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Instruction manual

™

126 Bailey Road North Haven, CT 06473Ph 203-680-9401 Fx 203-680-9403

Carlin Combustion Technology, Inc.

Tech support 800-989-2275 carlincombustion.com

© Copyright 2011 — Carlin Combustion Technology, Inc.

Exceptwherespecificallystatedotherwise,thismanualmustbeusedonlybyaqualifiedservicetechnician.

In the state ofMassachusetts, this productmust beinstalledbyalicensedPlumberorGasFitter.

Failuretocomplywiththeaboveorotherrequirementsin thismanualcould result inseverepersonal injury,deathorsubstantialpropertydamage.

USER—Referonly toUsercareandmaintenanceonbackpage for information regardingoperationofthisburner.TheburnerInstructionManualisintendedonlyforyourservicetechnician.Theburnerandheatexchangermustbeinspectedandstartedatleastan-nuallybyyourservicetechnician.

Check burner cartons carefully.TheModel 702G/Ocombinationgas/oilburnerwasassembledandtestedatthefactorybeforeshipment.Iftheburnerwasorderedwithacompletedassembledgas train, the trainwaspressure tested and electrically checked for properoperation.Wherepossible,thegastrainorcomponentswereshippedinthesamecartonastheburner.Checkyourpacking slip for thenumberof cartons shippedfromthefactory.

Model 702G/O Advanced gas/oil burners — Instruction manual

Carlin part number MN702GO Rev. 06/23/14– 2 –

Where appliance instructions differ from this manual, follow the appliance instructions.

ContentsPLEASEreadthisfirst.................................................................2

Generalinformation.....................................................................3

1. TheCarlinModel702G/Ocombinationgas/oilburner...........4

2. Preparesite•assembleburner•mountburner.............6

3. Installgaspiping...................................................................12

4. Installoilpiping.....................................................................14

5. Wiretheburner.....................................................................16

6. Checkoutprocedure—beforestartingtheburner...............18

7. Setburnerinitialheadanddamperpositions.......................19

8. Adjusttheburnerusingtestinstruments..............................20

9. Maintenanceandserviceprocedures..................................24

10.Repairparts........................................................................26

11.Dimensions.........................................................................30

Usercareandmaintenance........................................ Rearcover

PLEASE read this first . . .

Special attention flags . . .Please pay particular attention to the followingwhen you see themthroughoutthismanual.

NotifiesyouofhazardsthatWILLcauseseverepersonalinjury,deathorsubstantialpropertydamage.

NotifiesyouofhazardsthatCANcauseseverepersonalinjury,deathorsubstantialpropertydamage.

Notifies you of hazards thatWILL orCAN causeminorpersonalinjuryorpropertydamage.

Notifiesyouofspecialinstructionsoninstallation,operationormaintenance that are important, but arenot normallyrelatedtoinjuryorpropertydamagehazards.

Before installing or servicing:

Shouldoverheatingoccur: (1)Shutofftheoilandgassuppliestotheburner. (2)DONOTshutoffthecontrolswitchtotheboiler

circulatorortheburner.

Followtheguidelinesbelowtoavoidpotentialseverepersonalinjury,deathorsubstantialpropertydam-age.

Installer/service technician . . .• Readallinstructionsbeforeproceeding.Performallprocedures,

andintheordergiventoavoidpotentialofseverepersonalinjury,deathorsubstantialpropertydamage.

• Beforeleavingthesiteafterstartuporservice,reviewtheUsercareandmaintenancepagewiththeuser.Maketheuserawareofallpotentialhazardsandperformthetrainingoutlinedbelow.

Installer/service technician — Train the user . . .• Toproperlyoperatetheburner/applianceperthismanualand

theapplianceinstructions.SeeUsercareandmaintenance.• Tokeepthismanualatorneartheburner/applianceforready

accessbytheuserandservicetechnician.• Tocontacttheservicetechnicianoroildealerifheencounters

problemswiththeburner/appliance.• Tokeeptheappliancespacefreeofflammableliquidsorvapors

andothercombustiblematerials.• Toneveruselaundryproducts,paints,varnishesorotherchemi-

calsintheroomoccupiedbytheburner/appliance.• Tocontacttheservicetechnicianatleastannuallyforstartupand

burner/applianceservice.

When servicing the burner . . .• DISCONNECTELECTRICALSUPPLYandallotherelectrical

connections to burner before attempting to service to avoidelectricalshockorpossibleinjuryfrommovingparts.

• CLOSEallmanualgasandoilvalvesbeforedisconnectinganyportionoffuellinesandbeforecleaningorremovinganypartsfromtheburnerorrelatedequipment.

• Burnerandappliancecomponentscanbeextremelyhot.Allowallpartstocoolbeforeattemptingtohandleorservicetoavoidpotentialofsevereburns.


Carlin part number MN702GO Rev. 06/23/14 – 3 –


Burner applicationsFollowallinstructionsinthismanual,theprimarycontroldatasheetandtheappliancemanual.Verifytheburneriscorrectfortheappliancebeingusedandforallap-plicablecodes/standards.Adjustthenozzleselection/firingrateifnecessaryduetopositiveoverfirepressureand/oraltitudesmorethan2,000feetabovesealevel.SeetheNOTICEundertheRatingsinformationatright.Whereapplianceappli-cationinformationisavailable,therecommendedfiringrateandburnerinformationwill include appropriate adjustments for positive overfirepressureandrecommendationsforhighaltitudes.Followtheappliancemanualguidelineswhenavailable.

Damage or shortage claimsThe consigneeof the shipmentmust file damageor shortage claimsimmediatelyagainst the transportationcompany.See theNOTICEonpage1forburnercartoninformation.

When calling or writing about the burner:PleaseprovideuswiththeULserialnumberandburnermodelnumbertoassistusinlocatinginformation.Thisinformationcanbehelpfulwhentroubleshootingorobtainingreplacementparts.

Codes and standardsCertification702G/OburnersareU.L.listedfortheU.S.,certifiedtocomplywith:• ANSI/UL296,forusewith#1or#2heatingoil(perstandardASTMD396).• UL795,forusewithnaturalgasorpropane.• Burnerlabelslistcompliance,whenrequired,withspeciallocal,state

orprovincialapprovals.

Install thisburner inaccordancewithall localcodesandauthoritieshavingjurisdiction.Regulationsoftheseauthori-tiestakeprecedenceoverthegeneralinstructionsprovidedinthismanual.

United States installationsBurner/applianceinstallationsintheUnitedStatesmustcomplywiththelatesteditionsof:• InstallationofDomesticGasConversionBurners,ANSIZ21.8.• NationalFuelGasCode,ANSIZ223.1/NFPA54.• StandardfortheInstallationofOil-BurningEquipment,NFPA31• NationalElectricalCode,ANSI/NFPA70.• Alladditionalapplicablenational,stateandlocalcodes.

The702G/Oburner,configured forMassachusettsCodecompliance,differsfromthestandard702G/Oin:

1 Lowandhighgaspressureswitchesareaddedtothegastrain.

2 JumperJR2ontheprimarycontroliscut,causingthecontroltobenon-recycling.

Ratings (With0.00”w.c.overfirepressure,altitude2,000feetmax.;seeNOTICEbelow)

Oil Input ................................................................Highfire:6.0to11.2GPH ................................................................. Lowfire:3.5to6.5GPH

Gas Input ............................................................ Highfire:840to1,600MBH ............................................................... Lowfire:490to940MBH

Fuels ......................................................................No.1orNo.2Fueloil ....................................................................Naturalgasorpropane

Fuel unit & oil valves: ................Fuelunit,2-stage, 300 psig(withinternalblockingvalve) ..................................................................... (2)Oilsolenoidvalves

Gas train: (availableinstraightorangledconfiguration) ............................(2)Maingasvalves&RV-61orRV-81regulator ............................................ Butterflygasvalveforinputregulation ................ 1"gastrainstandard;1¼",1½"or2"gastrainavailable

Electrical Power............................................................. 120V/60Hz/1-Phase Limitcircuitinput(RM7895CorRM7897C).............. 120vac/60hz Controlcircuitload(120vac)............................................. 1.2 amps Motor................................... 1/2 hp, 3450 rpm, 48-frame, “N” flaNge .............................. 115 / 208-230 vac/60 hz/1-ph, 8.4 / 3.8-4.2 amps

Oilvalve/gasvalvepower.......................................... 120 vac/60 hz Dampermotor(withendswitch).........................hoNeywell m436a

Ignition & primary control .............................CarlinModel41000solidstateelectronicignitor Ignitionvoltage............................................................. 14,000volts Primarycontrol...............................................HoneywellRM7897C

Agencies ................................................................................. ULListed(US)

Reducenozzle/firing ratewhen required—Maximumburnercapacityisreducedwhenoverfirepressureispositiveandforaltitudesabove2,000 feet.Seebelow,andadjust firing rate/nozzleselectionifnecessary.

702G/O — Maximum firing rate forpositive overfire pressure and high altitude

Overfire pressure (Inches w.c.) Oil – GPH Gas – MBH

0.00 11.2 1,6000.10 10.9 1,5300.20 10.7 1,5000.30 10.6 1,4800.40 10.3 1,4400.50 10.2 1,4300.60 9.9 1,390

Altitudes: For altitudes more than 2,000 feet above sea level, reduce the above capacities an additional 4% per 1,000 feet higher than 2,000 feet above sea level.

General information




702G/O overview

TheModel702G/Ocombinationgas/oilburner isa low-high-low(stepmodulating)burnerthatutilizesadampermotortocontrolair(andgasfuelrate).FuelisselectedusingtheGas/oilchangeoverswitch.Theburneroperatesoneither#2fueloilorgas(naturalorpropane).

Seethenextpageforgastraincomponentlocations.

Gas mode operation

Ignitionformainflameisaccomplishedbyaprovedgaspilotofapproxi-mately280,000Btuh.Pilotgasisintroducedatthemainburnerflameretention ring, and is ignited byaCarlin 14,000-volt electronic ignitorwiredtothetwoelectrodes.Afterthepilotflameisproven,thetwomaingassafetyvalvesopen.Thepilotgasvalveclosesafteratimedelaytoallowmainflametoestablish.FlameismonitoredbothforpilotflameandmainflamewithaUVscannermountedtotheundersideoftheburnercombustionheadassembly.Theburnermainflamebeginsat lowfire.Ifadditionalinputisrequired,thedampermotoropensthegasbutterflyvalveandairdampertotheirhighfirepositions.

