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EZ-Temp ™ Microprocessor Temperature Control Guide TABLE OF CONTENTS Model 90000 Dual Limit Manual Reset for Direct Fired Storage Water Heaters 2-3 Model 90000CE Combination Operating Limit Manual Reset High Limit for Commercial Boilers 2-3 Model 90100 Averaging Limit Manual Reset for Commercial Direct Fired Storage Water Heaters 4-5 Model 90200 Single Limit for Direct or Indirect Fired Storage Water Heaters, or Single Limit Manual Reset for Hot Water Boilers, or Operating Limit for Commercial Boilers 6-7 Model 90200E Manual Reset High Limit for Commercial Boilers 8-9 Model 90200H Proportional Modulating Control for Commercial Boilers 10-11 Model 90200H Proportional Modulating Control for Commercial Boilers Instruction Manual 12-15 EZ-Temp™ Temperature Controls - Model 90224 Low Voltage Single Limit for Indirect Fired Storage Water Heaters 16-17 Model 90300 Dual Limit Manual Reset for Commercial Direct Fired Storage Water Heaters 18-19 Model 90320 240 VAC Dual Limit for Direct Fired Storage Water Heaters 20-21 Model 90524A Triple Limit or Cold Start for Hot Water Boilers 22-23 Model 90524A Instruction Manual 24-31 Model 99000A Operating Limit Manual Reset High Limit Commercial Boiler Package 32-33 Model 99000B Operating Limit Manual Reset High Limit for Lo-Hi-Lo Mode of Operation Commercial Boiler Package 34-35 Model 99000C Operating Limit Manual Reset High Limit for Lo-Hi-Lo Mode of Operation Commercial Boiler Package 36-37 Model 99000D Operating Limit Manual Reset High Limit and Proportional Control for Full Modulation Mode of Operation for Commercial Boilers 38-39 Model 99000E Operating Limit Manual Reset High Limit and Proportional Control for Full Modulation Mode of Operation for Commercial Boilers 40-41 EZ-Temp Instruction Manual for Older Style E-clamp with Red Sensor Retainer Plug 42-43 EZ-Temp Instruction Manual for Well Clamp with Sensor Retainer Spring 44-45 Thermister Resistance Chart for EZ-Temp Sensors 46-47 70 Maple Street, East Longmeadow, MA 01028 Telephone: 413-525-7700 1 2 Data sheet Specifications s #ARLINS-ODELMICROPROCESSOROPERATEDMULTIPLECONTACTTEMperature limit controls are available in four configurations, described below. Each model provides two contacts — one for operating limit and one from high limit. s 2EFERTOSEPARATEPRODUCTLISTINGSHEETSFORPREDElNEDMODELSORREquest a control to meet your specifications, within the available ranges listed below. Multiple sensor option (1 or 2) 90000A 90000AL Dual limit temperature control 7.$/ 1(,& ,#'(&'*(+(1 "1(-, 7+ /1+ ,2 */$0$1-,'(&'*(+(1 7$*$"1/-,("0$,0-/0-.$/ 1(,& ,#'(&'*(+(1 7,#$.$,# ,1-.$/ 1(,&*(+(1"-,1 "1 7,#$.$,#$,1'(&'*(+(1"-,1 "1 90000B 90000BL Temperature limit control 7.$/ 1(,& ,#'(&'*(+(1 "1(-, 7+ /1+ ,2 */$0$1-,'(&'*(+(1 7$*$"1/-,("0$,0-/ 7.$/ 1(,& ,#*(+(1"-,1 "10(,0$/($0 90000C 90000CL Redundant limit temperature control 7.$/ 1(,& ,#'(&'*(+(1 "1(-, 7+ /1+ ,2 */$0$1-,'(&'*(+(1 7$*$"1/-,("0$,0-/0-.$/ 1(,& ,#'(&'*(+(1 7.$/ 1(,& ,#*(+(1"-,1 "10(,0$/($0 (Using individual and/or dual sensor assemblies) Easy remote sense 90000CE 90000CEL (Electronic sensors, wired to control) Smart manual reset (Manual reset only if operating limit doesn’t open) Control model Serviceman reset protection Contacts (1) Power-independent lockout Wires Diagnostic LED’s (Power, call for heat, and lockout/latchup) (2) Latch-up mode shuts down the control after three consecutive lockouts, and requires a special procedure to reset. This ensures the owner will call in a licensed technician to troubleshoot and correct burner problems. The 90000 provides two limit relays. Carlin’s patented SMC technology (Safety Monitoring Circuit) monitors the contacts of both relays. Lockout occurs if a limit relay contact is found closed when it should be open. 2***- # -")$#/-1-/ 2 ,1(15 C/CL (,0$/($0 VAC VAC /$#4'(1$4'(1$ (&'*(+(1INOUT !* ")/$# !* ")5$**-4 .$/*(+(1INOUT !* ")&/$$, !* ") black (+(10OUT ,5/ ,&$!$14$$, 81- 8 Adjustable oper. limit range Fixed high limit temperature CE/CEL VACVA VAC-1$21/ * (Power cycling won’t reset from lockout or latch-up) (1) B/BL (,#$.$,#$,1 Contact rating SMC Technology A/AL Control power input /$#4'(1$4(/$ (Latch-up after three consecutive lockouts ) (2) Combination operating limit and manual reset high limit control 7,#$.$,#$,1-.$/ 1(,& ,#'(&'*(+(1"-,1 "10(,0$/($0 7$*$"1/-,("0$,0-/0-.$/ 1(,& ,#'(&'*(+(1 7-")-21-,#( &,-01("% (*2/$ ,#*(+(1 "1(-, 7 ,2 */$0$1%/-+*-")-21 7(&'*(+(11$01%2,"1(-, ,53 *2$%/-+ 81- 8 ,53 *2$%/-+ 81- 8 Fixed differential (subtractive) ,53 *2$%/-+81- 8 Operating temperature limits 81- 8 Storage temperature limits Agencies TECH SUPPORT 800-989-2275 6 81-8 Recognized & Listed ,(1$#1 1$0 , # carlincombustion.com 3 Model 90000 Microprocessor Temperature Controls — Data sheet — Operation & Dimensions Model 90000A, B, C, & CE diagnostic LED’s GREEN – OFF – ON Power RED – OFF – ON Lockout – FLASHING (Slow) Latch-up AMBER – OFF – ON Control call for heat – FLASHING (Fast) Hi-Test Electrical shock hazard: Disconnect power to appliance when wiring or servicing any electrical component. Operation Power OFF (See wiring diagrams below for wiring connections.) Configurations With no power applied to the red-white wire, all lights are off. Power can be wired directly from appliance 120 VAC terminal to maintain power at all times. Or jumper red-white wire and black-green wire to cycle power with the appliance limit circuit. s Control kits — 90000 controls mount to a standard 4x4 J-box, supplied with the control. Mount the box directly to a well (new or existing) with hardware supplied, or panel mount. See below for dimensions. s Well kits — Wells for 90000 sensors are available in the sizes shown below. Well kits include sensor mounting hardware designed to hold sensor securely in position. s Sensors — Sensors are available in single and dual configurations. s Notice: UL-Listed control — UL-Listed controls are supplied complete with control, J-Box, well, sensor, and mounting hardware. Power ON When power is applied to the red-white wire, the green LED turns on. Self-test When power is applied, the 90000 performs a self-test, checking sensor(s) and microprocessor and verifying limit contacts are open. The power-up test lasts from 3 to 5 seconds. The 90000 continues diagnostic checing during the operating cycle as well. Any self-check failure causes a lockout (see below). Operate If the temperature at the operating sensor(s) is below setpoint by at least the fixed differential, the control closes the operating limit contacts. The amber LED turns on. Stand-by When the operating sensor(s) see setpoint temperature or above, the 90000 opens the operating limit contact. The amber LED turns off. Limit action 90000A, B or C: If the high limit sensor(s) see a temperature above high limit setting, the control opens the high limit contacts, turns on the red LED and checks the operating limit contacts. If the operating limit contacts are open, the control will automatically reset when temperature drops below high limit setting minus differential. The high limit contacts close and the red LED turns off. Diagnostic failures invoke “limit action” until cause is cleared. Lockout If the high limit sensor(s) sees a temperature above high limit setting and the 90000A, B, or C model finds the operating limit contacts closed, the high limit contact opens, the red LED turns on and lockout occurs. If the high limit sensor on the 90000CE sees a temperature above the high limit setting, the high limit contact opens, the red LED turns on and lockout occurs. When the temperature drops below high limit setting minus differential, reset the control by pressing the manual reset button. The control will not reset by cycling power off and on. Latch-up )F THE LOCKS OUT THREE CONSECUTIVE TIMES IT ENTERS LATCHUP 2ESET from latch-up requires a special procedure, intended to require licensed serviceman intervention. During latch-up, the red LED stays on and the GREEN,%$mASHESSLOW2ESETASFOLLOWS ............ Hold reset button at least 10 seconds. The green LED flashes faster. ............ Continue holding button another 20 seconds. The control resets and the red LED turns off. ............ h(I4ESTvMODE#%/.,9USEDTOTESTh(IGH,IMIT2ESETvATOPERATING boiler temperature. Start test with system operational and calling for heat. Turn setpoint full clockwise to Hi-Test position. Green LED flashes fast. The setpoint now adjusts both the high and operating limits. Turn setpoint slowly counter clockwise until Lockout occurs. Now the setpoint temperature equals the hi-limit sensor temperature. Test is complete, adjust setpoint to THEDESIREDOPERATINGLIMIT2EMOVEFROMLOCKOUT Temperature is less than high limit setting minus differential: Power must flow through the contacts in the direction shown. Changing flow direction will cause the control to lockout or fail to operate. 