Carlin 51300S Parts list manual

1
Installation Instructions
and Operating Manual
126 Bailey Road North Haven, CT 06473
Phone [phone] Fax [phone]
Carlin Combustion Technology
Tech support 800-989-2275 carlincombustion.com
©Copyright 2022 – Carlin Combustion Technology
Patent No. 11,428,407
CAP
System Kit
Combustion
Air Proving Kit with
Burner Cut-Off
Designed to meet NFPA31*
requirements for combustion air
CAP
Model Description Firing Rate (GPH)
51300S
Complete
CAP System Kit
(for Carlin burners without covers)
0.50 - 2.00
51300AS Low Rate CAP Kit
(for Carlin burners with covers) 0.50 - 1.00
51300BS Medium Rate CAP Kit
(for Carlin burners with covers) 1.05 - 1.45
51300CS High Rate CAP Kit
(for Carlin burners with covers) 1.50 - 2.00
Note: All CAP System models require Carlin 70200
Primary Control manufactured after Sept. 2018
*See Section 5.4.3.3 as covered by April 2019 TIA 16-2
Electrical shock hazard. To prevent electrical
shock, death, or equipment damage, disconnect power sup-
ply before installing or servicing CAP System. Only qualified
personnel may install or service the CAP System in accor-
dance with local codes and ordinances. Read instructions
completely before proceeding.

2
CAP SYSTEM KIT COMPONENTS
(see page 3 for part descriptions)
8
13
9
1
14
17
18
20
15
19
16
2
12
3
6
7
4
5
10
11
10a
10b
10c
1b
1a
19a
COMPONENTS CONTAINED IN POLYBAG

3
Reference
Number Description Part Number Quantity MODEL
51300S 51300AS 51300BS 51300CS
1Burner Cover 50404ABLK 1 •
Following items come assembled with Burner Cover (above)
1a Burner Cover Reset Button 51288 1 •
1b
5/16-18 x 5/8" Phillips Head Screw 50008 1 •
1/4" Retaining Nylon Washer 50800 1 •
2Burner Cover Backplate 50433B 1 •
3CAP System Air Flow Switch (0.18" WC) 50806A 1 • •
4CAP System Air Flow Switch (0.30" WC) 50806B 1 • •
5CAP System Air Flow Switch (0.85" WC) 50806C 1 • •
6Clamp 51642 1 ••••
73" 90° PVC Elbow 51314 1 ••••
83" Air Intake Screen 51322 1 ••••
9
5/16" Plated Star Washer 31179 2 •
5/16-18 x 5/8" Hex Head Bolt 50604 2 •
10 CAP System Air Inlet 51300 1 ••••
Following items come assembled with CAP System Air Inlet (above)
10a 24 inch Air Flow Switch Wiring Harness 51308A 1 ••••
10b 10-14 x 1/2" Phillips Head Screw 50605 2 ••••
10c 8-16 x 3/4" Phillips Head Screw 51327 1 ••••
11 Connecting Flange 51305 1 ••••
12 CAP System Kit Instructions and
Operating Manual MNCAP 1 ••••
13 9/32"ID x 7/8" OD Grommet 51669 1 •
14
5/16" Plated Star Washer 31179 2 ••••
5/16-18 x 5/8" Hex Head Bolt 50604 2 ••••
15 .88" Split Grommet 51425A 2 ••••
16 Hole Plugs 99715 4 ••••
17 1.62" Split 5Grommet 50844A 1 ••••
18 Burner Cover Oil Line Insert 50703 1 ••••
19 Burner Cover Backplate Filler 50433B1 1 ••••
Following item comes assembled with Burner Cover Backplate Filler (above)
19a 1/8" Black Nylon Rivets 50851 2 ••••
20 Label – Burner Setup Chart 51316 1 ••••
Components inside red box are contained in the polybag.
Components 14-20 indicate parts included with 50433KITS (Cover Seal Kit).
CAP SYSTEM KIT COMPONENTS