Gasisintroducedintotheburnerthroughamanifoldaroundtheairtube.Thegasthencirculatesthroughasetoffourorificespudsintotheairstream,aheadoftheretentionring.Thespinoftheairflowattheretentionringthoroughlymixesthegas/airbeforeitreachesthecombustionzone.

Oil mode operation

Oil ignitionisaccomplishedbytheCarlin14,000-voltelectronic ignitorwiredtothetwoelectrodes.Theoilflamebeginsatlowfire,with100psig oilpressureatthenozzle.Ifadditionalinputisneeded,thedampermo-toropenstheairtothehighfireposition.Thedampermotorendswitchenergizesthe2ndstageoilvalve(fuelunitblockingvalve)asthedamperapproachesitshighfireposition.Thisprovides300psigpressuretotheoilnozzleforhighfire.FlameismonitoredbytheUVscannermountedtotheundersideofthecombustionheadassembly.

Firing rate adjustment

• Firingrateisdeterminedbytheoilnozzle.Airflowismatchedtotheoilflowforoilfiring.Thengasflowisadjustedtomatchtheairflowatlowandhighfirerates.

• Seethe“Startingandoperating”sectionofthismanualforthecompletedescriptionoftheadjustmentprocess.Thefollowingisabriefsummaryonly.

• High-fireairissetbyadjustingthecombustionheadposition(tocontrolairflowthroughandaroundtheretentionring).

• Low-fireair is thenadjustedbyfine-tuning thepositionof the lowfireadjustingscrew.

• Pilotgasflowissetforasmoothlight-off.Thengasinputsareadjustedforgoodcombustionatlowandhigh-fireairsettings.

1. The Carlin Model 702G/O combination gas/oil burner

702G/O oil nozzles

Use the selections belowwhen the heating equipmentmanufacturer’sspecificnozzleselectiondataisnotavailable,either in theequipmentmanualor theCarlinOEMSpecGuide.Followallinstructionsprovidedwiththeappliance.

Nozzle specifications

• Preferred— Hago45°SS• Alternate— Hago45°PorMonarch45°PLP

Nozzle ratings

Fullinput(highfire)occursat300psignozzlepressure.Sincenozzlesareratedat100psig,theactualflowat300psigisapproximately73%higher than the ratednozzlecapacity.See the tablebelow fornozzleratingselections.

Table 1 702G/O oil nozzles

Oil Nozzle Sizing

EquipmentInput rating

GPH

Recommendednozzle rating

GPH

Low fireinput

(100 psig)

High fireinput

(300 psig)

6.00 3.50 3.50 6.00

6.50 3.75 3.75 6.50

6.90 4.00 4.00 6.90

7.80 4.50 4.50 7.80

8.70 5.00 5.00 8.70

9.50 5.50 5.50 9.50

10.40 6.00 6.00 10.40

11.20 6.50 6.50 11.20

1. For a packaged appliance application on which the burner has been tested, use the noz-zle given in the appliance manufacturer's instructions or supplement for the best results.

Gas pressure requirementsThe702G/Oburnerrequires3.4"w.c.minimumpressureatthebutterflyvalveduringhighfire.Selectagas train thathasapressuredropnomore than theavailablepressureat thegas train inletminus the3.4"neededatthebutterflyvalve.Seepage13forgastrainpressuredropinformation.Theburnerisequippedwitha1"gastrainunlessalargergastrainisordered.

Example:Aboilerhasaninputratingof1,300,000Btuh.Gaspressureavailableat thegas trainentrance is6.0"w.c.Subtract3.4” from theavailable6.0"w.c.Thegastrainpressuredropmustbe2.6”orless.A1"gastrainhasapressuredropof3.3"w.c.,andcannotbeused.Selecta1¼"RV-61regulatorgastrain,whichhasapressuredropof0.87"w.c.




1. The Carlin Model 702G/O combination gas/oil burner (continued)

1 Castaluminumburnerhousing2 Airtube(withgasmanifold)3 Burnerflange4 Burnermotor7 Ignitor,Carlin410008 Dampermotor9 Airdamper&lowfire

adjustingscrew10 Airdamperlinkage11 Airflowswitch12 Controlpanel(connectionfor120

vacpowerand120vaccontrolandlimitcircuitinputfromboiler)

13 Gas/oilchangeoverswitch14 Lowfireholdswitch(LFS)20 Fuelpump21 Combustionheadassembly22 Oilvalvejunctionbox23 1ststageoilvalve24 Safetyoilvalve25 2ndstageoilvalve(fuel

unitblockingvalve)29 Gasmanifold

30 Gasspuds(4required)31 Gasbutterflyvalve32 Butterflyvalvelinkage33 Union34 Gasshut-offvalve(with

2testtappings)35 Automaticgasvalve(diaphragmtype)36 Automaticgasvalve37 Gastrainjunctionbox38 Gaspressureregulator39 Manualgasvalve(with

twotesttappings)

40 Gasentranceconnection

41 Pressuretap&bleedport

42 Pilotgaslinemanualvalve(with2testtappings)

43 Combinationpilotgasvalve

60 Headpositionindicatorscale

61 Headpositionadjustmentscrew

62 Nozzleline

63 Electrodeleadwires

64 Thermalfuse

65 Electrodeceramicinsulators

66 Electrodes

67 Electrodeclamp

68 Nozzleadapter

69 Nozzle

70 Retentionringassembly

71 UVscannertube/adapter

72 UVscanner




2. Prepare site • assemble burner • mount burner

Vent system

Vent/chimney sizing1. Followalllocalcodeswhensizingtheventandchimney.2. Refertotheappliancemanufacturer’smanual,whenavailable,forventing

recommendations.

Prepare vent/chimney1. Secureallmetalventjointswithscrews,followingtheventmanufacturer’s

instructions.Sealalljointsintheventsystemandchimney.Repairma-sonrychimneyliningandrepairallmortarjointsasneeded.

2. Wheredraftfluctuationsarelikely,installadouble-actingbarometricdraftregulatorintheventpiping.(Thedampermustbelocatedinthesamespaceastheappliance.)Installamanualresetspillswitchinthetopofthedraftregulatoroutlet.Wiretheswitchintotheappliancelimitcircuittoshutofftheappliance/burnerifsustaineddowndraftshouldoccur.Refertotheappliancemanufacturer’sinstructionmanualforrecommendationsregardingtheneedforabarometricdraftregulator.

3. Providesupportfortheventpiping.Donotresttheweightofanyoftheventpipingontheapplianceflueoutlet.

Clearances

Check codes, standards and the equipment manual• Verifythattheburner/appliancewillmaintainallclearancestocombustible

walls or floor andall clearances required for service/maintenanceasrequiredintheappliancemanualandapplicablecodes.

Inspect, repair and/or replace vent system

Donotinstallthisburnerunlessyouhaveverifiedtheentireventsystemandtheapplianceareingoodcondition and complywith all applicable codes. And...

The vent and chimneymust be sized and con-structedinaccordancewithallapplicablecodes.Ifintendedforusewithanoilburneraswell,theventsystemmustcomplywithrelevantcodesforbothgasandoilfiring.

Theventsystemmustnotbepressurizedunlesstheventpipingandventsystemaredesignedac-cordingly.Theventmustprovidedraftatalltimes(negativepressureinvent).

Donotinstalloruseanexistingmanualdamperintheventconnectororvent.

Donotconnecttheapplianceventconnectortoachimneyorventservingafireplace,incineratororsolid-fuel-burningapparatus.

Inacoldclimate,donotventintoamasonrychimneythathasoneormoresidesexposedtotheoutside.Installalistedstainlesssteellinertoventtheflueproducts.

Adefectiveventsystemcouldresultinsevereper-sonalinjury,deathorsubstantialpropertydamage.

Figure 1 Vent and vent connector installations, typical




2. Prepare site • assemble burner • mount burner (continued)

Combustion air/ventilation openings

Sizing air openingsFollowallapplicablecodesandtheapplianceinstructionmanual(whenavailable)tosizecombustionairopenings.Usethefollowingguidelineswhenapplianceinstructionsarenotavailable.• Allairfrominsidebuilding(buildingmustbewell-ventilated): Sizeairopeningsforafreearea(afterlouverdeduction)ofatleast1

squareinchper1,000Btuhinputofallappliancesinthespace.• Allair throughopeningsdirectly fromoutside thebuilding throughan

adjacentoutsidewall: Ifairopeningsconnectdirectlytooutside,providetwoopenings,one

within12inchesoftheceiling,theotherwithin12inchesofthefloor.Eachopeningmusthaveafreearea(afterlouverdeduction)of:• Ifdirectly throughsidewall:1square inch foreach4,000Btuhofall

appliancesinthespace.• Ifthroughverticalducts:1squareinchforeach4,000Btuhofallappli-

ancesinthespace.• Ifthroughhorizontalducts:1squareinchforeach2,000Btuhofallap-

pliancesinthespace.

Locating air openingsFollowallapplicablecodesandtheapplianceinstructionmanual(whenavailable)tosizecombustionairopenings.RefertoFigure2whenap-plianceinstructionsarenotavailable.

Estimating free areaWhenspecific informationonthefreeareaof louvers isnotavailable,estimatefreeareaasfollows:1. Woodlouvers—freearea=areatimes0.25.2. Metallouversorgrilles—freearea=areatimes0.60.3. Screens,whenusedmustbenosmallerthan¼inchmesh.

Motorized vent dampersWiretheventdamperendswitchtopreventoperationoftheburneruntiltheairopeninglouversarefullyopen.

Combustion air/ventilation opening checklist• Verifythatairopeningsareunobstructed.• Verifythatappliancespaceandairsourcespacesarefreeof:

• Gasolineorotherflammableliquidsorvapors.• Combustiblematerials.• Aircontaminants,suchaslaundryproducts,paint,thinner,varnish,etc.

• Confirmwithuser that theareawillbekept freeof thesematerialsatalltimes.

Figure 2 Locating combustion air/ventilation openings

ApplianceMinimum24 inches above

grade or snow line

Air opening

Where air opening is high on the wall,duct to within 12 inches of the floor

Installingtheburner/applianceinaspacethatdoesnotprovideenoughairforcombustionandventila-tioncanresultinseverepersonalinjury,deathorsubstantialpropertydamage.Followallapplicablecodesandguidelinesbelowtoensurespacehassufficientairopenings.