90000A G G 90000B, C, CE N White Wiring shown cycles power with appliance limit circuit. To maintain constant power on 90000A, connect direct to red/white wire from appliance 120 vac. 120 VAC 120 VAC CONNECTIONS AT APPLIANCE POWER TO APPLIANCE Red/White Service switch H G G N White Red/White 120 VAC 120 VAC CONNECTIONS AT APPLIANCE POWER TO APPLIANCE Service switch HIGH LIMT H Black-red HIGH LIMIT Black-yellow High limit OUT Operating Limit IN Black-green OPERATING LIMIT Black High limit Limit sensor OPERATING LIMIT Black Sensor Dual limit OUT To sensor (90000C and 90000CE use 2 sensors connected the same as the 90000A) Operating limit OUT To high limit sensor To operating limit sensor © Copyright 2010 — Carlin Combustion Technology, Inc. Carlin part number MN90000C Rev. 01/26/10 4 Data sheet Specifications • • Carlin’s 90100 microprocessor-operated, multiple-contact temperature limit controls are available in three configurations, described below. Each model provides two contacts — one for operating limit and one from high limit. Refer to separate product listing sheets for pre-defined models, or request a control to meet your specifications, within the available ranges listed below. Multiple sensors (2 or 3) (Using individual and/or dual sensor assemblies) Sensor averaging (Average operating limit, high limit or both) Easy remote sense (Electronic sensors, wired to control) Smart manual reset (Manual reset only if operating limit doesn’t open) Serviceman reset protection (Latch-up after three consecutive lockouts (1)) Power-independent lockout (Power cycling won’t reset from lockout or latch-up) Diagnostic LED’s (Power, call for heat, and lockout/latchup) SMC Technology (2) (1) Latch-up mode shuts down the control after three consecutive lockouts, and requires a special procedure to reset. This ensures the owner will call in a licensed technician to troubleshoot and correct burner problems. (2) The 90100 provides two limit relays. Carlin’s patented SMC technology (Safety Monitoring Circuit) monitors the contacts of both relays. Lockout occurs if a limit relay contact is found closed when it should be open. TECH SUPPORT 800-989-2275 carlincombustion.com 5 Model 90100 Microprocessor Temperature Controls — Data sheet — Operation & Dimensions Model 90100 diagnostic LED’s Configurations GREEN – OFF – ON Power • RED – OFF – ON Lockout AMBER – OFF – ON Control call for heat – FLASHING Latch-up • Electrical shock hazard: Disconnect power to appliance when wiring or servicing any electrical component. Operation (See wiring diagrams below for wiring connections.) Power OFF With no power applied to the red-white wire, all lights are off. Power can be wired directly from appliance 120 VAC terminal to maintain power at all times. Or jumper red-white wire and black-green wire to cycle power with the appliance limit circuit. Power ON When power is applied to the red-white wire, the green LED turns on. Self-test When power is applied, the 90100 performs a self-test, checking sensor(s) and microprocessor and verifying limit contacts are open. The power-up test lasts from 3 to 5 seconds. The 90100 continues diagnostic checking during the operating cycle as well. Any self-check failure causes a lockout (see below). Operate If the temperature at the operating sensor(s) is below setpoint by at least the fixed differential, the control closes the operating limit contacts. The amber LED turns on. Stand-by When the operating sensor(s) see setpoint temperature or above, the 90100 opens the operating limit contact. The amber LED turns off. Limit action If the high limit sensor(s) see a temperature above high limit setting, the 90100 opens the high limit contacts, turns on the red LED and checks the operating limit contacts. If the operating limit contacts are open, the control will automatically reset when temperature drops below high limit setting minus differential. The high limit contacts close and the red LED turns off. Lockout If the high limit sensor(s) sees a temperature above high limit setting and the 90100 finds the operating limit contacts closed, the red LED turns on and lockout occurs. (Lockout also occurs on any diagnostic test failure.) When the temperature drops below high limit setting minus differential, reset the control by pressing the manual reset button. The control will not reset by cycling power off and on. Latch-up If the 90100 locks out three consecutive times, it enters latch-up. Reset from latch-up requires a special procedure, intended to require licensed serviceman intervention. During latch-up, the red LED stays on and the green LED flashes. Reset as follows: ............ Temperature must be less than high limit setting minus differential. ............ Hold reset button at least 10 seconds. The green LED flashes faster. ............ Continue holding button another 20 seconds. The control resets and the red LED turns off. • Control kits — 90100 controls mount to a standard 4x4 J-box, supplied with the control. Mount the box directly to a well (new or existing) with hardware supplied, or panel mount. See below for dimensions. Well kits — Wells for 90100 sensors are available in the sizes shown below. Well kits include sensor mounting hardware designed to hold sensor securely in position. Sensors — Sensors are available in single and dual configurations. Power must flow through the contacts in the direction shown. Changing flow direction will cause the control to lockout or fail to operate. © Copyright 2005 — Carlin Combustion Technology, Inc. Carlin part number MN90100C Rev. 01/31/05 6 Data sheet Specifications s #ARLINS -ODEL !, ", $, AND ', MICROPROCESSOROPERATED TEMPERATURECONTROLSARE5,,ISTEDANDPROVIDEDASACOMPLETEPACK AGECONSISTINGOFCONTROL*BOXSENSORANDWELL-ODEL! " $ OR ' CONTROLS ARE 5, 2ECOGNIZED AND PROVIDED AS INDIVIDUAL COMPONENTSWITH*BOXSENSORANDWELLAVAILABLESEPARATELY s #ARLINSMODELMICROPROCESSOROPERATEDTEMPERATURECONTROLS ARE AVAILABLE IN FOUR CONlGURATIONS DESCRIBED BELOW %ACH MODEL PROVIDESONELIMITDUTYRATEDCONTACT s 2EFERTOSEPARATEPRODUCTLISITNGSHEETSFORPREDElNEDMODELSOR REQUEST A CONTROL TO MEET YOUR SPECIlCATIONS WITHIN THE AVAILABLE RANGESLISTEDBELOW Microprocessor-operated 90200AL Temperature limit control 7 !/$ )-,/(0$"-,1 "1 7 $*$"1/-,("0$,0-/ 7*-")-21-,#( &,-01("% (*2/$ 7/$0$1%/-+*-")-213( .-4$/"5"*$ 90200BL Temperature limit control 7 + )$-,/(0$"-,1 "1 7 $*$"1/-,("0$,0-/ 7*-")-21-,#( &,-01("% (*2/$ 7/$0$1%/-+*-")-213( .-4$/"5"*$ 90200DL Temperature limit control 7"-,1 "10 !/$ ) + )$-,/(0$ 7 $*$"1/-,("0$,0-/ 7*-")-21-,#( &,-01("% (*2/$ 7/$0$1%/-+*-")-213( .-4$/"5"*$ 90200GL Temperature limit control 7 !/$ )-,/(0$(0-* 1$#"-,1 "1 7 $*$"1/-,("0$,0-/ 7*-")-21-,#( &,-01("% (*2/$ 7/$0$1%/-+*-")-213( .-4$/"5"*$ (Processor coordinates limit and diagnostic functions) Easy remote sense (Electronic sensor, wired to control) Control model AL Contacts Select from break-on-rise, make-on-rise or SPDT operation "1(-,-,1$+.$/ 12/$/(0$ Contact rating Wires !/$ )0 + )$0 2***- # -")$#/-1-/ 2 ,1(15 (Control locks out on diagnostic failure) Diagnostic/status LED’s !* ") )$-,/(0$OUT NA (LED’s indicate power, call for heat, and lockout) Fixed differential (subtractive) !/$ )0 + )$0 NA !* ") !*)4'(1$ !*)4'(1$ !* ") &/$$, !* ") ,5/ ,&$!$14$$,81-8 ,53 *2$%/-+81- 8 81- 8 Storage temperature limits 681- 8 TECH SUPPORT 800-989-2275 !/$ )0 Operating temperature limits Agencies GL /$#4'(1$4'(1$ /$ )-,/(0$OUT Adjustable oper. limit range DL VAC VAC VACH(+(1INN Self-checking program BL VAC VA Control power input /$#4'(1$4(/$ Recognized & Listed "-+.-,$,1,(1$#1 1$0 , # carlincombustion.com 7 Model 90200 Microprocessor Temperature Controls — Data sheet — Operation & Dimensions Model 90200 diagnostic LED’s nOFF nON Power on Center AMBER nOFF nON Call for low fire (90200GL only) Right AMBER nOFF nON Control call for heat or high fire GREEN nFLASHING Lockout s Electrical shock hazard:$ISCONNECTPOWERTOAPPLIANCEWHENWIRINGOR SERVICINGANYELECTRICALCOMPONENT Operation s s 3EEWIRINGDIAGRAMSBELOWFORWIRINGCONNECTIONS Indicator LED’s Configurations 90200CONTROLSHAVEAGREEN,%$POWERLOCKOUTINDICATOR AND CENTER AMBER ,%$ ,OW &IRE INDICATOR ONLY PRESENT ON ', RIGHT AMBER ,%$ OPERATION OR (IGH &IRE INDICATOR Power OFF 7ITHNOPOWERAPPLIEDTOTHEREDWHITEWIREALLLIGHTSARE OFF Power ON 7HENPOWERISAPPLIEDTOTHEREDWHITEWIRETHEGREENAND CENTERAMBER,%$SONLYPRESENTON',TURNON Self-test 7HEN POWER IS APPLIED THE PERFORMS A SELFTEST CHECKING THE SENSOR AND MICROPROCESSOR 4HE POWERUP TESTLASTSFROMTOSECONDS 4HECONTINUESDIAGNOSTICCHECKINGDURINGTHEOPERAT INGCYCLEASWELL!NYSELFCHECKFAILURECAUSESALOCKOUT SEEBELOW Call for heat 7HENTHETEMPERATUREATTHEOPERATINGSENSORISATORBELOW or high fire SETPOINTMINUSlXEDDIFFERENTIALTHECONTROLPOWERSTHELIMIT RELAYBREAKONRISECONTACTCLOSESMAKEONRISECONTACT OPENS4HECENTERAMBER,%$IFPRESENTTURNSOFFTHE RIGHTAMBER,%$TURNSON Stand-by 7HENTHEOPERATINGSENSORREACHESSETPOINTTEMPERATUREOR or low fire ABOVETHETURNSOFFTHERELAYBREAKONRISECONTACT OPENSMAKEONRISECONTACTCLOSES4HECENTERAMBER,%$ IFPRESENTTURNSONANDTHERIGHTAMBER,%$TURNSOFF Lockout )FTHECONTROLDETECTSADIAGNOSTICFAILURElockout OCCURS $URINGLOCKOUTTHEGREEN,%$mASHES !FTERTHETEMPERATUREDROPSBELOWHIGHLIMITSETTINGMINUS DIFFERENTIALRESETTHECONTROLBYTURNINGPOWEROFFTHENBACK ON4HEGREEN,%$WILLSTOPmASHING s Mounting !, ", $, AND ', CONTROLS MOUNT TO A STANDARD X *BOX SUPPLIED WITH THE CONTROL -OUNT THE BOX DIRECTLY TO A WELL NEW OR EXISTING WITH HARDWARE SUPPLIED OR PANELMOUNT3EEBELOWFORDIMENSIONS Well kits 7ELLSFOR!,",$,AND',SENSORSAREAVAIL ABLEINTHESIZESSHOWNBELOW7ELLKITSINCLUDESENSORMOUNTING HARDWAREDESIGNEDTOHOLDSENSORSECURELYINPOSITION Sensors 3ENSORSAREAVAILABLESEPARATELYFOR!"