4
Getting Started
1Ensure you have the right CAP System Kit for your applica-
tion by confirming the firing rate (in GPH) with the table on
page 1.
IMPORTANT: If you change the firing rate, pressure
switches are available separately to convert the CAP
System after installation. (See instructions for Installing
Pressure Switch on page 8).
2Ensure that the burner is equipped with a
Carlin Pro-X 70200 primary control with low voltage
blocked vent (BV) terminals as shown.
NOTE: 70200 controls
manufactured prior
to Sept. 2018
are not
compatible
with the
CAP System.
3INSTALLING BACKPLATE (for uncovered burners)
If installing on a covered burner, skip to Step 4.
• Mount backplate
•
2
in the desired orientation and secure
to the burner using the mounting bolts and star wash-
ers
•
9
provided (as shown). The backplate is reversible to
accommodate left-hand or right-hand mounting of the air
inlet. (See step 8 for available inlet mounting configura-
tions.)
• Reroute any BX cable, wiring harness, etc. through one
of the circular knockouts in the backplate•
2
.
4ROUTE THE OIL LINE
• Route the oil line through one of the circular knockouts in
the burner cover backplate•
2
.
5REMOVE AIR INLET KNOCKOUT
• Remove the 2" x 4" air inlet knockout that corresponds
to the desired air inlet position (vertical or horizontal) as
shown in step 8.
Pressure Switch Conversion
Firing Rate GPH Pressure Switch
0.50-1.00 50806A
1.05-1.45 50806B
1.50-1.90 50806C
CAP System Operation
The CAP System is designed to shut down the burner in the event the outside combustion air supply becomes blocked. At each
burner startup, the system will check the air intake during pre-purge (Valve Delay On*). If the air is blocked, the control will abort
ignition and shutdown the burner. If the air intake is not blocked during this startup test, but becomes blocked during normal burner
operation, the burner will shut down if the air remains blocked for 20 seconds. Following any shutdown, the burner will be permitted
to recycle 3 times following a 1 minute delay. The system will lock out the burner if the blockage continues throughout 3 recycles
during any single call for heat.
*If the Burner has no valve, the air intake cannot be checked during pre-purge. In this case, the burner will shut down following the
20 second blockage described above. For all burners with valves, Valve Delay settings of less than 15 Seconds will be automatically
changed to 15 Seconds to allow for the prepurge test.

5
6SEAL THE BACKPLATE
• Use the plastic rivets 19a at the bottom corners of the
filler plate to properly align the filler plate with the burner
backplate
2.
• Secure the filler plate 19 below the burner air tube using
the two 5/16" bolts and star washers 14 provided.
• Install the 1.62"split grommet 17 around any BX cable,
wiring harness, etc. leaving the burner backplate•
2
.
• Install one of the .88" split grommets 15 around the oil
line.
• Fill the 1/4" and 7/8" holes in the backplate with plugs
provided 16 .

6
7SEAL THE COVER
• Install the rubber filler 18 into the 4" opening in the bot-
tom of the cover
1as shown.
8INSTALL THE AIR INLET
• Using the screws provided 10b , mount the CAP System
air inlet 10 onto the 2" x 4" air inlet knockout removed in
Step 5. Mounting examples below.
9Slide the connecting flange 11 onto the air inlet 10
until fit is tight. Reverse flange when using galvanized
piping. Secure with clamp
6.
VERTICAL CONFIGURATIONS
HORIZONTAL CONFIGURATION (left side only)
Galvanized pipe requires
hi-temp foil tape or mastic
tape (see Step 12).
GALVANIZED
PVC