Exhaust fans and negative pressure conditions— Isolate theboiler room fromareas subject tonegativepressure.Sizecombustionairopeningstoensureneutralairpressure in theboiler roomwhenevertheburneroperates.

Makesurethespaceprovidesenoughventilationtopreventoverheatingoftheappliance,burnerandcontrols. If there isriskofoverheating,youmustinstallventilationairopeningssizedlargeenoughtoprovideairforcoolingtheequipment.Failuretoprovide ventilation can result in severe personalinjury,deathorsubstantialpropertydamage.

The space and combustion air supplymust notcontaincorrosivecontaminants, suchas laundryproducts,paints,varnishesorotherchemicals.




Prepare the appliance

Burnerinput:Installaburnersizedforthenormalinputrat-ingoftheappliance.Donotinstallaburnerwithahigherfiringratethantheappliancerating.Donotinstallaburnerwithafiringratemorethan10%lowerthantheappliancerating.Theapplianceandventsystemcouldbedamagedduetocondensation.

Cleantheappliance:Cleantheappliancethoroughly.Testallelectricalcomponentsandverifythereliefvalveworks(boilersonly).

Sealtheappliance:Sealallflue-gascontainingjoints.Sealallconnectionstotheventpipingorbreeching.

Verify combustion chamber dimensions complywith theminimumdimensionsrecommendedonpage9.Installorreplacechamberlinerifrequiredbytheappliancemanu-facturer.Theburnermustnotextendintothecombustionchamber.Theendoftheburnerairtubemustbewithin¼"oftheinsidefaceofthechamber.Ifthespacearoundtheburnerairtubeismorethan¼",wraptheburnerairtubewithminimum2300-°F-ratedceramicfiberblankettosealoffthegap.

Repairorreplacedamagedappliancecomponents.Inspecttheappliancethoroughly.Followappliancemanufacturer’sguidelinesforrepairorreplacementofanycomponentfounddefective.

Whencleaningtheapplianceorworkingwithceramicfiberrefractoriesorfiberglassinsulation,seeWARNINGonthispage.

Failure to complywith the above could result in severepersonalinjury,deathorsubstantialpropertydamage.

Prepare appliance for burner mounting

Positive overfire pressure applications:When firingwithpositive overfire pressure, do not exceed the pressurespecifiedintheappliancemanual.

Positiveoverfirepressurereducesmaximumburnercapac-ity.SeePage3forestimatedreductioninburnercapacitywithpressurizedfiringandhighaltitudeapplications.

Failure to comply could result in severepersonal injury,deathorsubstantialpropertydamage.

Ceramic fiber or Fiberglass insulation

Ceramicfibermaterials,suchaschamberliners,maycontaincarcinogenicparticles(chrystobalites)after exposure to heat.Airborne particles fromfiberglassorceramicfibercomponentshavebeenlistedaspotentiallycarcinogenicby theStateofCalifornia.Take the following precautionswhenremoving,replacingandhandlingtheseitems.

Avoid breathing dust and avoid contact with skin or eyes.Wear long-sleeved, loose-fittingclothing,glovesandeyeprotection.UseaNIOSHN95 certified respirator. This respiratormeetsrequirements for protection from chrystobalites.Actual job requirements or NIOSH regulationsmay require other or additional protection.For information, refer to the NIOSHwebsite, http://www.cdc.gov/niosh/homepage.html.

Ceramic fiber removal:Topreventairbornedust,thoroughlywet ceramic fiberwithwater beforehandling.Placeceramicfibermaterialsinaplasticbagandsealtodispose.

Avoid blowing, tearing, sawing or sprayingfiber-glassorceramicfibermaterials.Ifsuchoperationsare necessary,wear extra protection to preventbreathingdust.

Wash work clothes separately from other laun-dry.Rinseclotheswasherthoroughlyafterwardstopreventcontaminationofotherclothing.

NIOSH First aid procedures: Eyeexposure—irrigateimmediately Breathing—freshair.






Figure 3 Chamber dimensions & tube configurations

Table 2 Minimum combustion chamber dimensions (see Figure 3)

Prepare burner and components Donotinstalloroperatetheburnerifanycomponentisdam-agedor ifburnerdoesnotcomplywiththespecificationsofTable2andotherguidelinesinthismanual.

Combustion chamber minimum dimensions

1. Forapplicationsthathavenotbeenspecificallytested(OEMapplications),verifythatthecombustionchamberprovidestheminimumdimensionsshowninTable2andFigure3.ForspecificOEMapplications,theappliancetestingensuressuitabilityofthechamber.

2. Chamberdimensionsmaybe larger than listed inTable2,butshouldnotbeexcessivelylarge.

CombustionchambersshouldbesizedasrecommendedinTable2.Theyshouldbeconstructedof refractorymaterialswiththecapacitytowithstand2600°Forhigher.

Itisdifficulttoincludeallpossiblechamberconstructionsinthismanual.Therefore,youshouldusetheinformationpresentedinthismanualcombinedwithcommonlypracticedtechniqueswhendeterminingchamberdesign.Ifcertainconditionsareinquestion,consultthefactory.

Using chamber linings

1. Whenusing refractory liners or lightweight chambers, use insulating-typerefractoryrated2600°Fminimum,orasspecifiedbytheappliancemanufacturer.

2. Youmustinstallatargetwalllinerifflamelengthisclosetothelengthofthechamber.

3. Useafloorlinerwhenpossible.Thefloorlinerwillimprovefiringinmostapplications.Extendfloorliner3to4inchesupthesidewalls.

4. Targetwallliners—Extendtargetwalllinersatleast3to4inchesabovethecenteroftheflamecorbelthetop1½to2½inchesdeep.

5. Usepreformedchamberlinerswhenavailable.Liningthefloorandtar-getwallwater-backedcombustionchamberswithlightweightinsulatingrefractorywillaccomplishthesame.

6. Whenconvertingcoal-firedunits, installacombustionchamber in theashpitarea,orfilltheashpitwithsandupto2inchesabovethe“mudring”oftheboiler(firingthroughthedoor).Installalightweightrefractorylineronthetargetwall.

Air tube insertion length (UTL)

1. Usableairtubelength(UTL)isthedistancefrommountingflangetoendofairtube.Verifythattheendoftheairtubewillbeflushwith,ornomorethan¼inchshortof,theinsideoftheappliancecombustionchamberfrontwallwhentheburnerismounted.SeeFigure3forfurtherinformation.

High fire input Refactory combustion chamber applications(all dimensions in inches)

Oil–GPH Gas–MBH “L” “W” “C” “H”

6.00 840 21 15.0 7.5 15

6.50 910 23 15.5 8.0 16

6.90 966 25 16.0 8.0 16

7.80 1092 28 17.0 8.5 17

8.70 1218 31 17.5 9.0 18

9.50 1330 34 18.0 9.0 18

10.40 1456 38 19.0 9.5 19

11.20 1568 43 20.0 10.0 20

High fire input Refactory combustion chamber applications(all dimensions in inches)

Oil–GPH Gas–MBH “L”W/ target

“L”No target “W” “C” “D”

6.00 840 21 25 17.0 8.5 10.5

6.50 910 23 27 17.5 9.0 11.0

6.90 966 25 29 18.0 9.0 11.0

7.80 1092 28 32 19.0 9.5 11.5

8.70 1218 31 35 19.5 10.0 12.0

9.50 1330 34 38 20.0 10.0 12.0

10.40 1456 38 42 21.0 10.5 12.5

11.20 1568 43 47 22.0 11.0 13.0




Inspect burner and components• Checktheairtubelength.VerifytheusablelengthofthetubeUTLwill

belongenough(see“Mountburnerinappliance”).• Visuallyinspectallburnercomponentsandwiring.• Verifythatwiringisintactandleadsaresecurelyconnected.• Verifythatallburnercomponentsareingoodcondition.

Donot installoroperate theburner ifanycomponent isdamagedorifburnerdoesnotcomplywithotherguidelinesofthismanualandtheappliancemanual.

Mount burner in appliance

Welded-flange burners

1. Verify thebolt patternon theappliance chambermatches the flangepattern.

2. Verify the insertion depth (UTL)matches the depth of the applianceopening(sotheendoftheairtubeisflushwith,orslightlyshortof,theinsidesurfaceofthecombustionchamber).

3. Placegasketontoboilerfrontplate.4. Slidetheendoftheairtubeintotheopeningandsecuretheflangeto

theboilerfrontplate.

Burners with adjustable flanges

1. Verifytheflangemountingslotswilllineupwiththeappliancebolts.(SeeFigure4foradjustableflangedimensions.)

2. Placetheflangegasketinpositionontheappliancemountingplate.3. Measurethedistancefromtheinsideofthecombustionchambertothe

outsideoftheappliancemountingplate.Slidetheadjustableflangeontheairtubeuntilitisthisdistancefromtheendoftheairtube.

4. Markthispositionoftheflangeontheairtubewithapencilorpensoyoucanverifytheflangeiscorrectlypositionedasyoucompletetheinstalla-tion.Theendoftheairtubemustbeflush,oralmostflush,withtheinsideofthecombustionchamberwall.(SeeFigure3,page9)

5. Tightentheflangelockingscrewsfingertight.6. Inserttheairtube/flangeassemblyintotheapplianceopening.(Rotate

theflangeifneededtoalignwiththemountingbolts.)Securetheflangetotheappliancefrontplate.

7. Seethefollowinginstructionstoinstalltheburnerpedestal,neededtoproperlysupporttheburner.

Aforceddraftadjustableflangemustbesealedtotheairtubetopreventpossibleleakageofflueproducts.Failuretocomplycouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.

Figure 4 Adjustable flange


Install the burner pedestal

702G/Oburnerssuppliedwithanadjustableflangearealsosuppliedwithapedestal for supporting theburner. (Thepedestal isavailableasanoption foraburnerequippedwithaweldedflange.)

1. Adjustthepedestalsothattheheightoftheairtubematchesthelocationoftheburneropening.

2. Thepedestalhasapproximately3"ofadjustment.Iftheburneropeningistoohighforthepedestaltorestonthefloor,thenconstructabase.Twosolidcementblocks,sidebyside,isrecommended.Alternatethedirectionaslayersareputdown.

3. Placeaspirit levelontheairtube.Adjustthepedestalsotheairtubeslopesdownslightlytowardtheappliance.Theslopeshouldbeabout2degrees.