$AND 'ONLY4HESENSORISSUPPLIEDWITH!,",$,AND', NOTICE 5,,ISTEDMODEL!,",$,',CONTROLSMUST BE SHIPPED COMPLETE WITH A SENSOR WELL AND *BOX /NLY 5, RECOGNIZEDCOMPONENTMODELS!"$AND'CONTROLSCAN BEPURCHASEDASINDIVIDUALCOMPONENTS 0OWERMUSTmOWTHROUGHTHECONTACTSINTHEDIRECTIONSHOWN#HANGING mOWDIRECTIONWILLCAUSETHECONTROLTOLOCKOUTORFAILTOOPERATE 90200AL or BL G G N White 120 VAC 120 VAC CONNECTIONS AT APPLIANCE POWER TO APPLIANCE Red/White Service switch H Limit contact: Model A breaks on temperature rise; Model B makes on temperature rise Limit OUT Black Sensor To sensor 90200DL G G 90200GL G N White N White 120 VAC 120 VAC CONNECTIONS AT APPLIANCE POWER TO APPLIANCE Limit OUT Black Service switch BREAK ON TEMP RISE Red/White H 120 VAC 120 VAC CONNECTIONS AT APPLIANCE POWER TO APPLIANCE Red/White Service switch Black/Green MAKE ON TEMP RISE Control contact — Breaks on temperature rise Make-on-rise contact OUT Black-white Low-fire control to burner Black Sensor G To sensor © Copyright 2008 — Carlin Combustion Technology, Inc. Sensor To sensor Carlin part number MN90200C Rev. 10/30/08 H 8 Manual Reset High Limit Data sheet Specifications s s s -ODEL%,CONTROLIS5,LISTEDANDPROVIDEDASACOMPLETEPACKAGE CONSISTINGOFCONTROL*BOXSENSORANDWELL-ODEL%CONTROL IS5,RECOGNIZEDANDPROVIDEDASINDIVIDUALCOMPONENTSWITH*BOX SENSORANDWELLAVAILABLESEPARATELY #ARLINS-ODEL%AND%,MICROPROCESSOROPERATEDTEM PERATURE CONTROLS ARE DESCRIBED BELOW 4HE % AND %, PROVIDEASINGLECONTACTBREAKONRISEWITHMANUALRESET 2EFER TO SEPARATE PRODUCT LISTING SHEETS FOR PREDElNED MODELS OR REQUEST A CONTROL TO MEET YOUR SPECIlCATIONS WITHIN THE AVAILABLE RANGESLISTEDBELOW Microprocessor-operated (Processor coordinates limit and diagnostic functions) 90200E 90200EL Temperature limit control 5-"'+*-&." +*/ / 5(+ '+0/+*!&$*+./& #&(0-"(&)&/ /&+* 5)*0(-"."/#-+)(+ '+0/ 5*+-"."/#-+),+2"-&*/"--0,/&+* Easy remote sense Control model (Electronic sensor, wired to control) Control power input -"!2%&/"2&-" VACVA Contacts -"'+*-&." Contact rating Break-on-rise operation Wires 90200E & 90200EL 0(((+! + '"!-+/+- 0*/&/3 VAC"0/-( VACHOT&)&/IN Self-checking program (Control locks out on diagnostic failure) Diagnostic/status LED’s &)&/OUT Adjustable limit range VACAMPS VACAMPS 3 2%&/" -"!2%&/" ( ' *3-*$""/2""*6/+ 6 Fixed differential (subtractive) *31(0"#-+)6/+6 Operating temperature limits 6/+6 Storage temperature limits Agencies (LED’s indicate power and lockout) TECH SUPPORT 800-989-2275 46/+6 Recognized & Listed +),+*"*/*&/"!//".*! carlincombustion.com 9 Model 90200E/EL Microprocessor Temperature Controls — Data sheet — Operation & Dimensions Model 90200E/EL diagnostic LED’s GREEN nOFF nON Power on RED nOFF nON Lockout nFLASHING Lockout pending Electrical shock hazard:$ISCONNECTPOWERTOAPPLIANCEWHENWIRINGOR SERVICINGANYELECTRICALCOMPONENT Operation s s s 3EEWIRINGDIAGRAMSBELOWFORWIRINGCONNECTIONS Indicator LED’s Configuration 90200EAND90200ELCONTROLSHAVEAGREEN,%$POWERLOCKOUT PENDINGINDICATORANDRED,%$LOCKOUT Power OFF 7ITHNOPOWERAPPLIEDTOTHEREDWHITEWIREALLLIGHTSAREOFF Power ON 7HEN POWER IS APPLIED TO THE REDWHITE WIRE THE GREEN ,%$ TURNSON Self-test 7HENPOWERISAPPLIEDTHE%%,PERFORMSASELFTEST CHECKING THE SENSOR AND MICROPROCESSOR 4HE POWERUP TEST LASTSFROMTOSECONDS 4HE %%, CONTINUES DIAGNOSTIC CHECKING DURING THE OPERATINGCYCLEASWELL!NYSELFCHECKFAILURECAUSESALOCKOUT SEEBELOW Call for heat 7HENTHETEMPERATUREATTHEOPERATINGSENSORISBELOWSETPOINT MINUSlXEDDIFFERENTIALTHECONTROLPOWERSTHELIMITRELAYTHE BREAKONRISECONTACTCLOSES Lockout pending )FADIAGNOSTICFAILUREOCCURSORTHESENOSRTEMPERATURERISES ABOVETHELIMITSETTINGTHEGREEN,%$WILLmASHFORSECONDS )FTHECONDITIONSTILLEXISTSAFTERSECONDSTHECONTROLWILLENTER LOCKOUT)FTHECONDITIONCORRECTSBEFORESECONDSTHEGREEN ,%$WILLRETURNTONORMAL Lockout $URINGLOCKOUTTHEGREEN,%$STOPSmASHINGANDSTAYSONAND THERED,%$TURNSON !FTERTHETEMPERATUREDROPSBELOWHIGHLIMITSETTINGMINUSDIF FERENTIALRESETTHECONTROLBYPRESSINGTHERESETBUTTON s Mounting %%,CONTROLSMOUNTTOASTANDARDX*BOX SUPPLIEDWITHTHECONTROL-OUNTTHEBOXDIRECTLYTOTHEWELLWITH HARDWARESUPPLIEDORPANELMOUNT3EEBELOWFORDIMENSIONS Well kits 7ELLS FOR %%, SENSORS ARE AVAILABLE IN THE SIZESSHOWNBELOW7ELLKITSINCLUDESENSORMOUNTINGHARDWARE DESIGNEDTOHOLDSENSORSECURELYINPOSITION Sensors 3ENSORSAREAVAILABLESEPARATELYFOR%ONLY4HE SENSORISSUPPLIEDWITH%, NOTICE 5,LISTED-ODEL%,CONTROLSMUSTBESHIPPED COMPLETE WITH A SENSOR WELL AND *BOX /NLY 5, RECOGNIZED COMPONENT-ODEL%CONTROLSCANBEPURCHASEDASINDIVIDUAL COMPONENTS 0OWERMUSTmOWTHROUGHTHECONTACTSINTHEDIRECTIONSHOWN#HANGING mOWDIRECTIONWILLCAUSETHECONTROLTOFAILTOOPERATE © Copyright 2008 — Carlin Combustion Technology, Inc. Carlin part number MN90200EC Rev. 08/1/08 10 Data sheet Features s s s s s s s %LECTRONICSENSORINPUT operating temperatureADJUSTMENT lXEDtemperature differential modulating bandADJUSTMENT ,OCKOUTONDIAGNOSTICFAILURE ,ATCHUPONHARDWAREFAILURE )SOLATEDPROPORTIONALOHMMODULATINGCONTROLOUTPUT (ONWIRESIN*BOX (4ONTERMINALSONFRONTOFCONTROL Specifications s #ARLINS -ODEL ( MICROPROCESSOR OPERATED TEMPERATURE CONTROL ISDESIGNEDTOOPERATEOHMMODULATEDDEVICESREPLICATINGOLDER SLIDEWIREDEVICESANDISAVAILABLEINCONlGURATIONSDESCRIBEDBELOW .OTETHAT((4CONTROLSREQUIREAVOLTPOWERINPUT4HE OHMCIRCUITISISOLATED s &ORELECTRONICMODMOTORCONTROLSYSTEMSSUCHAS3IEMENS31CONSULT MANUFACTURER s 2EFERTOSEPARATEPRODUCTLISTINGSHEETSFORPREDElNEDMODELSORRE QUESTACONTROLTOMEETYOURSPECIlCATIONSWITHINTHEAVAILABLERANGES LISTEDBELOW Model 90200H Input power (L1-L2) (SHOWN(4ALSOAVAILABLEWITH TERMINALSTRIPONFRONTFORLOWVOLTAGECONNECTIONS 135-ohm proportional output Modulating output Control Max drive Balance circuit Connections: (For regulating 135-ohm modulating devices) 120 VAC H/N Microprocessor-operated To “W” on device To “R” on device To “B” on device 90200HT 120 VAC, 2 VA 3.5 +/- 0.5 VDC, 4.2 +/- 0.2 mA 20 VDC O.C., 6 mA S. C. Adjustment on rear of control 5 wires (no terminals) 2 wires (120 VAC) 3 terminals (mod) Red/White & White wires Yellow/White wire Yellow/Red wire Yellow/Black wire “White” terminal “Red” terminal “Black” terminal (Processor coordinates operation and diagnostic) Operating temp. range Adjustable (any range between 40°F and 250°F) Easy remote sense Temp. differential range Fixed (any value between 1°F and 10°F) (Electronic sensor, wired to control) Self-checking program (Control locks out on diagnostic failure) Diagnostic/status LED’s (LED’s indicate power, call for heat, and lockout) Modulating band range Adjustable (Any range between 10°F and 100°F) Ambient temp. limits +32°F to +140°F (0°C to +60°C) Storage temp. limits -40°F to +185°F (-40°C to +85°C) Agencies UL & ULC Recognized & Listed Component US and Canada TECH SUPPORT 800-989-2275 carlincombustion.com 11 Model 90200H/HT Microprocessor Temperature Controls — Data sheet Model 90200H/HT diagnostic LED’s 90200H/HTCONTROLSHAVEAGREEN,%$POWERFAULTINDICATORANDAMBER,%$lRINGRATE PERCENTFAULTINDICATOR3EE,%$CONDITIONSBELOW GREEN Figure 1 Wiring connections 90200H n/.Indicates control is oprational) White nShort on/Long off flash nLong on/Short off flash Yellow/White nFLASH uniformly ABOUTONCEPERSECONDEQUALONOFFDURATIONS AMBER Red/White nOFF nOFF n/. nShort on/Long off flash nLong on/Short off flash N R Yellow/Black Sensor 90200HT B Red/White H Service switch White Power Off: When no power is applied to the Red-White wire, the modulating output is at LOW FIRE. Power On: When power is applied to the Red-White wire, the circuit is energized starting the Fault Log Display followed by the Self Test. When these are complete the control becomes operational and turns the Green LED on steady 135-ohm modulated device To sensor W R R B Sensor 120 VAC N W LED’s Control status 120 VAC W Yellow/Red nON time equals firing rate percentage Operation H Service switch B 135-ohm modulated device To sensor Swap connections to B and W to reverse the motor direction. See