7
12 PIPING (continued)
Combustion air outdoor termination:
Use PVC elbow
7facing downward
and air intake screen provided
8. Maintain 12"
clearance above highest anticipated snow level.
Galvanized
IMPORTANT: For proper operation of the CAP System
galvanized pipe must be sealed air tight (including all
joints and seams) with hi-temp foil tape or mastic stress
tape.
When using galvanized, the CAP system connect-
ing flange 11 needs to be reversed (groove stripes/
wider opening on top). Galvanized should be fitted
inside wider opening until it hits stop/lip (may require
lubricant). Thinner end should be inserted into air inlet
opening 10 . There will be a smaller gap between edge
of connector and galvanized pipe. Tight seal is made
inside connector.
Termination hood (not provided) is needed for use with
galvanized pipe. Maintain 12" clearance above highest
anticipated snow level.
WARNING: Be sure to adhere to manufacturer’s
recommendations and all local codes with regards
to proximity of combustion air piping to appliance
vent/exhaust stack.
Avoid locations where snow may drift and block
combustion air. Ice or snow may cause boiler to
shut down if combustion air becomes obstructed.
Combustion air termination must be min. 12" from
or below doors, windows or gravity inlet. USE
SWEEP ELBOWS FOR ALL COMBUSTION AIR
PIPING. DO NOT USE short radius elbows for com-
bustion air piping – boiler performance could be
affected.
13 Mount the cover
1by aligning the two holes on the
top flange of the cover with the mounting tabs on the
backplate. Tighten the mounting screw 1b , located in
the center of the cover, securely to prevent basement air
from entering the cover.
14 CHECK BURNER SETUP
CAP System utilizes outside air for combustion.
Incoming air temperature will fluctuate by season
which can significantly impact combustion. Use the
table below to set the combustion settings based on
outside temperatures at the time of setup.
• Apply the burner setup label 20
to the top of the burner cover
1.
10 Route the Air Flow Switch Wire Harness 10a from the
combustion air inlet 10 to the low voltage blocked vent
(BV) contacts on the Pro-X 70200 primary control.
11 SETTING BLOCKED VENT + AIR INTAKE FEATURE
The Pro-X 70200 Primary Control (manufactured
Sept. 2018 or later) is equipped with a Blocked Vent
Air Intake feature that works in conjuction with the CAP
System. To activate this setting:
• Press and simultaneously for 2 seconds. This
brings you to the settings menu.
• Scroll through the settings using until you reach
Vent Input.
• Scroll down to Intake using the .
• Press / ENTER button. The display will briefly indi-
cate Vent Input has been “Entered” and has replaced
any previous setting.
NOTE: If the Pro-X 70200 is also connected to a
blocked exhaust switch, call Carlin Technical Support
for assistance.
12 PIPING
3" PVC (recommended) or 4" galvanized vent pipe must
be installed to provide outside air to the CAP System.
(Maximum run of 80 total feet with each elbow equaling
10 feet. Example: 40 feet straight pipe and 4 elbows =
80 feet total run.)
Secure piping to connecting flange 11 using
clamp
6. (See step 9.)
NOTE: Galvanized pipe should not be used with firing
rate less than 0.65 GPH.
Important PVC Specs
For proper operation of the CAP System, air inlet piping
should only use schedule 40 or 80 PVC.
Incoming combustion
air temperature
during setup CO2min CO2max O2max O2min
–20°F to 0°F 10.2% 11.0% 7.0% 5.8%
5°F to 30°F 11.0% 11.5% 5.8% 5.5%
35°F to 60°F 11.5% 12.2% 5.5% 4.2%
65°F or higher 12.0% 12.5% 4.6% 3.9%

8
Testing CAP System Operation
1With the CAP System installed and the cover securely
mounted, initiate a call for heat and allow the burner to
fire.
2With the burner firing, move the
Test Lever to the TEST position .
The burner will shut down following
a 20 second delay.
NOTE: The 70200 will allow the
burner to recycle three times to
prevent nuisance shutdowns caused by temporary block-
ages or high wind conditions. If the blockage persists the
burner will shut down and lock out after the third recycle
attempt.
NOTE: If the burner does not have a prepurge cycle, the
burner will fire upon recycle, but will shut down following
20 seconds of operation. (See the 70200 instructions for
more details).
Annual Test
Using the instruction above, the CAP System operation should
be tested annually.
Troubleshooting
Burner Will Not Shut Down During Test
If the burner did not shut down with the test damper closed for
a sustained 20 seconds, check the following:
• Make sure that the burner cover
1is properly sealed. If
a significant amount of air is leaking into the cover
1or
backplate
2, the burner will not shut down during the test.
Check for proper installation of all components in the Burner
Seal Kit (see Step 6).
• Make sure that the burner cover screw 1b is tight. This also
prevents basement air from entering the cover.
• Check that the correct air pressure switch
3 4 5is
installed based on the firing rate of the burner (See table on
page 2 and instructions for changing the switch on this page)
• Make sure Vent Input on 70200 control is set to “Intake” (see
step 11).
Changing the Air Pressure Switch
The air pressure switch
3 4 5must correspond with
the firing rate of the burner – see table on page 2. Carlin’s
Complete CAP System Kit (51300S) contains all three pressure
switches. Switches are also available separately. If you need
to change the switch to accommodate your application, follow
the instructions below:
1Remove the switch cover which is secured by two mount-
ing screws 10c (shown above).
2Unplug the two female fast-ons from the switch.
3Pull the switch outward to remove it from the assembly.
Replace it with the switch that corresponds to the burner’s
firing rate. Reattach the wires and secure the switch cover
TEST
RUN
MNCAP 091922
© Copyright 2022 — Carlin Combustion Technology
TECH SUPPORT HOTLINE [phone]
Carlin Combustion Technology
126 Bailey Road North Haven, CT 06473 Phone [phone] Fax [phone]
e-mail us at: [email protected] visit our website: www.carlincombustion.com