Carlin EZ Series - User Manual

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MODEL

EZ SERIES

Oil Burners

Instruction Manual

Contents

Read this rst............................................................... 2

Application information ................................................ 3

Prepare site • Assemble burner • Mount burner .......... 4

Prepare burner ............................................................ 6

Wire burner • Start burner ........................................... 9

Adjustment and verication ......................................... 9

Annual start-up and service ....................................... 10

Maintenance procedures ........................................... 11

Repair parts ............................................................... 12

User care and maintenance .........................Rear cover

Installer/servicer — Except where specically

stated otherwise, this manual must be used

only by a qualied service technician. Failure

to comply with this or other requirements in this

manual could result in severe personal injury,

death or substantial property damage.

User — The burner Instruction Manual is in-

tended only for your service technician. The

burner and heat exchanger must be inspected

and started at least annually by your service

technician.

The National Oilheat Research Alliance (NORA)

recommends single pipe oil systems and high-

quality ltration for all fuel types. This should in-

clude at least a 10 micron Spin-on lter. Double

ltration provides even greater assurance clean

fuel will get to the pump. Contaminants in the

tank that enter the fuel supply to the burner

can cause pump sticking/seizing. These con-

taminants may increase in the early stages of

transitioning to modern fuels (Ultra Low Sulfur

and Bio Blends). High quality ltration adds

protection against pump sticking

Ratings

Input: EZ LF .....................................0.35 to 1.45 GPH

EZ 1 .......................................0.50 to 1.65 GPH

Fuels: US: No.1 or No. 2 heating oil, including bio

blends up to B20 (U.S ONLY) (ASTMD396)

Canada: No. 1 stove oil or No. 2 heating oil

(ASTM D396)

Fuel unit: Suntec A2VA-3006

Electrical: Power .................................120V/60 hz/1-phase

Motor .................. Carlin PSC, 1/6 hp, 3450 rpm

Current ...................................Approx. 2.5 amps

Ignition: Carlin Model 45000 electronic ...... 19,000 volts

Control: U.L. Group I or II primary safety control

Agencies: UL Listed (US and Canada)

126 Bailey Road • North Haven, CT 06473

Phone 203-680-9401 • Fax 203-764-1714

Tech support 800-989-2275 • carlincombustion.com

Main Page

Need help?

Do you have a question about the Carlin EZ Series and is the answer not in the manual?

Summary

Read This First

Special Attention Flags

Explains safety symbols like DANGER, WARNING, CAUTION, and NOTICE used throughout the manual.

Installer;Service Technician

Instructions for qualified technicians regarding installation and initial setup.

Application Information

Codes and Standards

Details UL listing, ANSI compliance, and installation codes for US and Canada.

Prepare Site • Assemble Burner • Mount Burner

Inspect;Repair;Replace Vent System

Ensures the vent system is in good condition and complies with all applicable codes for safe operation.

Combustion;Ventilation Air Openings

Details requirements for air openings for safe and efficient burner operation.

Prepare Site • Assemble Burner • Mount Burner (continued)

Prepare Burner

Removing;Installing Head Assembly

Detailed steps for removing and installing the combustion head assembly for maintenance.

Install Nozzle;Check Electrodes

Instructions for installing the oil nozzle and checking electrode settings for proper ignition.

Prepare Burner (continued)

Inspect;Install Fuel Supply

Guides on inspecting and installing the fuel supply system for safe and reliable operation.

Adjust Air Band (Initial Setting)

Perform Checkout Procedures

Lists essential checks before starting the burner for the first time.

Verify Before Starting Burner

Crucial checks to ensure the burner and installation are ready for initial startup.

Wire Burner • Start Burner

Adjustment and Verification

Covers the process of adjusting and verifying the burner's performance and safety.

Perform Combustion Test

Detailed steps for conducting a combustion test using appropriate instruments.

Adjust Burner Using Test Instruments

Adjustment and Verification (continued)

Verify Burner;Appliance Operation

Checks burner and appliance controls, primary control, and overall operation.

Check Burner;Appliance;Controls Operation

Verify Vent System Operation

Confirms the vent system is operating correctly and exhausting flue products safely.

Maintenance Procedures

Maintenance;Service Procedures

General safety warning for all maintenance and service procedures.

EZ Series Oil Burner User Care and Maintenance

Do Not Obstruct the Flow of Combustion

The Carlin EZ Series Oil Burner is a combustion device designed for residential heating applications, utilizing No. 1 or No. 2 heating oil, including bio blends up to B20 in the U.S., and No. 1 stove oil or No. 2 heating oil in Canada (ASTM D396). It is UL Listed for both the US and Canada, and certified to comply with ANSI/UL 296. The burner is intended for use by qualified service technicians for installation, adjustment, and maintenance, with specific user care instructions provided for safe operation.