Fault log display below — faults will display when power is applied. NOTE: When flashing, the LED’s flash once every second in Fault display mode. The green LED flashes once every 3 seconds when in Self Test mode. Configurations Self Test: When the fault log display is complete, the self test checks the sensor and the microprocessor and internal circuits. This test lasts up to 6 seconds before the control becomes fully operational. During the self test the green LED flashes on once every 3 seconds. s Control kits ((4CONTROLSMOUNTTOASTANDARDX*BOX SUPPLIEDWITHTHECONTROL-OUNTTHEBOXDIRECTLYTOAWELLNEWOR EXISTINGWITHHARDWARESUPPLIEDORPANELMOUNT3EE&IGUREFOR DIMENSIONS Burner @ High-Fire: When the sensor temp is at or below the operating temp minus 1/2 the modulating band, the modulation signal is at High-fire. The Amber LED is full on. s Well kits 7ELLSFOR(SENSORSAREAVAILABLEINTHESIZES SHOWN IN &IGURE 7ELL KITS INCLUDE SENSOR MOUNTING HARDWARE DESIGNEDTOHOLDSENSORSECURELYINPOSITION Burner @ Low-Fire: When the sensor temp is at or above the operating temp plus 1/2 the modulating band, the modulation signal is at Low-fire. The Amber LED is full off. Burner in Proportional Modulation: When the sensor temperature is in the modulating band (1/2 the band setting either side of the operating temp), the control modulation signal varies proportionally between high and low fire. The Amber LED flashes proportionally. The percentage of time the LED is on equals the modulating output percentage. s Sensors 3ENSORSAREAVAILABLEINSINGLECONlGURATIONS Figure 2 Mounting the 90200H/HT Lockout: The control goes into lockout on ANY of the fault code conditions and Logs the fault code indicated below under “Fault log display.” While in lockout, the Motor modulation output is at low fire. The Amber LED is off. The green LED flashes uniformly once per second. Reset from Lockout:4HE CONTROL AUTOMATICALLY RESETS FROM ,OCKOUT WHEN !,,CONDITIONSRETURNTONORMAL4HECONTROLRETURNSTOWHATEVERSTATEISDElNED BYITSINPUTS ,ATCHUP#ONTROLGOESINTO,ATCHUPONHARDWAREFAILURE#ONTROLSHOULDBERE PLACED4HEGREEN,%$ISOFF4HEAMBER,%$ISON4HISWILLOCCURIMMEDIATELYIF POWERISTURNEDOFFANDBACKONAGAININCONTROLISINLATCHUP Fault log display (based on LED status) If the control has detected a fault condition, it will display the fault conditions when power is turned off, then turned on again. Each fault code will occur 4 times. The control will then display the next fault code, if any. The fault log is erased after displaying the results. The codes will display in the following sequence: 1 )NTERNALCONTROLMICROPROCESSORFAILURE 4EMPERATURESENSORISSHORTED 4EMPERATURESENSORISOPEN2EPEATSTHESAMECODE 4 )NTERNALCONTROLMICROPROCESSORPINISOPEN -ODULATINGBANDINTERNALCIRCUITISOPEN 6 /PERATINGTEMPERATUREINTERNALCIRCUITISOPEN2EPEATSTHESAMECODE 7 #ONTROLINTERNALDIAGNOSTICFAILURE © Copyright 2009 — Carlin Combustion Technology, Inc. Carlin part number MN90200HC Rev. 04/16/09 12 Instructions Features s s s s s s s %LECTRONICSENSORINPUT operating temperatureADJUSTMENT lXEDtemperature differential modulating bandADJUSTMENT ,OCKOUTONDIAGNOSTICFAILURE ,ATCHUPONHARDWAREFAILURE )SOLATEDPROPORTIONALOHMMODULATINGCONTROLOUTPUT (ONWIRESIN*BOX (4ONTERMINALSONFRONTOFCONTROL Specifications s #ARLINS -ODEL ( MICROPROCESSOR OPERATED TEMPERATURE CONTROL ISDESIGNEDTOOPERATEOHMMODULATEDDEVICESREPLICATINGOLDER SLIDEWIREDEVICESANDISAVAILABLEINCONlGURATIONSDESCRIBEDBELOW .OTETHAT((4CONTROLSREQUIREAVOLTPOWERINPUT4HE OHMCIRCUITISISOLATED s &ORELECTRONICMODMOTORCONTROLSYSTEMSSUCHAS3IEMENS31CONSULT MANUFACTURER s 2EFERTOSEPARATEPRODUCTLISTINGSHEETSFORPREDElNEDMODELSORRE QUESTACONTROLTOMEETYOURSPECIlCATIONSWITHINTHEAVAILABLERANGES LISTEDBELOW Model 90200H Input power (L1-L2) (SHOWN(4ALSOAVAILABLEWITH TERMINALSTRIPONFRONTFORLOWVOLTAGECONNECTIONS 135-ohm proportional output Modulating output Control Max drive Balance circuit Connections: (For regulating 135-ohm modulating devices) 120 VAC H/N Microprocessor-operated To “W” on device To “R” on device To “B” on device 90200HT 120 VAC, 2 VA 3.5 +/- 0.5 VDC, 4.2 +/- 0.2 mA 20 VDC O.C., 6 mA S. C. Adjustment on rear of control 5 wires (no terminals) 2 wires (120 VAC) 3 terminals (mod) Red/White & White wires Yellow/White wire Yellow/Red wire Yellow/Black wire “White” terminal “Red” terminal “Black” terminal (Processor coordinates operation and diagnostic) Operating temp. range Adjustable (any range between 40°F and 250°F) Easy remote sense Temp. differential range Fixed (any value between 1°F and 10°F) (Electronic sensor, wired to control) Self-checking program (Control locks out on diagnostic failure) Diagnostic/status LED’s (LED’s indicate power, call for heat, and lockout) Modulating band range Adjustable (Any range between 10°F and 100°F) Ambient temp. limits +32°F to +140°F (0°C to +60°C) Storage temp. limits -40°F to +185°F (-40°C to +85°C) Agencies UL & ULC Recognized & Listed Component US and Canada TECH SUPPORT 800-989-2275 carlincombustion.com 13 Model 90200H/HT Microprocessor Temperature Controls — Instructions Where appliance instructions differ from this manual, follow the appliance instructions. Model 90200H/HT diagnostic LED’s 90200H/HTCONTROLSHAVEAGREEN,%$POWERFAULTINDICATORANDAMBER,%$lRINGRATE PERCENTFAULTINDICATOR3EE,%$CONDITIONSBELOW GREEN Figure 1 Wiring connections 90200H n/.Indicates control is oprational) White nShort on/Long off flash nLong on/Short off flash Yellow/White nFLASH uniformly ABOUTONCEPERSECONDEQUALONOFFDURATIONS AMBER Red/White nOFF nOFF n/. nShort on/Long off flash nLong on/Short off flash 90200HT Operation N W R Yellow/Black B Power Off: When no power is applied to the Red-White wire, the modulating output is at LOW FIRE. Power On: When power is applied to the Red-White wire, the circuit is energized starting the Fault Log Display followed by the Self Test. When these are complete the control becomes operational and turns the Green LED on steady 135-ohm modulated device To sensor Red/White H Service switch White W R R B Sensor 120 VAC N W LED’s Control status 120 VAC Yellow/Red Sensor nON time equals firing rate percentage H Service switch B 135-ohm modulated device To sensor Swap connections to B and W to reverse the motor direction. See Fault log display below — faults will display when power is applied. NOTE: When flashing, the LED’s flash once every second in Fault display mode. The green LED flashes once every 3 seconds when in Self Test mode. Configurations Self Test: When the fault log display is complete, the self test checks the sensor and the microprocessor and internal circuits. This test lasts up to 6 seconds before the control becomes fully operational. During the self test the green LED flashes on once every 3 seconds. s Control kits ((4CONTROLSMOUNTTOASTANDARDX*BOX SUPPLIEDWITHTHECONTROL-OUNTTHEBOXDIRECTLYTOAWELLNEWOR EXISTINGWITHHARDWARESUPPLIEDORPANELMOUNT3EE&IGUREFOR DIMENSIONS Burner @ High-Fire: When the sensor temp is at or below the operating temp minus 1/2 the modulating band, the modulation signal is at High-fire. The Amber LED is full on. s Well kits 7ELLSFOR(SENSORSAREAVAILABLEINTHESIZES SHOWN IN &IGURE 7ELL KITS INCLUDE SENSOR MOUNTING HARDWARE DESIGNEDTOHOLDSENSORSECURELYINPOSITION Burner @ Low-Fire: When the sensor temp is at or above the operating temp plus 1/2 the modulating band, the modulation signal is at Low-fire. The Amber LED is full off. Burner in Proportional Modulation: When the sensor temperature is in the modulating band (1/2 the band setting either side of the operating temp), the control modulation signal varies proportionally between high and low fire. The Amber LED flashes proportionally. The percentage of time the LED is on equals the modulating output percentage. s Sensors 3ENSORSAREAVAILABLEINSINGLECONlGURATIONS Figure 2 Mounting the 90200H/HT Lockout: The control goes into lockout on ANY of the fault code conditions and Logs the fault code indicated below under “Fault log display.” While in lockout, the Motor modulation output is at low fire. The Amber LED is off. The green LED flashes uniformly once per second. Reset from Lockout:4HE CONTROL AUTOMATICALLY RESETS FROM ,OCKOUT WHEN !,,CONDITIONSRETURNTONORMAL4HECONTROLRETURNSTOWHATEVERSTATEISDElNED BYITSINPUTS ,ATCHUP#ONTROLGOESINTO,ATCHUPONHARDWAREFAILURE#ONTROLSHOULDBERE PLACED4HEGREEN,%$ISOFF4HEAMBER,%$ISON4HISWILLOCCURIMMEDIATELYIF POWERISTURNEDOFFANDBACKONAGAININCONTROLISINLATCHUP Fault log display (based on LED status) If the control has detected a fault condition, it will display the fault conditions when power is turned off, then turned on again. Each fault code will occur 4 times. The control will then display the next fault code, if any. The fault log is erased after displaying the results. The codes will display in the following sequence: 1 )NTERNALCONTROLMICROPROCESSORFAILURE 4EMPERATURESENSORISSHORTED 4EMPERATURESENSORISOPEN2EPEATSTHESAMECODE 4 )NTERNALCONTROLMICROPROCESSORPINISOPEN -ODULATINGBANDINTERNALCIRCUITISOPEN 6 /PERATINGTEMPERATUREINTERNALCIRCUITISOPEN2EPEATSTHESAMECODE 7 #ONTROLINTERNALDIAGNOSTICFAILURE -2- Carlin part number MN90200HM Rev. 04/16/09 14 Model 90200H/HT Microprocessor Temperature Controls — Instructions Where appliance instructions differ from this manual, follow the appliance instructions. Figure 3 90200H Equivalent circuit diagram Wiring connections Line voltage power to control 5. When the throttle arm stops moving and the Amber LED is full ON (if not full on, the water temperature is too hot — wait for it to cool), turn the rear calibration pot slowly ccw until the arm just starts to move away from Hi-Fire. 1. 90200H and 90200HT controls require a 120 VAC power source as shown in Figure 3. The power must be taken from the appliance line voltage power source to ensure correct phasing. 6. When the arm stops, slowly turn the pot cw until the arm just starts to move toward Hi-Fire. Modulating terminal wiring 7. Setup is complete. Remove power, re-mount the control for operation, then Set Band and Operating temperature setpoints to desired operating settings. 1. Connect the modulating device’s R, B and W terminals to the three 90200H/ HT wires as shown in Figure 3. s 07-3ETUPTOGUARANTEEBURNERh&ULLOFFvPOSITION 0ERFORMSTEPSFROMhFULLONvSETUPABOVE Setup Procedure: s Mount the control so there will be access to the back when the system is powered up. Be careful when making rear adjustments as circuits will have power. s 07-3ETUPTOGUARANTEEBURNERh&ULLONvPOSITION 1. Set the rear calibration potentiometer to the full cw position. 2. Set the Modulation Band setpoint to its min value. 3. Set the Operating Temperature setpoint to its mid value. 0OWERUPCONTROLWITHTHESTRIPEDYELLOWWIRESCONNECTEDTOTHEBURNERS proportional throttle motor. Apply power to the throttle motor. The throttle arm should move toward Hi-Fire. (If not, power down & reverse the connections to the B & W pins on the motor). Carlin part number MN90200HM Rev. 04/16/09 2. Allow the burner to heat the vessel, and when the Amber LED starts flashing (vessel temperature is in proportional band), set the Operating temperature setpoint to its min value. The Amber LED should turn off. 3. Set the rear calibration potentiometer to the full ccw position. 4. When the throttle arm stops moving at Lo-Fire, turn the rear calibration pot slowly cw until the arm just moves away from Lo-Fire. 5. When the motor stops, turn the pot ccw slowly until the motor starts to move toward Lo-Fire. 6. Setup is complete. Remove power, set Band Temperature and Operating temperature setpoints to desired operating settings. -3- 15 Model 90200H/HT Microprocessor Temperature Controls — Data sheet © Copyright 2009 — Carlin Combustion Technology, Inc. Carlin part number MN90200HC Rev. 04/16/09 16 Specifications • • 24VAC Carlin’s Model 90224 microprocessor-operated temperature controls are available in two configurations, described below. Each model provides one contact (either normally-open or normally-closed). Refer to separate product listing sheets for pre-defined models, or request a control to meet your specifications, within the available ranges listed below. Microprocessor-operated (Processor coordinates operation and diagnostic) Easy remote sense 90224A Temperature control • 1 break-on-rise contact • 1 electronic sensor • lockout on diagnostic failure • reset from lockout via power cycle 90224B Temperature control • 1 make-on-rise contact • 1 electronic sensor • lockout on diagnostic failure • reset from lockout via power cycle (Electronic sensor, wired to control) Control model Select from break-on-rise or make-on-rise operation A Control power input (black-red wire) Contacts (action on temperature rise:) 1 1 (breaks) (makes) Contact rating Self-checking program (Control locks out on diagnostic failure) Diagnostic/status LED’s Wires Quantity Contact IN / OUT Adjustable operating range B 24 VAC, 1 VA 24 VAC, 1 AMP 2 2 black-red / black-yellow Any range between 50°F to 240°F Fixed differential (subtractive) Any value from 5°F to 100°F Operating temperature limits +32°F to +140°F Storage temperature limits Agencies (LED’s indicate power, call for heat, and lockout) TECH SUPPORT 800-989-2275 –40°F to +185°F UL & ULC recognized component United States & Canada carlincombustion.com 17 Model 90224 Microprocessor Temperature Controls — Data sheet — Operation & Dimensions Model 90224 diagnostic LED’s Configurations GREEN • – OFF – FLASH Slowly (every 3 seconds) Power on – FLASH Rapidly (every second) Lockout AMBER – OFF Operation – ON Control call for heat (See wiring diagrams below for wiring connections.) • • Control kits — 90224 controls mount to a standard 4x4 J-box, supplied with the control. Mount the box directly to a well (new or existing) with hardware supplied, or panel mount. See below for dimensions. Well kits — Wells for 90224 sensors are available in the sizes shown below. Well kits include sensor mounting hardware designed to hold sensor securely in position. Sensors — Sensors are available in single configurations. Indicator LED’s 90224 controls have a green LED (power/lockout indicator) and amber LED (operation indicator). Power OFF With no power applied to black/red wire, all lights are off. Power ON When power is applied to the black/red wire, the green LED turns on, flashing every 3 seconds. Self-test When power is applied, the 90224 performs a self-test, checking the sensor and microprocessor. The power-up test lasts from 3 to 5 seconds. The 90224 continues diagnostic checking during the operating cycle as well. Any self-check failure causes a lockout (see below). Call for heat When the temperature at the operating sensor is below setpoint minus fixed differential, the 90224 break-on-rise contact is closed, or the make-on-rise contact is open. The amber LED is on. Stand-by When the 90224 operating sensor reaches setpoint temperature or above, the 90224 break-on-rise contact opens; or the makeon-rise contact closes. The amber LED turns off. Lockout If the control detects a diagnostic failure, lockout occurs. During lockout, the green LED flashes every second. After the temperature drops below setpoint minus differential, reset the control by turning power off, then back on. The green LED will flash more slowly, every 3 seconds. Power must flow through the contacts in the direction shown. Changing flow direction will cause the control to lockout or fail to operate. The 90224 is polarity-sensitive with some controls. If the 90224 goes to lockout on power up, disconnect power. Swap the wires coming to the black/red and black/yellow lead wires. Restore power and restart. © Copyright 2005 — Carlin Combustion Technology, Inc. Carlin part number MN90224C Rev. 08/09/05 18 $ATASHEET -ULTIPLESENSOROPTION 5SINGINDIVIDUALANDORDUALSENSORASSEMBLIES 3ENSOR2EDUNDANCY (IGHERTEMPERATUREOFTWOOPERATINGSENSORSUSED %ASYREMOTESENSE 3PECIlCATIONS s s #ARLINS -ODEL MICROPROCESSOROPERATED MULTIPLECONTACT TEMPERATURELIMITCONTROLSAREAVAILABLEASDESCRIBEDBELOW4HEMODEL PROVIDESTWOCONTACTSONEFOROPERATINGLIMITANDONEFROMHIGH LIMIT 2EFER TO SEPARATE PRODUCT LISTING SHEETS FOR PREDElNED MODELS OR REQUEST A CONTROL TO MEET YOUR SPECIlCATIONS WITHIN THE AVAILABLE RANGESLISTEDBELOW %LECTRONICSENSORSWIREDTOCONTROL 3MARTMANUALRESET -ANUALRESETONLYIFOPERATINGLIMITDOESNTOPEN 3ERVICEMANRESETPROTECTION ,ATCHUPAFTERTHREECONSECUTIVELOCKOUTS 0OWERINDEPENDENTLOCKOUT 0OWERCYCLINGWONTRESETFROMLOCKOUTORLATCHUP $IAGNOSTIC,%$S 0OWERCALLFORHEATANDLOCKOUTLATCHUP 3-#4ECHNOLOGY ,ATCHUPMODESHUTSDOWNTHECONTROLAFTERTHREECONSECUTIVELOCKOUTSANDREQUIRES ASPECIALPROCEDURETORESET4HISENSURESTHEOWNERWILLCALLINALICENSEDTECHNICIANTO TROUBLESHOOTANDCORRECTBURNERPROBLEMS 4HEPROVIDESTWOLIMITRELAYS#ARLINSPATENTED3-#TECHNOLOGY3AFETY-ONITOR ING#IRCUITMONITORSTHECONTACTSOFBOTHRELAYS,OCKOUTOCCURSIFALIMITRELAYCONTACTIS FOUNDCLOSEDWHENITSHOULDBEOPEN 4%#(3500/24 CARLINCOMBUSTIONCOM 19 -ODEL-ICROPROCESSOR4EMPERATURE#ONTROLS$ATASHEET/PERATION$IMENSIONS -ODELDIAGNOSTIC,%$S '2%%. n/&& n/.0OWER n&,!3().',ATCHUP 2%$ n/&& n/.,OCKOUT !-"%2 n/&& n/.#ONTROLCALLFORHEAT %LECTRICALSHOCKHAZARD$ISCONNECTPOWERTOAPPLIANCEWHENWIRINGOR SERVICINGANYELECTRICALCOMPONENT /PERATION 3EEWIRINGDIAGRAMSBELOWFORWIRINGCONNECTIONS 0OWER/&& 7ITHNOPOWERAPPLIEDTOTHEREDWHITEWIREALLLIGHTSAREOFF0OWERCANBEWIRED DIRECTLYFROMAPPLIANCE6!#TERMINALTOMAINTAINPOWERATALLTIMES 0OWER/. 7HENPOWERISAPPLIEDTOTHEREDWHITEWIRETHEGREEN,%$TURNSON 3ELFTEST 7HENPOWERISAPPLIEDTHEPERFORMSASELFTESTCHECKINGSENSORSAND MICROPROCESSORANDVERIFYINGLIMITCONTACTSAREOPEN4HEPOWERUPTESTLASTSFROM TOSECONDS4HECONTINUESDIAGNOSTICCHECKINGDURINGTHEOPERATINGCYCLE ASWELL!NYSELFCHECKFAILURECAUSESALOCKOUTSEEBELOW /PERATE )FTHETEMPERATUREATBOTHOPERATINGSENSORSISBELOWSETPOINTBYATLEASTTHElXED DIFFERENTIALTHECONTROLCLOSESTHEOPERATINGLIMITCONTACTS4HEAMBER,%$TURNS ON 3TANDBY 7HENEITHEROPERATINGSENSORSEESSETPOINTTEMPERATUREORABOVETHEOPENS THEOPERATINGLIMITCONTACT4HEAMBER,%$TURNSOFF ,IMITACTION )F THE HIGH LIMIT SENSOR SEES A TEMPERATURE ABOVE HIGH LIMIT SETTING THE OPENSTHEHIGHLIMITCONTACTSTURNSONTHERED,%$ANDCHECKSTHEOPERATINGLIMIT CONTACTS)FTHEOPERATINGLIMITCONTACTSAREOPENTHECONTROLWILLAUTOMATICALLYRESET WHENTEMPERATUREDROPSBELOWHIGHLIMITSETTINGMINUSDIFFERENTIAL4HEHIGHLIMIT CONTACTSCLOSEANDTHERED,%$TURNSOFF ,OCKOUT )FTHEHIGHLIMITSENSORSEESATEMPERATUREABOVEHIGHLIMITSETTINGANDTHE lNDSTHEOPERATINGLIMITCONTACTSCLOSEDTHERED,%$TURNSONANDLOCKOUTOCCURS ,OCKOUTALSOOCCURSONANYDIAGNOSTICTESTFAILURE7HENTHETEMPERATUREDROPS BELOWHIGHLIMITSETTINGMINUSDIFFERENTIALRESETTHECONTROLBYPRESSINGTHEMANUAL RESETBUTTON4HECONTROLWILLNOTRESETBYCYCLINGPOWEROFFANDON ,ATCHUP )F THE LOCKS OUT THREE CONSECUTIVE TIMES IT ENTERS LATCHUP 2ESET FROM LATCHUPREQUIRESASPECIALPROCEDUREINTENDEDTOREQUIRELICENSEDSERVICEMAN INTERVENTION$URINGLATCHUPTHERED,%$STAYSONANDTHEGREEN,%$mASHES 2ESETASFOLLOWS 4EMPERATUREMUSTBELESSTHANHIGHLIMITSETTINGMINUSDIFFERENTIAL (OLDRESETBUTTONATLEASTSECONDS4HEGREEN,%$mASHESFASTER #ONTINUEHOLDINGBUTTONANOTHERSECONDS4HECONTROLRESETSANDTHERED,%$ TURNSOFF #ONlGURATIONS s s s #ONTROLKITSCONTROLSMOUNTTOASTANDARDX*BOX SUPPLIEDWITHTHECONTROL-OUNTTHEBOXDIRECTLYTOAWELLNEW OREXISTINGWITHHARDWARESUPPLIEDORPANELMOUNT3EEBELOW FORDIMENSIONS 7ELLKITS7ELLSFORSENSORSAREAVAILABLEINTHESIZES SHOWNBELOW7ELLKITSINCLUDESENSORMOUNTINGHARDWAREDE SIGNEDTOHOLDSENSORSECURELYINPOSITION 3ENSORS3ENSORSAREAVAILABLEINSINGLEANDDUALCONlGURA TIONS 0OWERMUSTmOWTHROUGHTHECONTACTSINTHEDIRECTIONSHOWN#HANGING mOWDIRECTIONWILLCAUSETHECONTROLTOLOCKOUTORFAILTOOPERATE ¥#OPYRIGHT#ARLIN#OMBUSTION4ECHNOLOGY)NC 9Whb_dfWhjdkcX[hCD/&)&&9H[l$&'%)'%&+ 20 Data sheet Multiple sensor option (3) Specifications • (Using individual and/or dual sensor assemblies) Sensor Redundancy (Higher temperature of two operating sensors used) • Carlin’s Model 90320 microprocessor-operated, multiple-contact temperature limit controls are available as described below. The model provides two contacts — one for operating limit and one for high limit. Refer to separate product listing sheets for pre-defined models, or request a control to meet your specifications, within the available ranges listed below. Easy remote sense (Electronic sensors, wired to control) Smart manual reset 90320B (Manual reset only if operating limit doesn’t open) Serviceman reset protection (Latch-up after three consecutive lockouts (1)) Control model Contacts (Power cycling won’t reset from lockout or latch-up) Contact rating Diagnostic LED’s Wires (Power, call for heat, and lockout/latchup) (1) (2) The 90320 provides two limit relays. Carlin’s patented SMC technology (Safety Monitoring Circuit) monitors the contacts of both relays. Lockout occurs if a limit relay contact is found closed when it should be open. 240 VAC, 50/60 hz, 12 VA 2 in series Motor load General Quantity 240 VAC Hot / Neutral Limits OUT (2) Latch-up mode shuts down the control after three consecutive lockouts, and requires a special procedure to reset. This ensures the owner will call in a licensed technician to troubleshoot and correct burner problems. B Control power input (red-white wire) Power-independent lockout SMC Technology Dual limit temperature control • operating and high limit action • smart manual reset on high limit • operating limit sensors, redundant • high limit sensor • operating and limit contacts in series 240 VAC, 50/60 hz, 1 HP 120/240 VAC, 50/60 hz, 15 AMPS 3 red-white / white black Adjustable oper. limit range Any range between 50°F to 240°F Fixed high limit temperature Any value from 160°F to 240°F Fixed differential (subtractive) Any value from 5°F to 100°F Operating temperature limits +32°F to +140°F Storage temperature limits –40°F to +185°F Agencies TECH SUPPORT 800-989-2275 — carlincombustion.com 21 Model 90320 Microprocessor Temperature Controls — Data sheet — Operation & Dimensions Model 90320 diagnostic LED’s GREEN – OFF – ON Power RED – OFF – ON Lockout AMBER – OFF – ON Control call for heat Configurations • – FLASHING Latch-up • Electrical shock hazard: Disconnect power to appliance when wiring or servicing any electrical component. Operation (See wiring diagrams below for wiring connections.) Power OFF With no power applied to the red-white wire, all lights are off. Power can be wired directly from appliance 240 VAC terminal to maintain power at all times. Power ON When power is applied to the red-white wire, the green LED turns on. Self-test When power is applied, the 90320 performs a self-test, checking sensor(s) and microprocessor and verifying limit contacts are open. The power-up test lasts from 3 to 5 seconds. The 90320 continues diagnostic checking during the operating cycle as well. Any self-check failure causes a lockout (see below). Operate If the temperature at both operating sensors is below setpoint by at least the fixed differential, the control closes the operating limit contacts. The amber LED turns on. Stand-by When either operating sensor sees setpoint temperature or above, the 90320 opens the operating limit contact. The amber LED turns off. Limit action If the high limit sensor sees a temperature above high limit setting, the 90320 opens the high limit contacts, turns on the red LED and checks the operating limit contacts. If the operating limit contacts are open, the control will automatically reset when temperature drops below high limit setting minus differential. The high limit contacts close and the red LED turns off. Lockout If the high limit sensor sees a temperature above high limit setting and the 90320 finds the operating limit contacts closed, the red LED turns on and lockout occurs. (Lockout also occurs on any diagnostic test failure.) When the temperature drops below high limit setting minus differential, reset the control by pressing the manual reset button. The control will not reset by cycling power off and on. Latch-up If the 90320 locks out three consecutive times, it enters latch-up. Reset from latch-up requires a special procedure, intended to require licensed serviceman intervention. During latch-up, the red LED stays on and the green LED flashes. Reset as follows: ............ Temperature must be less than high limit setting minus differential. ............ Hold reset button at least 10 seconds. The green LED flashes faster. ............ Continue holding button another 20 seconds. The control resets and the red LED turns off. • Control kits — 90320 controls mount to a standard 4x4 J-box, supplied with the control. Mount the box directly to a well (new or existing) with hardware supplied, or panel mount. See below for dimensions. Well kits — Wells for 90320 sensors are available in the sizes shown below. Well kits include sensor mounting hardware designed to hold sensor securely in position. Sensors — Sensors are available in single and dual configurations. Power must flow through the contacts in the direction shown. Changing flow direction will cause the control to lockout or fail to operate. 90320B G G White 240 VAC, 50/60 HZ 240 VAC, 50/60 HZ CONNECTIONS AT APPLIANCE POWER TO APPLIANCE Appliance limits Red/White OPERATING LIMT Service switch HIGH LIMIT Dual limit OUT Black Sensor 2 To operating limit sensor #2 High limit To high limit sensor Sensor 1 To operating limit sensor # 1 © Copyright 2006 — Carlin Combustion Technology, Inc. Carlin part number MN90320C Rev. 02/15/06 22 Data sheet Functions s Carlin’s 90524 triple limit control provides high limit function and can also provide: s Minimum water temperature control for operation with a tankless heater in a boiler. (Function can be turned off by turning LOW LIMIT setting to “OFF.”) s Low temperature limit to prevent flow through boiler if temperature is below preset minimum — for preventing condensation in conventional boilers. s Operates as a cold-start control when Low Limit is in “OFF” position. s Provides input from zone controllers or relays and output to enable circulators. s Provides operation of burner/gas valve and heating circulator. Specifications Easy-wire terminal strip Microprocessor-operated (Processor coordinates operation and diagnostic) Easy remote sense (Electronic sensor, wired to control) Self-checking program (Control locks out on diagnostic failure) Diagnostic/status LED’s (LED’s indicate power, call for heat, and lockout) SMC technology on burner relay (lockout when welded contact sensed) s Carlin’s Model 90524 microprocessor-operated temperature controls are described below. s Refer to separate product listing sheets for pre-defined models, or request a control to meet your specifications, within the available ranges listed below. Model 90524A Input power (L1-L2) Control power (T-T) High limit range High limit differential 120 VAC, 10 VA, 60 Hz 24 VAC, 130 mA Adjustable Fixed if low limit is used or if differential setpoint is OFF Adjustable if low limit is turned OFF Adjustable with OFF position Adjustable (fixed if differential setpoint is OFF) Fixed Fixed Low limit range Low limit differential Low temp function Low temp differential Temperature ranges Setting — Differential — Contact ratings Full load Locked rotor Ambient temperature Storage temperature Agencies Any value/range between 50° & 250° Any value/range between 5°F and 100°F Burner, circulator and ZC contacts 120 VAC, 10 amps (total current on all contacts not to exceed 16 amps) 120 VAC, 60 amps (total current on all contacts not to exceed 96 amps) +32°F to +140°F (0°C to +60°C) -40°F to +185°F (-40°C to +85°C) UL Listed US and Canada TECH SUPPORT 800-989-2275 carlincombustion.com 23 Model 90524 Microprocessor Temperature Controls — Data sheet Figure 1 Equivalent circuit diagram (the 90524 controls power to the burner and circulators as in the simplified circuit below) Model 90524 diagnostic LED’s Configurations LED’s s Control kits — 90524 controls mount to a standard 4x4 J-box, supplied with the control. Mount the box directly to a well (new or existing) with hardware supplied, or panel mount. See Figure 2 for dimensions. s Well kits — Wells for 90524 sensors are available in the sizes shown in Figure 2. Well kits include sensor mounting hardware designed to hold sensor securely in position. s Sensors — Sensors are available in single configurations. 90524 controls have a green LED (power/lockout indicator) and amber LED’s (operation indicator) for Burner and Circulator. – OFF GREEN – ON Power on – FLASH Slowly (once per second) Soft lockout – FLASH Rapidly (twice per second) Hard lockout AMBER – OFF – ON Burner on or Circulators powered Figure 2 Mounting the 90524 LED indications Power OFF — With no power applied, the thermostat (TT) circuit and all output contacts are de-energized. All LED’s are off. Power ON — When power is applied to the L1/L2 terminals, the thermostat circuit is energized. Voltage (24 VAC) is applied to the thermostat terminals. The 90524 starts a self test to check the sensor and the microprocessor, and to verify that the limit contacts are open. The 90524 becomes fully operational after this 2-second self test. or Soft lockout — Green light flashing once per second, burner light off, burner contact open, and circulator light on or off — occurs if control senses internal failure or sensor problem (open or shorted sensor). The control will revert to normal operation if the problem is corrected within 15 seconds. Otherwise, the control enters hard lockout. Hard lockout — Green light flashing twice per second, burner light off and burner contacts open, circulator light on and circulator contacts closed — occurs when burner contact is sensed closed, and does not clear after two attempts. Reset by cycling power off/on. Latchup — Green light off, burner light off, B1 contact open, circulator light on, and ZC and C1 contacts closed — occurs when burner contact is sensed closed, and does not clear after three attempts. Not resettable — requires control replacement. Fault log 90524 controls self monitor and indicate fault conditions with the LED’s. Fault conditions are recorded in the retrievable fault log. For applications that might encounter unexplainable control outages, contact Carlin Technical Support for instructions to access the fault log and interpret the results. © Copyright 2008 — Carlin Combustion Technology, Inc. Carlin part number MN90524C Rev. 11/24/08 24 Instructions Functions F Front s Carlin’s 90524A can be operated as either a triple limit control or a cold-start control, determined by the setting of the LOW LIMIT adjustment. s Triple limit operation (LOW LIMIT on): Provides adjustable high limit setting and maintains an adjustable minimum temperature in the boiler (low limit setting) while in stand-by (no space heating call); used for tankless heater applications. (See Figure 3 , page 4.) s Cold-start operation (LOW LIMIT off): Provides adjustable high limit setting and low temperature protection (delays circulator start until the boiler is heated above the fixed minimum temperature setpoint); used to prevent condensation in the boiler on cold start. (See Figure 4 , page 4.) s The 90524A provides input from zone controllers or relays (ZR contact) and output to enable circulators (C1 contact) or zone controllers (ZC contact). The gas valve/burner output is on the B1 terminal. Call for heat input is on the T-T terminals. Specifications Rear s Carlin’s Model 90524A microprocessor-operated temperature controls are described below. s Refer to separate product listing sheets for pre-defined models, or request a control to meet your specifications, within the available ranges listed below. (size reduced) Easy-wire terminal strip Microprocessor-operated (Processor coordinates operation and diagnostic) Easy remote sense (Electronic sensor, wired to control) Self-checking program (Control locks out on diagnostic failure) Diagnostic/status LED’s (LED’s indicate power, call for heat, and lockout) SMC technology on burner relay Model 90524A Input power (L1-L2) Control power (T-T) High limit range High limit differential 120 VAC, 10 VA, 60 Hz 24 VAC, 130 mA Adjustable Adjustable (fixed if low limit is used or if differential setpoint is OFF) Adjustable with OFF position Low limit range Low limit differential Low temp function Low temp differential Temperature ranges Setting — Differential — Contact ratings Full load Locked rotor Ambient temperature Storage temperature Agencies Adjustable (fixed if differential setpoint is OFF) Fixed Fixed Any value/range between 50° & 250° Any value/range between 5°F and 100°F Burner, circulator and ZC contacts 120 VAC, 10 amps (total current on all contacts not to exceed 16 amps) 120 VAC, 60 amps (total current on all contacts not to exceed 96 amps) +32°F to +140°F (0°C to +60°C) -40°F to +185°F (-40°C to +85°C) UL Listed US and Canada (lockout when welded contact sensed) TECH SUPPORT 800-989-2275 carlincombustion.com 25 Model 90524A Triple limit or cold-start control — Instructions Where appliance instructions differ from this manual, follow the appliance instructions. Figure 1 90524A components 1 2 Front 3 1 Green LED — POWER ON (Lockout, see page 3) 2 Amber LED — CIRCULATOR ON 3 Amber LED — BURNER ON 4 Thermostat T-T input terminals 5 Terminal strip (back of control) 6 Sensor terminal strip (quick-release style) 7 Differential adjustment (adjusts High Limit differential when in cold-start operation; adjusts Low Limit differential when in triple limit operation) — when in OFF position, default high and low limit differentials are used 8 Hidden reset button 9 Low limit adjustment (set to OFF for coldstart operation) 10 High limit setpoint adjustment 4 Rear 10 7 9 8 6 5 –2– Carlin C li partt number b MN90524AM R Rev. 01/19/09 26 Model 90524A Triple limit or cold-start control — Instructions Where appliance instructions differ from this manual, follow the appliance instructions. Configurations Model 90524A diagnostic LED’s s Control kits — 90524A controls mount to a standard 4x4 J-box, supplied with the control. Mount the box directly to a well (new or existing) with hardware supplied, or panel mount. See Figure 2 for dimensions. s Well kits — Wells for 90524A sensors are available in the sizes shown in Figure 2. Well kits include sensor mounting hardware designed to hold sensor securely in position. s Sensors — Sensors are available in single configurations. 90524A controls have three LED’s, as explained below. See following pages for operating sequence and LED behavior. Figure 2 Mounting the 90524A Left LED POWER ON Center LED CIRCULATOR ON green Right LED BURNER ON amber amber The LED’s can be off, on or flashing. The symbols below are used in this manual to show the state of these LED’s during operation of the control. Green LED OFF – ON Power on FLASH Slowly (once per second) Soft lockout FLASH Rapidly (twice per second) Hard lockout Amber LED’s ; OFF – ON Burner on or Circulators powered Indicates the LED in this position can be either on or off. LED status Indicates the following: Power OFF With no power applied, the thermostat (TT) circuit and all output contacts are de-energized. All LED’s are off. Power ON ; Soft lockout When power is applied to the L1/L2 terminals, the thermostat circuit is energized. Voltage (24 VAC) is applied to the thermostat terminals. The 90524A starts a self test to check the sensor and the microprocessor, and to verify that the limit contacts are open. The 90524A becomes fully operational after this 2-second self test. Green LED flashing once per second, burner LED off, B1 contact open, and circulator LED on or off — occurs if control senses internal failure or sensor problem (open or shorted sensor). The control will revert to normal operation if the problem is corrected within 15 seconds. Otherwise, the control enters hard lockout. See “Fault log” information below. Green LED flashing twice per second, burner LED off and B1 contacts open, circulator LED on and circulator contacts closed — occurs when burner contact is sensed closed, and does not clear after two attempts Hard lockout or soft lockout has timed out. Reset by cycling power off/on. Latchup Green LED off, burner LED off, B1 contact open, circulator LED on, and ZC and C1 contacts closed — occurs when burner contact is sensed closed, and does not clear after three attempts. Not resettable — requires control replacement. Definitions 90524A controls self monitor, and can indicate fault conditions with the LED’s. High limit Shut-off temperature during space heating (call for heat at T-T or ZR). s Setpoint is adjustable at lower front center of control. s Differential is fixed when in triple limit operation (LOW LIMIT on). s Differential is adjustable on back of control when in cold start operation (LOW LIMIT set to OFF). Low limit Temperature maintained during stand-by (no call for heat at T-T or ZR) when in triple limit operation (LOW LIMIT on). s The setpoint for the low limit (minimum temperature in the boiler during standby) is adjustable with the lower left adjustment. s The differential for low limit is adjustable with the adjustment on the back of the control. s The circulator output at C1 is activated only when the temperature in the boiler is above the low limit setting. Low temp Boiler condensation protection setting when in cold-start operation (LOW LIMIT set to OFF). s This setting is fixed. s The differential is fixed. s The circulator outputs are disabled until the boiler temperature rises above the low temp setting. Carlin part number MN90524AM Rev. 01/19/09 Fault conditions are recorded in the retrievable fault log. Two conditions, caused by sensor detection problems, are shown below. Other LED conditions displayed in the fault log are related to internal control problems. Reset the control as explained above. Controls in latchup cannot be reset. They must be replaced. Fault log To access the fault log, press the hidden reset button (located left of the LOW LIMIT adjustment on the front of the control). Hold for one second or longer. All three LED’s will come on for 1 second, then go off for 1 second. If any error codes have been logged since the last error code display, the LED’s will flash a pattern four times for each error code, then proceed to the next. After all codes have been shown, the error code log will automatically clear. For applications that might encounter unexplainable control outages, contact Carlin Technical Support for instructions to access the fault log and interpret the results. Sensor OPEN fault code. Sensor open The sensor is detected OPEN (resistance more than 60 Kohms). Sensor SHORTED fault code. Sensor shorted The sensor is detected SHORTED (resistance less than 300 ohms). –3– 27 Model 90524A Triple limit or cold-start control — Instructions Where appliance instructions differ from this manual, follow the appliance instructions. Figure 3 Equivalent circuit diagram — Triple limit operation (LOW LIMIT on) Triple limit operation — Setup & adjustment ; s Set low limit setpoint on front of control (item 9, page 2). Set low limit differential at the adjustment potentiometer on the back of the control (item 7, page 2). The differential range is shown on the control label. Rotate the potentiometer fully counterclockwise for minimum setting, fully clockwise for maximum setting. s Set high limit setpoint on front of control (item 10, page 2). High limit differential is fixed. Triple limit sequence of operation ; Figure 4 Burner turns ON when sensor temp is below the high limit (minus high limit differential) — AND — sensor temp is below low limit setting (minus low limit differential) OR there is a call for heat at T-T or ZR. ; ; ;; ;; Burner turns OFF when sensor temp is above high limit setting — OR — when sensor temp is above the low limit AND there is no call for heat at T-T or ZR. Circulator turns ON when sensor temp is at or above low limit — AND — there is a call for heat at T-T. Circulator turns OFF when the sensor temp goes below the low limit setting (minus the low limit differential) — OR — there is no call for heat at T-T. Zone feed (terminal ZC) turns ON when sensor temp is at or above the low limit. Zone feed (terminal ZC) turn OFF when sensor temp goes below the low limit setting (minus the low limit differential). Equivalent circuit diagram — Cold-start operation (LOW LIMIT set to OFF) Cold-start operation — Setup & adjustment ; Burner turns OFF when sensor temp is above high limit setting — OR — there is no call for heat at T-T or ZR. s Set low limit adjust on front of control to OFF (item 9, page 2). This activates the low temp setting. Low temp and its differential are fixed settings. ; s Set high limit setpoint on front of control (item 10, page 2). Set high limit differential at the adjustment potentiometer on back of the control (item 7, page 2). Circulator turns ON when sensor temp is at or above low temp — AND — there is a call for heat at T-T. ; Circulator turns OFF when the sensor temp goes below the low temp setting (minus the low temp differential) — OR — there is no call for heat at T-T. ;; Zone feed (terminal ZC) turns ON when sensor temp is at or above the low temp. ;; Zone feed (terminal ZC) turn OFF when sensor temp goes below the low temp setting (minus the low temp differential). Cold start sequence of operation ; –4– Burner turns ON when sensor temp is below the high limit (minus high limit differential) — AND — there is a call for heat at T-T or ZR. Carlin part number MN90524AM Rev. 01/19/09 28 Model 90524A Triple limit or cold-start control — Instructions Where appliance instructions differ from this manual, follow the appliance instructions. Figure 5 Typical — Triple limit operation (LOW LIMIT ON) — Multi-zone controller, zoning with zone valves Carlin part number MN90524AM Rev. 01/19/09 –5– 29 Model 90524A Triple limit or cold-start control — Instructions Where appliance instructions differ from this manual, follow the appliance instructions. Figure 6 –6– Typical — Triple limit operation (LOW LIMIT ON) — Multi-zone controller, zoning with circulators Carlin part number MN90524AM Rev. 01/19/09 30 Model 90524A Triple limit or cold-start control — Instructions Where appliance instructions differ from this manual, follow the appliance instructions. Figure 7 Typical — Cold-start operation (LOW LIMIT OFF) — Delays circulator until boiler has heated above LOW TEMP setting Carlin part number MN90524AM Rev. 01/19/09 –7– 31 Model 90524A Microprocessor Temperature Controls — Data sheet © Copyright 2008 — Carlin Combustion Technology, Inc. Carlin part number MN90524AM Rev. 01/19/09 32 EZ-Temp™ Model 99000A On-Off Mode of Operation Data sheet Specifications s The EZ-Temp Commercial Boiler Package controls are provided as an assembled package. Pre-assembled and pre-wired operating limit and manual reset high limit temperature controls for commercial boilers and similar applications. Includes EZ-Temp model 90200EL manual reset high limit temperature control and EZ-Temp model 90200AL operating temperature limit control, mounted and wired on a two-gang J-box with terminal strips, one dual sensor, 3/4” immersion well (1.55” length) and mounting hardware. s Model 90200AL and 90200EL microprocessor-operated temperature controls are UL Listed. The 90200AL provides a single contact (break-on-rise) and the 90200EL provides a single contact (break-on-rise) with a manual reset. s The 90200A and 90200E are UL Recognized and may be purchased separately for replacement. Microprocessor-operated 90200AL Temperature limit control 6 .#(,+.'/#!,+0!0 6#)#!0.,+'!/#+/,. 6,!(,10,+"'%+,/0'!$')1.# 6#/#0$.,*),!(,102'-,3#.!4!)# 90200EL Manual reset high limit control 6 .#(,+.'/#!,+0!0 6#)#!0.,+'!/#+/,. 6,!(,10,+"'%+,/0'!$')1.#+")'*'0 !0',+ 6+1).#/#0$.,*),!(,10 6,.#/#0$.,*-,3#.'+0#..1-0',+ (Processor coordinates limit and diagnostic functions) Easy Remote Sense (Electronic sensors, wired to control) Break-on-Rise Operation Self-checking Program Control model AL Contacts !0',+,+0#*-#.01.#.'/# Contact Rating (Control locks out on diagnostic failure) .#(,+.'/# .#(,+.'/# VAC Full load VAC Locked rotor Quantity Wires EL VAC Power input 3 3 120 VAC#10.) &'0# 120 VAC,0,. '*'0 #"&'0# