Flame-establishing period during ignition.
•Post-Purge: Time period the motor is on after the Call for Heat is
satisfied to allow for evacuation of combustion gases. A call for
heat during Post-Purge will result in a recycle.
• Allowed Recycles: Number of Recycles allowed during a single
Call for Heat prior to lockout.
• TT Jumpered Internal: Allows TT to be “jumpered” by software
program.
• Clear Fault History: Allows all prior burner fault conditions stored
in control to be cleared.
• Restore Factory Defaults: Allows all factory defaults to be
restored in control (refer to settings shaded in gray in the table
above). Will reset and reboot control .
PRESS THE BUTTON TO VIEW DIFFERENT SETTING MODES
Pre -Purge Trial for
Ignition Post-Purge Allowed Recycles
TT
Jumpered
Internal**
Clear Fault
History
Restore
Factory
Defaults
PRESS THE
BUTTONS
TO
CHANGE
SETTINGS
0 Sec†4 Sec 0 Sec None* Yes Yes Yes
10 Sec 6 Sec 10 Sec 1 No No No
30 Sec 15 Sec 3
90 Sec 30 Sec
60 Sec
2 min
SETTING
MODE
OPTIONS

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Carlin Combustion Technology, Inc. MN60200FR1 070319
Status Icons
Status Icons will appear at the top of the 60200FR display to indicate the control’s current operating condition.
POWER Indicates that the control is powered (flashes if voltage is too low or too high)
HV LIM Indicates that the burner limit circuit is powered.
TT Displayed when the TT terminals are physically jumpered, jumpered in the set-up menu, or when thermostat
is calling for heat.
BV Monitors the BV contacts where a Blocked Vent Switch (Spill Switch) is connected. (Flashes if the Spill Switch
contacts are open – indicating that the vent is blocked). See Blocked Vent Operation below for more information.
FLAME Indicates the control is sensing flame
FAULT Flashes in unison with other status icons indicating a problem exists in that area
MOTOR Indicates that the motor is energized (flashes if motor not detected)
IGNITOR Indicates that the ignitor is energized (flashes if ignitor not detected)
VALVE Indicates that the gas valve is energized (on entry to pump prime will flash if not detected)
Operating Sequence
With power to the control and the gas valve open, set
thermostat (and limit) to call for heat. NOTE: The thermostat
circuit must be closed and power must be coming to black
wire from limit circuit.
During Pre-Purge, the motor starts.
Following Pre-Purge, the control advances to a
3 second Pre-Ignition
During Pre-Ignition, the ignitor turns on and enters Trial for
Ignition.
During Trial for Ignition, the gas valve opens. When flame is
detected, the screen will briefly display “Flame Detected” and
then procedes to Burner Running
When the Call for Heat ends (or a limit control interrupts the
burner circuit), the gas valve will turn off. The motor remains
on for the Post-Purge period. When the Post-Purge timer
expires, the control returns to Standby mode awaiting the
next call for heat.
Pre-Purge
X X Sec
Pre-Ignition
X X Sec
Trial for Ign
X X Sec
Post-Purge
X X Sec
Standby 5 9 Sec
No Call for Heat
Burner Running
5 9 Sec

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Fault History
The 60200FR stores information from the last 32 cycles in
which a fault condition occurred. To Enter the Fault History
, simultaneously press and hold the Hand E buttons for 2
seconds. The display below will appear –
Press the E button to scroll through the history of fault
conditions. Fault 1 is the most recent cycle in which a fault
occurred. To view faults experienced in earlier run cycles,
continue to press the E button. The control will display Fault
2 followed by Fault 3, etc.
To view the details of any fault (ex. Fault 1 in the screen
above), press the Hbutton to see the Fault Message.
Press the Hbutton again to determine how many cycles ago
the fault occurred.
Press the Hbutton again to determine if the fault resulted in a
lockout or a recycle.
Press the Hbutton again to examine the Microamps at the
time of the fault.
View 13 Faults
To Exit Hold
Total History
To Exit Hold
Carlin Combustion Technology, Inc. MN60200FR1 070319
Fault 1 Message
No Flame Check Vlv
Fault 1
X X X X cycles ago
Fault 1 Result
Lockout
Fault 1
0.1 uAmps
Continue pressing the Hbutton to examine the following
information recorded during the fault cycle.
• Line Voltage • Recycle (Yes or No)
• Motor Amps (OK or Low) • Burn Time
• Ignitor Amps (OK or Low) • Flame Delay
• Valve Amps (OK or Low)
On any fault detail screen listed above, the Ebutton can be
pressed to view the same data in the previous fault cycle. For
example, if in Fault 1 (the most recent fault), the Ignitor Amps
were low, by pressing the Ebutton, the Ignitor Amps in Fault
2 (the previous fault cycle) will be displayed.
To Exit Fault History: Press and hold the F/ ESCAPE but-
ton for 3 seconds at any time.
Total/Run History
In addition to the Fault History (left),the 60200FR also logs the
total run history of the control. To enter this menu, simultane-
ously press the Eand F buttons for 3 seconds. The display
below will appear.
To Exit Total History: Press and hold the / ESCAPE but-
ton for 3 seconds at any time.
Press Hbutton to scroll through the history which includes:
• Total On Time • Max Line Volts
• Total Burn Time • Min Line Volts
• Total Burner Run Cycles • Total Recycles
• Faults Cleared (cycles ago)
Fault 1 Details
View Fault 2
PRESS THE BUTTON TO VIEW NEXT FAULT
FAULT 1 FAULT 2 FAULT 3 FAULT 4 FAULT 5
PRESS THE
BUTTONS
TO
VIEW
FAULT
DETAILS
Message No Flame ck vlv No Flame ck MTR No Flame ck IGN No Flame ck vlv No Flame ck vlv
Cycles Ago 23456
Result Lockout Lockout Lockout Lockout Lockout
µAmps 0.1 0.1 0.1 0.1 0.1
Line Volts 114 114 114 114 114
Motor Amps OK Low OK OK OK
Ignitor Amps OK OK Low OK OK
Valve Amps Low OK OK Low Low
Recycle Y/N No No No No No
Burn Time 5 sec 5 sec 5 sec 5 sec 5 sec
Flame Delay 4 sec 4 sec 4 sec 4 sec 4 sec
FAULT
HISTORY
NOTE: Fault information in chart
is representation only.
Fault 1
Ignitor Amps Low
Fault 2
Ignitor Amps OK

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MN60200FR1 070319© Copyright 2019 — Carlin Combustion Technology, Inc.
TECH SUPPORT HOTLINE [phone]
Carlin Combustion Technology, Inc.
126 Bailey Road North Haven, CT 06473 Phone [phone] Fax [phone]
e-mail us at: [email protected] www.carlincombustion.com
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 failure.
Service and Troubleshooting
Last Fault Display: When the control is reset from a lockout
condition, if the burner resumes normal operation, the screen
will toggle the last fault and its cause for five days (longer du-
ration if control is not wired for constant power). This feature
is designed to allow the service technician to easily see what
caused the condition in the event the homeowner reset the
control prior to their arrival. The screen will alternate between
displaying what the last fault was and displaying how to clear
the message hold ESC for 3 seconds.
Display Voltage and Current: Press + for 3 seconds to
display real time voltage and current.
Lockout: If lockout occurs, the screen turns on, the fault icon
flashes and a fault message is displayed on the screen. To
Reset Push in and hold the red Reset button for 1 second,
then release. NOTE: Recycling power to the control will not
reset it from it from a lockout condition.
Two fault conditions result in an immediate lockout. These
include; Flame detected during pre-purge and flame failure
during Trial for Ignition. All other faults will result in a Recycle
(unless the Allowed Recycles is set to ‘None’ in the Set-up
Menu). A Recycle results in the burner shutting down for 60
seconds then resuming operation in Standby (if there is no
Call for Heat) or initiating the Operating Sequence above (if
there is a Call for Heat).
Latch-up: If the control locks out 3 times during a single Call
for Heat, Latch-Up will be displayed on screen.
To Reset the control after latch-up, press and hold the red
Reset button for 30 seconds. WARNING: Only a qualified
service technician should attempt to reset the control
after latch-up. The problem that caused the repeat lock-
outs must be corrected before returning the burner to
normal operation. NOTE: Recycling power to the control will
not reset it from it from a latch-up condition.
Burner will not fire
• Check line voltage to the control (at least 102 vac).
• Check all electrical connections.
Other no start problems:
• Valve lead voltage on too early. Correct bad connection.
• Motor relay welded. If valve has no voltage, and line voltage
is okay (102 - 132 VAC), the issue is a welded motor relay.
Replace the control.
• Motor current less than 0.2 Amps.
Blocked vent – not recycling:
• Recycle only works on non-manual reset vent switch
Repeated flame failures
Check for:
• Excessive airflow or draft causing flame to leave burner
head- check for proper air band setting and draft.
• Excessive back pressure causing flame to be erratic –
check appliance and flue for sooting/plugging.
• “Flame rod shorted” message in lockout – defective flame
rod assembly.
Control locks out at end of TFI
• No fuel to burner – check fuel supply lines.
• Shorted electrodes – inspect for cracked porcelain and
replace as needed.
• Airflow too high – check air band setting.
• Ignitor module defective – replace if no spark.
• Check wiring connections.
• Flame rod shorted to ground or defective.
Amps = 7 uA
Line = 115 VAC
Toggle
Last Fault
No Flame Chk Ign
To Clear Message
Hold 3 Sec