Function Description:

The Carlin EZ Series Oil Burner is designed to efficiently burn heating oil to produce heat for residential appliances such as boilers and furnaces. It integrates a fuel unit, motor, ignitor, and primary safety control to ensure reliable and safe operation. The burner's design allows for precise control over combustion air and fuel delivery, enabling optimal combustion performance. It is equipped with an electronic ignitor for reliable ignition and a PSC motor for consistent airflow. The burner can be configured for either one-line or two-line oil systems, with a bypass plug provided for two-line setups. An optional burner cover with an air intake adapter allows for piped combustion air, which can improve efficiency and reduce the impact of room air variations.

Important Technical Specifications:

Input:
- EZ LF: 0.35 to 1.45 GPH (Gallons Per Hour)
- EZ1: 0.50 to 1.65 GPH
Fuels:
- US: No.1 or No. 2 heating oil, including bio blends up to B20 (U.S ONLY) (ASTMD396)
- Canada: No. 1 stove oil or No. 2 heating oil (ASTM D396)
Fuel unit: Suntec A2VA-3006, a single-stage, 3450-RPM oil pump.
Electrical:
- Power: 120V/60 Hz/1-PHASE
- Motor: Carlin PSC, 1/6 HP, 3450 RPM
- Current: Approx. 2.5 AMPS
Ignition: Carlin Model 45000 electronic, 19,000 VOLTS
Control: U.L. Group I or II primary safety control
Air Tube: Available with welded flange for specific appliances.
Electrodes: Set of 2, 7" nominal, approx. 8-1/2" oal.
Nozzle Line/Adaptor Assembly: 7" nominal, approx. 8-3/4" oal.
Blower Wheel: 5-1/16d x 2w.
Combustion Head Assembly: 7".

Usage Features:

Adjustable Air Band and Head Position: The burner features an adjustable air band and head position to optimize combustion for various firing rates and appliance types. These adjustments are critical for achieving desired combustion results, including CO2/O2 levels and smoke readings.
Optional Burner Cover with Air Intake Adapter: For installations where combustion air is piped from outside, an optional burner cover with an air intake adapter can be used. This feature helps maintain consistent combustion air temperature and quality, which is important for stable combustion.
Compatibility with Bio Blends: The burner is designed to operate with bio blends up to B20 in the U.S., reflecting modern fuel trends and environmental considerations.
Safety Controls: Equipped with a U.L. Group I or II primary safety control, the burner ensures safe operation by monitoring flame presence and shutting down in case of ignition failure or other unsafe conditions.
Installation Flexibility: The burner can be installed on the appliance or shipped separately, with nozzles either pre-installed, bagged, or tied to the chassis, or located in the appliance packaging. OEM burners have welded flanges for correct insertion depth and pitch.
Combustion Air Requirements: Detailed guidelines are provided for combustion and ventilation air openings, distinguishing between unconfined and confined spaces, and specifying requirements for air taken from inside or outside the building. This ensures adequate airflow for both combustion and cooling of the appliance and controls.

Maintenance Features:

Annual Service Requirement: The burner must be cleaned, tested, and adjusted annually by a qualified oil burner service technician to ensure proper and safe operation.
Easy Access for Maintenance: The combustion head assembly can be easily removed for inspection, nozzle replacement, and electrode adjustment. The ignitor plate can be swung open, and the oil line fitting can be unscrewed to facilitate access.
Blower Wheel Cleaning: The blower wheel accumulates dust and debris, which can reduce airflow. Instructions are provided for inspecting and cleaning the blower wheel by removing the access cover and, if necessary, the motor.
Electrode Inspection and Adjustment: The ignition electrodes and insulators require periodic inspection and adjustment to ensure reliable ignition. Specific settings for electrode placement are provided.
Fuel Filter Replacement: Regular inspection and replacement of the fuel line oil filter are recommended to prevent contaminants from reaching the fuel unit, which can cause pump sticking/seizing. NORA recommends high-quality filtration, including at least a 10 micron Spin-on filter, and double filtration for greater assurance.
Motor Maintenance: The Carlin PSC motor uses permanently-lubricated bearings and typically requires no oiling. However, if a different motor type is used, oiling instructions should be followed as per the manufacturer's recommendations.
Ceramic Fiber Handling Precautions: The manual includes warnings and precautions for handling ceramic fiber materials, which may be present in the appliance, due to potential health hazards. These include wearing protective gear, wetting materials, and proper disposal.
Combustion Test Verification: After any service or adjustment, a complete combustion test using instruments is required to verify that the burner operates correctly and safely, ensuring optimal CO2/O2 levels and zero smoke. This includes re-checking combustion with the burner cover in place if applicable.