4. Tightenthepedestalboltsecurely.

Install the oil nozzle1. Follow the instructions on page 24 to remove the combustion head

assembly.2. Installandtightenthenozzlelistedintheapplianceinstructionmanualor

theCarlinOEMSpecGuide.Ifnozzleinformationisnotavailable,beginwiththenozzlelistedonpage4.(Youmayhavetochangethenozzlelaterifcombustionresultsarenotacceptable.)

3. Slidetheflamescannersightpipeassemblytotherearbylooseningthe1/8”Allenscrewontheholdingbase.

4. Holdthenozzleadaptersecurelywhenremovingorreplacingthenozzle.Takecarenottodamagetheelectrodeinsulatorsortobendtheelectrodesintheprocess.

Inspectthenozzleadapterbeforereplacingthenozzle.Ifthethreadshavebeendamagedorshowscoremarks,replacethenozzleline/adapterassembly.




5. Slidetheflamescannersightpipeassemblyforwarduntilthe3/8"pipefitsagainsttheretentionringassembly.Thentightenthe1/8"Allenscrewtosecurethetubeinplace.

6. Checktheelectrodesandrepositionifnecessary.PositiontheelectrodesasshowninFigure5.Thesesettingsarecriticalinensuringareliableignition.

7. Oncetheelectrodesareset,checkallclampstobesuretheyaresecurelytightened.

8. Insertthecombustionhead/nozzleassemblyintotheburnerandsecureinplace.Seeinstructionsonpage24.

Figure 5 Electrode settings

Inspect components and wiring

• Visuallyinspectallburnercomponentsandwiring.

• Verifythatwiringisintactandleadsaresecurelyconnected.

• Verifythatallburnercomponentsareingoodcondition.

Install gas train on burner1. Thestandardburnergastrainisshippedfullyassembled,withthepiping

disconnectedatthegastrainunions.Seeseparateinstructionsifinstallinganoptionalknockeddowngastrain.Thegastrainisavailableineitheranangled(standard)orstraight(optional)configuration.

2. Connectthemainandpilotgastrainsattheunions(Figure6).

Toavoiddamagetogastraincomponents,donotholdcompo-nentswithapipewrenchorovertighten.Useonlyacrescentwrenchorothermeans.Failuretocomplycouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.

3. Connecttheflexibleconduit,pre-attachedtotheburnerJ-box,tothegastrainJ-box,andattachthewirestotheterminalstripinsidethegastrainJ-box.a. Matchwirecolorsoftheincomingwirestothosepre-wiredtotheterminal

stripinsidethegastrainJ-box.b. Seethelabelintheburnerjunctionboxorthewiringdiagramonpage17.

Gasvalveventopening—TheV48diaphragmgasvalveisNOTfittedwithaventlimitingorificeintheventconnection.Iflocalcodesrequire,installpipingfromtheventconnectiontooutside,sizedandinstalledasrequiredbycodes.Becausethisisadiaphragm-assistedsolenoidvalve,asmallamountofgaswillexitfromtheventorificeeachtimethevalveopens.

Figure 6 Gas train installation (shown with straight gas train)





3. Install gas piping

Piping from gas meter to burner1. Verifythegastrainontheburneriscorrectlysized.Thegastrainpres-

suredropmustnotbemore than thegaspressureat theburnergastrainentranceminus3.4"w.c.(pressurerequiredatentrancetobutterflyvalve).SeeFigure8forgastrainpressuredropinformation.Thestandardgastrainis1inch.

2. Ifpossible,installanewgaslinedirectlyfromthegasmeter.Ifyouareusinganexistinggasline,verifyitiscleanandingoodcondition,andverifyitislargeenoughtohandletheloadofallconnectedappliances.

3. Whenbranchingfromacommongasline,donottapofffromthebottomofhorizontalsections—onlyfromthesideortop.

4. Installamainmanualshutoffvalve,sedimenttrapandgroundjointunionneartheburnergastrainconnectionasshowninFigure7.

5. Iftheburnerisinstalledinsideanappliancejacket,installthemainmanualgasvalveandsedimenttrapexternaltothejacket.

6. Sizepiping(orverifysize)usingTable3.YouwillfindadditionalinformationongaslinesizingintheNationalFuelGasCode,ANSIZ223.1.

7. Gassupplypressure—naturalgasorpropane• Maximumsupplypressure: 14inchesw.c.• Minimumsupplypressure: 5inchesw.c.

Test and purge gas lineReadWARNINGabove.Pressuretestandpurgetheline.Pressuretestingshouldbedonebythegassupplierorutility,followingallapplicablecodes.

Check pilot gas line orifice nipple Check the label on the pilot line gas orifice nipple (item1,page29).Thelabelontheorificenipplemustagreewiththegasused(naturalorpropanegas).Ifthenippleisnotcorrectforthegasbeingused,obtainthecorrectorificenippleandreplace.Makesurethenippleisinstalledinthecorrectdirec-tion,asshownbythearrowonthelabel.

Figure 7 Connecting gas supply piping to burner (shown with straight gas train)

1 Pipetometerorbranch

2 T-handlemainmanualgasvalve

3 Useclean,burr-freeblackironpipeandmalleableironfittings

4 Groundjointunion

5 Sedimentleg

6 Upstreampressuretap,1/4"

7 Outletpressuretap,1/4"

8 Gasregulatoraccessscrew(theregulatorspringislocatedundertheadjustingscrew)

9 Gastrainwirejunctionbox

Connectfromthegassupplytotheburnergastraininletusingnew,cleanblackironpipeandmalleableironfittingsonly.Donotusecopper,brass,castironorgalvanizedpipeorfittings.

Providesupportforgaspiping.Donotresttheweightofthegaspipingonburnergastrain. Provideasupportfortheburnergastrain. Applypipedopesparinglyatalljoints.Useonlypipedopelistedforusewithpropanegas.Donotusepipesealingtape. Donotholdthegasvalvewithpipewrench.Usecrescentwrenchorothersmooth-jaweddevice.Donotovertighten. Failuretocomplywithabovecouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.

Donotexposethegastraintogaspressureinexcessof14incheswatercolumn.Higherpressurecoulddamagethevalveseat,resultinginpotentiallyhazardouscondition.Whenpressuretestingpipingathigherpressures,disconnectburnerfromgaslinebeforetesting.

Ifthegassupplypressurecanexceed14incheswatercolumnatanytime,youmustinstallalockuptypegaspressureregulatorinthegassupplypiping,aheadofthemainmanualgasvalveinstalledattheburner.




NATURAL GASCapacities in Cubic feet per hour

for Schedule 40 metal pipe

Pipe size (inches)

Total length of gas piping,from meter to burner connection (feet)

20 40 60 80 100

Natural gas @ .60 specific gravity, pressure drop 0.3 in. w.c. (note 1)

1¼ 730 500 400 350 305

1½ 1,100 760 610 530 460

2 2,100 1,450 1,150 990 870

2½ 3,300 2,300 1,850 1,600 1,400

Natural gas @ .60 specific gravity, pressure drop 0.5 in. w.c. (note 1)

1¼ 950 660 530 460 400

1½ 1,460 990 810 690 620

2 2,750 1,900 1,520 1,300 1,150

2½ 4,350 3,000 2,400 2,050 1,850

Note 1 For natural gas with specific gravity other than 0.60, consult National Fuel Gas Code for correction factor.

PROPANE GASCapacities in Btuh for

Schedule 40 metal pipe

Propane gas @ 1.5 specific gravity, pressure drop 1 psi

½ 1,839 1,264 1,015 869 770

¾ 3,845 2,643 2,122 1,816 1,610

1 7,243 4.978 3,998 3,422 3,033

Propane gas @ 1.5 specific gravity, pressure drop 0.5 in. w.c.

1 787 541 434 372 330

1¼ 1,616 1,111 892 677 543

1½ 2,422 1.664 1,337 1,114 1,014

Table 3 Capacities of black iron pipe, cubic feet gas/hour Figure 8 Gas train pressure drop

3. Install gas piping (continued)

Regulator spring:

Thestandardmaingaspressureregulatorspring(seeitem8,Figure7,page12)isplated.Therangeisfrom3.0to6.0incheswatercolumn.

The1"RV61regulatorisavailablewithanoptionalbluespring,witharangeof5.0to12.0incheswatercolumn.

The1¼"or1½"RV81regulatorisavailablewiththestandardplatedspring(3.0to6.0incheswatercolumn)oravioletspring,witharangeof4.0to12.0incheswatercolumn.




Inspect/install fuel supply

Inspecttheoilsupplysystem.Ensurethatthefuellinesarecorrectlysizedandinstalledandthatthefuelflowisunob-structed,theoiltankiscleanandonly#1or#2heatingoilaresupplied.Failuretosupplyareliableoilflowcouldresultinlossofheatandpotentialsevereequipmentdamage.

1. SeeFigure9fortypicaltwo-lineoilpiping.

2. Seepage15,Figures10and11,forfuelunitoilflowdiagrams.

3. Installthefuelunitbypassplug(two-linesystemsonly).

Fuel supply to multiple burners• Whenpossible,useseparatefuelsupplylinesforeachoilburner.Using

manifoldedoilsupplylinescancreateproblems.Ifthelinesareunder-sized,operatingvacuumwillexceed limits. If the linesareoversized,fuelunitsmayhavedifficultypriming.Becausethelinesmustbesizedtohandlethecapacityofalltheburners,thelinesizewillalmostalwaysbetoolargewhenonlyasingleburnerisrunning.

• Ifmanifoldingcannotbeavoided,carefullysizethelinesfollowingthefuelunitsmanufacturer’sinstructions.

Fuel unit vacuum limitations• SeeTable4forallowableliftsandlengthsofoillines.

• Thevacuumatthefuelunitinletportmustnotexceed12inchesmercuryduringanyoperatingcondition.

• Attachavacuumgaugetoeitherofthefuelunitinletports,andverifythevacuumdoesnotexceedthelimitbelowduringallfiringconditions.

Oil flow schematic / fuel unit connections• Figure10showsoilflowandfuelunitportfunctionsforCarlin702G/O

burners.

• Figure11appliesonlyforoptionalNYC-DARpressureregulationkits.

4. Install oil piping

Use two-line oil piping only Thefuelunitmustbeconnectedtoa two-line fuel

systemtoensureoilflowthroughthepumpduringgasoperation.This isneeded tokeep thepumpcool and lubricated.Failure to protect thepumpcanresultinearlypumpfailure.

Fuel unit bypass plug Thefuelunitisshippedwithitsbypassplugnotin-stalled.Installthebypassplugonlywhenconnectingtoatwo-lineoilsystem.Operatingwiththepluginplaceonaone-linesystem(notrecommended)willdamagethefuelunitandcouldleadtooilleakageandfirehazard.

Ifthefuellineorfuelsupplyisabovetheburner,neverexceed3PSIGpressureatthefuelunitinlet.InstallasuitableOSVtoreducethepressure.Operatingthefuelunitwithhigherinletpressurecouldresultinfuelunitsealdamage,oilleakageandpotentialfirehazard.

Guidelines:• When installing oil lines, use continuous runs of heavy-wall

coppertubingifpossible.• Check fuel unit (oil pump) data sheet for recommended line

sizing,liftlimitationsandmaximumlength.• Checkallconnectionsandjointstoensuretheyareair-tight.• Useflarefittings.DONOTusecompressionfittings.• Neverusepipesealingtape.Fragmentscanbreakoffandplug

fuellinecomponents.• Installashut-offvalveatthetankandoneneartheburner.(Use

fusiblehandledesignvalveswhenpossibleorwhenrequiredbycodes.)

• Installalargecapacityfuelfilter(ratedfor50micronsorless)neartheburner.




Figure 9 Two-line fuel system

Table 4 Two-line fuel system - allowable lengths and lifts

Lift(feet)

Length of tubing (feet)

3/8” O.D. 1/2” O.D.

0 41 100

2 37 100

4 32 100

6 28 100

8 24 96

10 20 80

12 16 64

14 — 48

16 — 32

Figure 11 702G/O burner with NYC-DAR pressure regulation kit

ObtainpressureregulatorkitsforNewYorkCityDepartmentofAirResourcesfromCarlin.Kitsmustbesetforthepropernozzlepressure.

4. Install oil piping (continued)

Figure 10 702G/O fuel unit and flow diagram (Low fire pressure is 100 PSIG, adjusted by screw on top of blocking valve; High fire pressure is 300 PSIG, applied when blocking valve is powered)




Figure 13 702G/O burner wiring using Honeywell RM7897C primary control (see appliance manual or separate wiring information for burner equipped with a primary control not covered in this manual); see Figure 12 for a legend to callouts.

5. Wire the burner — RM7897C primary control

Wire the burner (RM7895CorRM7897Cprimarycontrolonly)1. Allwiringmustcomplywith:

• IntheU.S.—theNationalElectricalCode,ANSIZ223.1/NFPA54.• InCanada—theCanadianElectricalCodePart1,CSAstandardC22.1.• Allapplicablelocalcodes/standards.

2. ConnecttheburnerfollowingFigures13and14andanyspecialinstructionsorwiringdiagramsprovidedwiththeappliance,burnerorothercomponents.

3. Theburnerrequiresa120VAC/60hz/single-phasecontrolpowersupply,witha10-ampfuse.Thecontrolcircuitcurrentdrawisapproximately1.2amps.Anadditionalpowersourceisrequiredforthemotor(120VACor208-220VAC,60hz),withfusesizedaccordingly.SeeFigure14forfieldwiringconnections.

4. ReadtheHoneywellRM7897Cinstructionsforinformationonsettingaroomthermostat,ifused.

5. Makesuretheburnerandappliancearecorrectlywiredandthelineswitchisproperlyfusedfortheload.

Turn off power to appliance when servicing burner.Failure to comply could result in severe person-al injury, death or substantial property damage.

Figure 12 Legend for Figures 13 and 14




Figure 13a 702G/O burner Mass Code wiring using Honeywell RM7897C primary control (see appliance manual or separate wiring information for burner equipped with a primary control not covered in this manual); see Figure 12 for a legend to callouts.

Turn off power to appliance when servicing burn-er. Failure to comply could result in severe per-sonal injury, death or substantial property damage.

5. Wire the burner — RM7895C/RM7897C primary control

Wire the burner (RM7895C or RM7897C primary control only)

1. All wiring must comply with:

• In the U.S. — the National Electrical Code, ANSI Z223.1/NFPA 54.

• In Canada — the Canadian Electrical Code Part 1, CSA standard C22.1.

• All applicable local codes/standards.2. Connect the burner following Figures 13, 14 and 15 and any special instructions

or wiring diagrams provided with the appliance, burner or other components.

3. The burner requires a 120 VAC/60 hz/single-phase control power supply, with a 5-amp fuse. The control circuit current draw is approximately 1.2 amps. An additional power source is required for the motor (120 VAC or 208-220 VAC, 60 hz), with fuse sized accordingly. See Figure 14 for field wiring connections.

4. Read the Honeywell RM7895C (or RM7897C) instructions for information on setting a room thermostat, if used.

5. Make sure the burner and appliance are correctly wired and the line switch is properly fused for the load.

Figure 12 Legend for Figures 13 through 15

APS Burner airflow switch

DM Damper motor

HL Appliance high limit control

IR Isolating relay

LFS Low fire switch

MC Motor contactor

OC Appliance operating limit control

OV Oil valve

TF Combustion head thermal fuse

UV UV sensor

Connector in gas train junction box

Connector in oil valve junction box

Wire nut

Wires BK=black; BU=blue; BN=brown; G=green; O=orange; R=red; V=violet; W=white; Y=yellow

NOTE See appliance manual or separate wiring information for burner equipped with a primary control not covered in this manual)




120 VACAppliancehigh firecontrol(remove jumper)

Figure 14 702G/O field wiring connections (RM7897C only) Low-High-Low step modulation1. Totakeadvantageoftheenergy-savingpotentialoftheModel702G/O

combinationgas/oilburner,itshouldbewiredtooperateatlow-high-lowcycles.Thefiringcyclecanbemuch longerusing low-high-lowfiring,because theburnercancycle to lowfireasdemanddecreases.Thiskeepstheburneronlonger,reducingcycliclosses.

2. Theappliancemustbeequippedwithahighfirecontrol.Thiswouldbeamake-on-fallcontrol,eithertemperature(waterboiler)orpressure(steamboiler)activated.Readtheappliancemanualforthelocationofthehighfirecontrol,whenused.

3. SeeFigure14toconnectthehighfirecontrol totheburnerfiringratecircuit.

4. Theburnerincludesapre-wiredmanualhigh-fireswitch.Closethisswitchtoholdtheburnerinhighfiremode.Opentheswitchtoholdtheburnerinlowfiremode.

5. Wire the burner — RM7897C primary control (continued)

Figure 15 702G/O ladder wiring diagram (burners with RM7895C or RM7897C primary only); see Figure 12 for a legend to callouts




Figure 15a 702G/O Mass Code ladder wiring

diagram (burners with RM7895C or

RM7897C primary only); see Figure 12

for a legend to callouts

Figure 14a 702G/O field wiring connections (RM7895C or RM7897C

only)

Low-High-Low step modulation1. To take advantage of the energy-saving potential of the Model 702G/O

combination gas/oil burner, it should be wired to operate at low-high-low cycles. The firing cycle can be much longer using low-high-low firing, because the burner can cycle to low fire as demand decreases. This keeps the burner on longer, reducing cyclic losses.

2. The appliance must be equipped with a high fire control. This would be a make-on-fall control, either temperature (water boiler) or pressure (steam boiler) activated. Read the appliance manual for the location of the high fire control, when used.

3. See Figures 14a and 15a to connect the high fire control to the burner firing rate circuit.

4. The burner includes a pre-wired manual high-fire switch. Close this switch to hold the burner in high fire mode. Open the switch to hold the burner in low fire mode.

5. Wire the burner — RM7895C/RM7897C primary control (continued)




6. Checkout procedure — before starting the burner

Before firing the burner . . .

Shouldoverheatingoranemergencyoccur,immediatelydothefollowing:

• Shutoffoilsupplylineandgassupplyvalves.

• Undersomecircumstancespowershouldremainonforwaterpumpsorblowers.Determineproperresponsebeforeattemptingstart-up.

• Ifburnerfailsignitiononseveralattempts,useburnerblowertopurgeappliancechamberbeforerestart.

Checklist before firing . . .

❏ Burner and appliance installed per thismanual and applianceinstructionmanual?

❏ Burner/applianceinstalledperallapplicablecodes?

❏ Installationsitehasadequatecombustion/ventilationairopeningsandventsystem?

❏ Arevoltagescorrect?Burner,applianceandmotorcorrectlywiredperburnerandappliancemanualsandwiringdiagrams?

❏ Gasmanifoldspudorifices(ongasmanifold,item29,page5)sealedwithpipedopeandtight?

❏ Burnernozzleverifiedperappliancemanufacturer’s instructions,

CarlinOEMSpecGuideorTable1,page4?

❏ Gasandoil supply lines in good condition, sizedanddesigned

correctly?

❏ Gasandoillineconnectionsandfittingstight?

❏ Oiltankhasoil,andoillinevalvesareopen.Oilsupplyandreturn

linespurged?

❏ Burner, appliance and all components inspected and in good

condition?

❏ Appliancelimitandoperatingcontrolsproperlyinstalled,wiredand

adjusted?

❏ Boilerwatersupply,feedpumps,automaticfeeders,andlowwater

cut-offsproperlypipedandwired?

❏ Breeching, draft regulator, draft inducer (if required)properly in-

stalledandoperational?

❏ Gas train pipingand components correctly installed, testedand

verifiedgastight?

❏ Ventlinesinstalledwhenrequired?

❏ Gaslinespurged?

❏ Sufficientgaslinepressurepresent?




Before firing the burner . . .

Set combustion head (Dimension “A”)1. Thecombustionheadadjustingscrewisusedtosetthespacingbetween

theretentionringandthrottlering(oraircone),regulatinghowmuchairpassesaroundtheretentionring.

2. SeeFigure16.Loosenthetwohousingcoverscrews.ThenrotatetheheadadjustingscrewuntilthedistancefromthehousingdetenttothebeginningofthescaleequalsthevaluegiveninTable5(Dimension“A”).Tightenthehousingcoverscrews.

Set air damper (low fire position)1. SeeFigure17. Loosen the air damper adjusting screwand locknut.

Rotatetheadjustingscrewuntiltheairopeningbetweenthedamperandthedamperhousingequalstheinitiallow-fireopeninginTable5.Leavescrewandlocknutlooseuntilfinaladjustment.

Determining final adjustments1. Theburnerisnowadjustedtotheapproximateairsettingsforthefiring

rateused.Follow theprocedureson the followingpages touse test instrumentsandmakefinalburneradjustments.

Figure 17 Set initial low fire air damper setting

Figure 16 Set initial combustion head position

Low-fire input High-fire input Combustionhead position

Dimension “A”

Air damperlow-fireopening

Butterfly valve open – low fire

(factory set)#2 Fuel oil Natural gas #2 Fuel oil Natural gas

GPH @ 100 PSIG(Nozzle rating) MBH GPH @ 300 PSIG MBH Inches

(approximately)Inches

(approximately)%

(approximately)

3.50 490 6.00 840 0 3/8 50

3.75 525 6.50 910 1/16 3/8 50

4.00 560 6.90 966 1/8 7/16 50

4.50 630 7.80 1092 3/16 7/16 50

5.00 700 8.70 1218 3/8 1/2 50

5.50 770 9.50 1330 5/8 1/2 50

6.00 840 10.40 1456 1-1/8 9/16 50

6.50 910 11.20 1568 1-3/8 9/16 50

Nozzle specifications:Standard Hago 45° SS

AlternatesHago 45° P

Monarch 45° PLP

Table 5 Initial burner settings (see the pages 20 through 21 for final adjustments using test instruments)

7. Set burner initial head and damper positions

Followtheproceduresgivenhereandonthefollow-ingpagestoensuretheburneriscorrectlyadjusted.Takeyourtimeandtheresultsinbothgasandoilmodesshouldresultingoodoperation,andavoidreturnservicecalls.

Youmustperformtheadjustmentsinthesequencegiveninthismanual.

Failuretofollowthecorrectprocedurescouldre-sultinseverepersonalinjury,deathorsubstantialpropertydamage.




Adjustment procedure, summaryStep 1: Sethigh-fireoil airflowbyadjusting thecombustionhead.See

detailsfollowing.

Step 2: Adjusttheairdamperforlow-fireoil.Seedetailsfollowing.

Step 3: Adjustthedampermotorendswitch(onlyifnecessary).Seedetailsfollowing.

Step 4: Setgaspilotoperation.Seedetailsfollowing.

Step 5: Sethigh-firegasflowtomatchhigh-fireair.Seedetailsfollowing.

Step 6: Adjustthebutterflyvalvelinkagetomatchlow-firegastolow-fireair.Seedetailsfollowing.

Step 7: Verifyoperationofburner,appliance,andcontrols.

Use test instruments1. Usecombustion testequipmentandanaccuratemanometerordraft

gaugetocorrectlysettheburnerasrequired.

2. Overfirepressuremustnotexceedtheappliancemanufacturer’srecom-mendations.Theburnermustneverbefiredatanoverfirepressuremorethan0.60inchesw.c.

Whentheoverfirepressureispositive,themaximumburnerfiring rate is reduced.Thefiring rate is also reduced foraltitudeshigherthan2000feetabovesealevel.Seepage3forratinginformation.Ensurethattheoilnozzleselectediscorrecttherequiredfiringrate.

3. Adjusttheburnerfuelandairsettingsusingthefollowingprocedures.Whenadjustmenthasbeencompleted,theCO2(orO2)shouldbewithintherangesinTable6,atbothlowfireandhighfire.

Table 6 Allowable values of CO2 and O2

FuelCO2 O2

Minimum Maximum Maximum Minimum

#2 Fuel Oil 10.5 % 12.5 % 6.6 % 3.9 %

Natural Gas 8.5 % 10.0 % 6.2 % 3.6 %

Propane 9.5 % 11.2 % 6.0 % 3.5 %

8. Adjust the burner using test instruments

ThesettingsgiveninSection7areinitialsettingsonly.You must use test instruments to checkcombustion,andadjusttheburnerasnecessary,following the procedures given in the followingpagesofthismanual.Failuretoproperlyadjusttheburnercanresultinseverepersonalinjury,deathorsubstantialpropertydamage.

Start the burner (firingonoil)

Donotstarttheburnerifthecombustionchambercontainsoiloroilvapor.

1. TurnserviceswitchOFF.

2. Performinspectionsandcheckoutsonpage18.

3. Verifyburnerissetaccordingtopage19.

4. Sliponeendofa3/16-inchI.D.clearplastichoseovertheendofthefuelunitbleedvalve,theotherendintoacontainer.Thenopenbleedvalve.

5. SetburnerfuelselectorswitchtoOIL.

6. Setthermostat(operatingcontrols)tocallforheat.

7. TurnserviceswitchON.

8. Burnermotor,fuelunitandblowershouldturnon.

9. Bleedtheoillineuntiltheplasticlineisfreeofbubbles;thenanother15secondslonger.(Shouldtheprimarycontroltimingcausealockoutdur-ingpurging,restarttheburnerfollowingtheprimarycontroldatasheetinstructions.)

10. Closethebleedvalve.Theburnershouldcyclethroughthesequencegivenintheprimarycontroldatasheet.

11. Shouldcontrol/burnerfailtooperatecorrectly,shutburneroffimmediatelyandcheckburnersettingsandfuelsupplies.

12. Operateburner for15minutesbeforemakingfinaladjustmentsusingtestequipment.

13. Checkforleaksinfuelpiping.

Inspect fuelpipingsystemfor leaks.Repairany leakstoavoidfirehazardfromoilleakageorcombustionproblemsduetoairinfiltrationintooil.

14. Inspecttheflame

• Lookattheflamethroughtheappliancecombustionchamberobserva-tionport,ifavailable.Theflameshouldbewell-definedandshouldnotimpingeonanyappliancesurface.(Ifyoumakeairchangeslater,inspecttheflameagain.)

Do not attempt to confirm combustion simply by inspect-ing the flame visually. You must use combustion test instruments.Failuretoproperlyverify/adjustcombustioncouldallowunsafeoperationoftheburner,resultinginseverepersonalinjury,deathorsubstantialpropertydamage.

15. Insertthecombustionequipmenttestprobeintoaventsampleopeningtosampleflueproducts.

Allinstallationsshouldbecheckedafteronetotwoweeksofoperationtoensuretheappliance/burnerunitsareoperatingcorrectly.




8. Adjust the burner using test instruments (continued)

3. SeeFigure17,page19.Adjustthelow-firedamperscrewuntilthelow-fireCO2isbetween11%and12%.Rotatethescrewclockwisetoincreaseairflow(reducedCO2).Rotatethescrewcounterclockwisetodecreaseairflow(increaseCO2).

4. Smokeatlowfiremustbezerooratrace.Notethattoomuchaircanactuallyincreasesmoke.

Step 3 (firing on oil) Damper motor end switch position

1. Modulatetheburnerfromlowfiretohighfireandbacktolowfire,pausingateachstepforaboutoneminute.

2. Iftheswingfromlowfiretohighfireisrough(burnerbangsorrumbles),orthefireisverysmoky,thedamperendswitchmaybeinthewrongposition.High-fireoilshouldpullinastheairdamper,NOTTHEDAMPERARM,isabouthalfwaythroughitsswing.

3. Fordifferentapplianceapplications,itissometimesnecessarytohavehigh-fireoilpressurepullinearlierorlaterthannormalduringtheswingtoachieveasmoother,cleanertransition.

4. If theswing is rough(flamegoesout,bangsor rumbles), therecouldbeairintheoil,orthenozzlemaybedefective.Check,andreplacethenozzleifnecessary.Thenretry.

5. Ifthefireistoolean,theflamecouldliftoffofthehead,causingrumbleorunsteadycombustion.Inthiscase,adjustthedampermotorendswitchtoenergizeearlier.

6. Iftheflameisverysmoky,thencleansupagain,thedampermotorendswitchshouldbesettoenergizelater.Toadjustthedampermotorendswitch:

• Removethedampermotorcover.

• Thiswillexposeawhiteplasticgearwithnotches.

• WiththeburnerOFF,usetheendofasmall-bladedscrewdriverinsertedintooneofthenotchesofthewhitegeartorotatethegearasneeded.

• TurnthegearonenotchCLOCKWISEforaLATERPULL-IN.

• Turn the gear one notchCOUNTERCLOCKWISE for anEARLIERPULL-IN.

7. Restarttheburnerandcheckmodulationagain.Continuewith1through6aboveasneededuntilresultsareacceptable.

8. Turnoff theburnerwhenStep3 iscompletedbeforeproceedingwithsetupforgascombustion,Step4.

Thelinkage between the damper motor arm and the air damper crank is set at the factory, andshouldONLYneedadjustmentifthedampermotororthedamperrodisreplaced.Withtheburnerinhigh-fireposition,thereshouldbeminimalplayintheconnectingrod.DONOTchangethislinkagesetting.

Step 1 (firing on oil) Set combustion head (Dimension “A”)

1. Allowtheburnertooperateapproximately15minutestoensuretheap-plianceisheatedandcombustionissteady.

2. Settheoverfiredraftto-.02inchesw.c.,orasspecifiedintheappliancemanual.

3. Thecombustionheadadjustingscrewisusedtosetthespacingbetweenthe retention ring and throttle ring, regulating howmuch air passesaroundtheretentionring.(SeeFigure16,page19.)ThelargerthevalueofdimensionA,thelargertheclearance,sothelargertheairflow.ThesmallerthevalueofdimensionA,thesmallertheairflow.

4. Measurethe%CO2intheapplianceflue.Thevalueshouldbeapproxi-mately12.5%forhighfireoil.IftheCO2ishigherthan12.5%,adjusttheheadadjustingscrew(seeFigure16,page19)toalargerdimensionAtoincreaseairflow.IftheCO2islessthan12.5%,adjustthescrewtoasmallerdimensionAtodecreaseairflow.

5. Resetoverfiredraftto-.02inchesw.c.,orasspecifiedintheappliancemanual,afteranyairflowadjustment.

6. Checkthesmokevalueintheapplianceflue.Itmustbezerotoatrace.If not, try increasing airflow (reducing theCO2). If increasing airflowincreasessmoke,thecombustionisprobablyonthewrongsideoftheCO2curve.Tocorrect,increasetheairflowuntilthesmokeiseliminated.

7. Whenadjustments are completed, theCO2must be between12.0%and12.5%athighfireoil,withsmokeequaltozerooratrace.Overfiredraftmustbe-.02inchesw.c.,orasspecifiedintheappliancemanual.

Step 2 (firing on oil) Set low-fire damper1. Flipthelow-fireswitchtolowfire.

2. Theburnerfuelunitblockingvalvewillbedeactivated,andtheoilnozzlepressurewilldropto100PSIG.




Step 4 (firing on gas) Check gas pilot operation

TheModel702G/Ousesagaspilotforignitionofthegasmainflame.Thegaspilotisignitedbytheburnerelectrodes.

1. After completingSteps1, 2 and3onpage21,move theburner fuelselectorswitchtoGAS.Setthelow-fireswitchtolowfire.

2. Makesurethegaslinehasbeencompletelybled.ThenturntheserviceswitchtoON.

3. Thepilotwillusually lightthefirsttimeoncethecombustionheadas-semblyandthelow-fireairdamperhavebeensetbySteps1and2,andthepilotgastrainhasbeencompletelypurgedofair.

4. Thepilotflameisapproximately280MBH,andis largeenoughtobeheardwhenlit.Ifthepilotfailstolight,besurethegaslinehasbeenbledproperly.Ifitstillfailstolight,increasethepilotgaspressureto4inchesw.c.Iftheprimarycontrolisequippedwithapilottestholdswitch,itcanbeusedtoholdthepilot“on”whileadjustingpilotgaspressure.

5. Followtheinstructionsintheprimarycontrolinstructionmanualtocheckflamesignal.Makesuretheflamesignalissteady,andgreaterthantherequiredminimumfortheUVsensor.

Step 5 (firing on gas) Set main gas pressure regulator

Thebutterflygasvalveisfactorysettoapreliminarysettingof50%openforlowfire,and100%openforhighfire.Thepilotregulatorissetfor3.5inchesw.c.

1. Leavethelow-fireswitchinlowfire.2. Withthegaspilotoperatingcorrectly,andtheUVsensorflamesignal

aboveminimum required, theprimary controlwill cycle theburner tomaingas.

3. Checktheflamesignalafterthepilothasshutdowntoensurethesignal


Smellaroundthegastrainandcheckalljointswithasoapsudsmixturetoensurethegastrainandallcomponentsaretightandleak-free.Shutdowntheburnerandcorrectanyleakimmediately.Failuretocomplycouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.

isstillstrongwithmainflameon.

4. MovetheburnerfuelselectorswitchtoOFF.Theburnerwillshutdown.

5. TemporarilyinstalltwoU-tubemanometerconnectionstocheckgaspres-sures.Installconnectionsattheinletpressuretapofthemainmanualgasvalveandatthedownstreampressuretapofthemanualgasvalvenexttothebutterflyvalve.(Seeitems41,page5.)

6. The gas pressure at the inlet to the gas trainmust never exceed14inchesw.c.,eitherwhentheburnerisofforfiringongas.

7. MovetheburnerfuelselectorswitchtoGAS.Theburnershouldstart.

8. Withtheburnerfiringinlowfire,checkthegaspressureatthedownstreammanualgasvalvetapping.Adjustthemaingaspressureregulatorifneces-saryuntilthegaspressurereads3.4inchesw.c.asastartingpressure.

9. Switchthelow-fireswitchtohighfire.CAUTION:Bepreparedtoturntheburneroffimmediatelyif itbeginstopulsateasitattemptstomovetohighfire.

10. Iftheflamepulsates,itisprobablytoorich.Switchthelow-fireswitchtolowfireandreducethegaspressurebyadjustingthemaingaspressureregulator.Thenreturnto9,above.

11. Ifthefireistoolean,itwillappearsmallandcanevenblowoutduringtheswingtohighfire.Ifitblowsout,shutofftheburnerimmediately.Switchthelow-fireswitchtolowfireandstarttheburneragain.Adjustthemaingaspressureregulatortoincreasethegaspressure.Returnto9,above.

Withtheburnerrunninginhigh fire,inspectthebutteflyvalveshaftslot(Figure18).Theslotmustbehorizontal.IFNOT,turntheburneroff.Loosenthetwohex-headscrewssecuringthevalvelinkagearm.Withthedampermotorlinkagearmpulledup,useascrewdrivertorotatethebutterflyvalveslotuntilitishorizontal.Tightenthetwohexheadscrewswhilestillholdingthedampermotorlinkagearmup.Returntostep9,above.DONOTproceedwithcombustionadjustmentunlessthebutterflyvalvepositionhasbeenverified,andcorrectedifnecessary.

12. Withtheburnerrunninginhigh fire,adjustthemaingaspressureregula-tortoachieve:• Naturalgas:9.6%to10.0%CO2.

• Propane:10.7%to11.2%CO2.

• MeasuretheCOcontent.Itshouldbenogreaterthan100PPM.

HighCOreadingsmayindicatethecombustionisonthewrongsideoftheCO2curve.YouwillknowthisifadecreaseingaspressurecausesanincreaseinCO2.

13. Thegaspressuremayhavetobesetaslowasabout2.0inchesw.c.toashighasabout4.0inchesw.c.,dependingonthefiringrateoftheburner.




Step 6 (firing on gas) Set butterfly gas valve linkage1. Switchthelow-fireswitchtolowfire.2. CheckCO2andCO.TheCO2shouldbebetween9.0%and10.0%(natural

gas)orbetween10.0%and11.2%(propane);withCOlessthan100PPM.3. Toadjust the low-fireair(changeCO2),movetheburnerfuelselector

switch toOFF.Adjust the butterfly gas valve linkageas described inthefollowingtochangethelow-firegasflowtotheburnerhead.Donotchangethemaingaspressureregulatorsetting.

4. DO NOT ADJUST THE LOW-FIRE AIR DAMPER SETTING.Thismustbeleftassetforoilfiring.

5. SeeFigure18forlocationoflinkagecomponents.

Figure 18 Butterfly gas valve linkage

6. Raise thedampermotor linkagebypullingupon thedamper linkagelocknutandholdinthisposition.

7. Loosenthetwohexheadscrewsonthebutterflyvalvelinkagearmboss.Thenlowerthedamperlinkagetothelowfirepositionwiththedamperlinkagelocknut.Releasethelocknut.

8. Markthepositionofthebutterflyvalvelinkagearmswiveljointlocknutwithapencilorfelt-tippen.Thenloosentheswiveljointlocknut.

Toadjustthelinkage,movetheswiveljointlocknutinsmallincrements.A1/8-inchmovecancauseCO2tochangeasmuchas1.5%.

• Ifmoregasisneeded(toincreaseCO2),movetheswiveljointtotheRIGHT.• Iflessgasisneeded(todecreaseCO2,),movetheswiveljointtotheLEFT.

9. Tightentheswiveljointinplace.10. Raise thedampermotor linkagebypullingupon thedamper linkage

locknutandholdinthisposition.The butterfly valve shaft slot must be horizontal.Ifnot,useacommon-bitscrewdrivertorotatethevalveslottohorizontal.


11. Tightenthetwohexheadscrewsonthebutterflyvalvelinkagearmboss.Thenlowerthedampermotorlinkagetothelowfireposition.

12. RestartandrepeatasnecessaryuntilCO2andCOareacceptable.

FOR MASS CODE, PROCEED TO STEP 6A

Step 6a (firing on oil and on gas) Verify operation

Perform all of the checkout procedures given in Step 6 of the burner manual. In addition, verify operation of the gas pressure switches as described below.

Verify high gas pressure switch operation ❏ Cycle the burner off with the appliance controls and turn off power to the

appliance/burner.

❏ Attach a manometer to the manifold-side manual gas valve test port.

❏ Turn on power and cycle the burner on with the appliance controls.

❏ Measure the manifold gas pressure with the manometer.

❏ Set the high gas pressure switch to a pressure less than actual manifold pressure. The high gas pressure switch should shut the burner down. Replace the switch if necessary.

❏ Turn off power to the appliance/burner; remove the manometer and replace the plug in the gas valve test port. Reset switch.

Verify low gas pressure switch operation ❏ Cycle the burner off with the appliance controls and turn off power to the

appliance/burner.

❏ Close the main manual gas valve.

❏ Cycle the burner on.

❏ The low gas pressure switch should shut the burner down. Replace the switch if necessary.

❏ Turn off power to the appliance/burner.

❏ Open the main manual gas valve.

❏ Reset low gas pressure switch.




Step 7 (firing on oil and on gas) Verify operation

Burner/appliance/controls operation ❏ Testoperatingandlimitcontrolsonapplianceasspecifiedinapplianceinstruc-tions.

❏ Checkoperationoftheprimarycontrolbyforcinglockouttooccur.Forprimarycontrolsthatenterlatch-upaftermultiplelockouts,forcelatch-uptooccuraswell.Resetprimarycontrolpercontroldatasheetinstructionsaftereachtest.

❏ Startandstoptheburnerseveraltimes,allowingtheprimarycontroltosequencethroughnormaloperation.Verifycorrectoperationofburnerandprimarycontrolthroughoutonbothoilandgas.

❏ Confirmand/oradjustoverfirecombustionpressureforoilandgasoperation.Refertoboiler/furnacemanufacturer’srecommendations.

Verify vent system operation ❏ Verifyventisoperatingcorrectlyandflueproductsareproperlyexhaustedfrombuilding.Ifthebuildingcontainsanyexhaustfansorconditionsthatcouldaffectventperformance,checkburner/appliance/ventoperationwithexhaustfans(orotherconditions)operating.

Combustion/ventilation air ❏ Verifycombustion/ventilationairopeningsarenot,andwillnotbeobstructed. ❏ Verifyairopeninglouversarefullyopen. ❏ Iflouversaremotor-operated,verifymotorandendswitchareinterlockedwithappliance/burnerwiringtopreventoperationoftheburneriftheairlouversarenotfullyopened.

Prepare burner for normal operation ❏ Cycleburneroffwithappliancecontrols. ❏ Turnoffpowertotheappliance. ❏ Sealtheappliancefluetestopening. ❏ Verifyallcomponentsandwiresareinplaceandburnerisreadyforoperation. ❏ Restorepowertotheappliance.

Train the user ❏ Traintheusertooperatetheburnerandapplianceundernormalconditions. ❏ Explaintheproceduretoshutdowntheburner/appliancewhenrequired. ❏ Reviewthebackcoverofthismanual(andtheappliancemanual)withtheuser. ❏ Verifytheuserisawareofallproceduresspecifiedinthemanuals. ❏ Verify that theuserwillnotstoreorusecombustible liquidsormaterialsorcontaminantsinthevicinityoftheburner/appliance.




4. Disconnectthe1/4"O.D.copperoilline.5. Removethetwohousingcoverlockingscrewsandswingthehousingopen.6. Removethezip-tieholdingtheUVscannercableandairtubethermalfuse

lead.7. Partially remove the combustionheadassembly, anddisconnect the two

ignitioncablesfromtheelectrodes.8. Rotatethecombustionheadassembly90°andunscrewthescannerfrom

thesighttube.9. Disconnect thehigh temperature fuse leads,andremove thecombustion

headassemblyfromthetube.

Thermal fuse

1. Whentheburnerisinahigh-overfiredraftcondition,andnotproperlyadjusted,itispossiblethattheflamecouldflashbackinsidetheairtube.Ifthisoccurs,thethermalfusewillopeninlessthantwoseconds.Thefusemustbereplaced.(Theburnerissuppliedwithsparefuses.)

Annual start-up and service

Thisburnermustbestartedandservicedatleastannuallybyaqualifiedservicetechnician.Failuretoproperlymaintainandservicetheburnercouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.

❏ Discussburner/applianceoperationwithusertodetermineanyproblemsthatmayhaveoccurredduringthepreviousseasonandtoverifyuserisawareofproperoperationandcareoftheburner/appliance.

❏ Reviewproperoperationoftheappliance/burnerunitwiththeuser. ❏ Turnoffpowertoappliance. ❏ Removecombustionheadassemblytocleanandadjust ifnecessary.(Seeabove.)

❏ If the inside surfaceof the air tubeand/or retention ring need to becleaned,cleanthemwithavacuumcleanerwithbrushattachmentwhilethecombustionheadassemblyisoutoftheburner.

❏ ReplacetheoilnozzlewiththecorrectsizespecifiedinthismanualortheOEMguide.Seepage10fortheaccess/replacementprocedure.

❏ Inspectandadjusttheignitionelectrodesandinsulatorsperinstructionsonpage11ofthismanual.Replaceifproperspacingcannotbeachievedorifcomponentsaredamaged.

❏ Closethehousingcoverplateandsecureinplace. ❏ Inspectthefuellineoilfilter.Replaceifnecessary.

Oillinefilters—Useanon-bypassingfiltertopreventnozzlepluggingcausedbypooroilfiltration.Non-bypassingfilterspreventsmallforeignparticlesfrombypassingthefilter,acommonproblemwithfiberelement typefilters.Anotherproblemofsomefiltersisthefiberfromfilterelementtearscanbreakawayandplugthenozzleorfuelunit.

❏ Performthecompletecheckoutproceduresofpages18to23,includingsysteminspectionandchecks.

❏ Informtheuserofanyproblemsfound.

8. Maintenance and service procedures

Turnoffpowertoappliancewhenservicingburner.Afterservic-ing, always operate burner/appliance to verify all componentsarefunctioningcorrectlyandthattheburnerisproperlyadjusted.Failuretocomplycouldresultinseverepersonalinjury,deathorsubstantialpropertydamage.

General maintenance

Cleaning blower wheel1. Theblowerwheelaccumulatesdustanddebrisfromnormaloperation.You

willneedtocleanthewheelbladesperiodicallytopreventreductioninairflow.Inspecttheblowerwheelregularlybyopeningthehousingcover.

2. Tocleanblades,whennecessary,removetheboltssecuringthemotortotheblowerhousing.a. Slidethemotoroutandrotatetoremoveandaccessblowerwheel.b. Useabrushandvacuumtocleaneachbladeandtheblowerhousing

interior.c. Installmotor/wheelinblowerhousingandsecurewiththetwobolts.d. Pushwireslackbackintojunctionbox.

Replacing blower motor or wheel1. Ifeithertheblowerwheelormotormustbereplaced,removetheboltssecur-

ingthemotortohousing.2. Disconnectthemotorwiresintheburnerjunctionbox(comingfromtheEZ-

Contactor).3. LoosentheAllenscrewsecuringtheblowertothemotorshaftandremove

thewheel.4. Whenassemblingthereplacementassembly,slidethewheelontothemotor

shaftandusefeelergaugestosetspacebetweentheblowerwheelandthemotorface.Thisspacemustbe3/16inch.

5. Installthemotor/wheelassemblyinthehousing,wirethemotorleadsandsecurethemotorwiththetwobolts.

Motor maintenance• Refertomotormanufacturer’sinstructionsforoilingthemotorasneeded.

Checking ignitor

Nevertestanignitorbyplacingascrewdriver(orothermetallicobject) across the high voltage clips.This could cause ignitordamageorseverepersonalinjury.

1. Checking41000ignitorsonly:• Disconnectelectricalpowertoburner.• Opentheburneraccesscoverandremoveignitorwiresfromtheelec-

trodes.Lightlyclampeachignitorwiretotheburnerhousing,withthewireendspointedtowardoneanother,spacedapartbya½"to¾"gap.

• Carefullyenergizeignitorandcheckforsparkarcingatthehighvoltageterminals.Ifsparkjumpsthegap,ignitorisgood.

Removing the combustion head assembly1. Tochecktheelectrodesettingsorchangethenozzle,youmustremove

thecombustionheadassemblyfromtheairtube.Followthestepsbelow,andreversethesequencetoreassemble.

2. Shutofftheburner.3. Removethefourgasorificespudsfromthemanifold.




8. Maintenance and service procedures (continued)

Installation/service certificate

Installation data

Burner model Serial number Measured gas firing rate, Btuh

Oil nozzle size & pattern: Manifold gas pressure, IWC (High fire/Low fire)

Inlet gas pressure, IWC

CO2% Oil Low Fire: ______

Oil High Fire: ______

Gas Low Fire: ______

Gas High Fire: ______

O2% Oil Low Fire: Oil High Fire:

Gas Low Fire: Gas High Fire:

Nozzle pressure:

• High fire: ______ PSIG • Low fire: ______ PSIG

Fuel unit vacuum (“Hg)

• High fire: ______ InHg • Low fire: ______ InHg

Were controls tested?

Comments about installation/start-up:

Installer’s name: Company name: Company address: Phone:

Service history

Date Technician Company/address Describe work performed




9. Dimensions

Figure 19 Dimensional data, straight gas train configuration

1HoneywellR7897Cprimarycontrol(standard)

2Airtube

3Universalflange(standard)

4Carlin41000solidstateignitor

5Junctionbox

6Motor,48N-frame




Figure 20 Dimensional data, angled gas train configuration

9. Dimensions (continued)

1HoneywellR7897Cprimarycontrol(standard)

2Airtube

3Universalflange(standard)

4Carlin41000solidstateignitor

5Junctionbox

6Motor,48N-frame




10. Repair parts — Burner housing and componentsForpartsnotshownorlisted,contactfactoryand/orcheckseparatedocumentationsuppliedwithappliance/burnerunit.

Item Description Part No.1 Blower housing with cover and pressure augmentor NA2 Fuel line 752913 Safety shut-off oil valve (2-way) 408574 Safety shut-off oil valve (3-way) 410045 Fuel unit with blocking valve (energized for high fire) 23556S6 Fuel line 752917 Airflow switch 985228 Honeywell M436 damper motor 358089 Gasket 4024610 14” airtube with pressurized flange; 1” main gas inlet; 1/2” pilot inlet 9954111 14” combustion head assembly (includes thermal fuse and electrode wire) 5781012 Blower cover NA13 Electronic ignitor on baseplate 41000S0LC14 Electrical Panel Box Including:

Honeywell RM7897C 99766Subbase for RM7897C 97656Amplifier for RM7897C 97662Timing card for RM7897C 97655

16 Motor 2770617 Blower wheel 98857KIT18 Pump coupling 9885619 Retention ring assembly 56747S20 Thermal fuse 3421521 Ignition electrodes -- Left & Right 9850722 Ignition wire (One wire in service pack) 55772S23 14” nozzle line with nozzle adapter 59030S24 Honeywell C7027A UV scanner 35311




10. Repair parts (continued)

Forpartsnotshownorlisted,contactfactoryand/orcheckseparatedocumentationsuppliedwithappliance/burnerunit.

Item Description Part No.1 Blower housing with cover and pressure augmentor NA2 Fuel line 752913 Safety shut-off oil valve (2-way) 408574 Safety shut-off oil valve (3-way) 410045 Fuel unit with blocking valve (energized for high fire) 23556S6 Fuel line 752917 Airflow switch 985228 Honeywell M436 damper motor 358089 Gasket 40246

10 14” airtube with pressurized flange; 1” main gas inlet; 1/2” pilot inlet 9954111 14” combustion head assembly (includes thermal fuse and electrode wire) 5781012 Blower cover NA13 Electronic ignitor on baseplate 41000S0LC14 Electrical Panel Box Including:

Honeywell RM7897C 99766Subbase for RM7897C 97656Amplifier for RM7897C 97662Timing card for RM7897C 97655

16 Motor 2770617 Blower wheel 98857KIT18 Pump coupling 9885619 Retention ring assembly 56747S20 Thermal fuse 3421521 Ignition electrodes -- Left & Right 9850722 Ignition wire (One wire in service pack) 55772S23 14” nozzle line with nozzle adapter 59030S24 Honeywell C7027A UV scanner 35311




User care and maintenance

Referonly to the informationonthispage,intendedforyouruse.Theremainderof thismanual isintended only for your servicetechnician.Failuretocomplycouldresult in severe personal injury,deathorsubstantialpropertydam-age.

Forotherthanroutinemaintenance,contacta qualified service company.Perform thefollowingasneeded.

• Keeptheareaaroundtheburnerclearand free fromcombustible vapors andliquids.

• Donotobstructtheflowofcombustionandventilatingair.

• Mostmotorscurrentlyusedonresidentialtypeburnersusepermanently-lubricatedbearings,anddonotrequirefieldlubri-cation.Read the labelon themotor todetermine oiling needs, if any.Do notover-lubricate.Thiscancauseasmuchtroubleasnotlubricatingatall.

Neverattempttousegasolineasafuelforthisburner,asitismorecombustibleandcouldresultinaseriousexplosion.Neverattempttoburnrefuseoruseanyfuelotherthan#1or#2heatingoil(ASTMD396).

702G/O burner

Should overheating occur:

(1) Shutoffbothfuelsuppliestotheburner.

(2) DONOTshutoffthecontrolswitchtothecirculatororblower.

(3) Contact your oil dealer or servicetechnicianandthefiredepartment(ifneeded).

Theburnermustbecleaned, testedandadjusted annually by a qualified burnerservicetechnician.

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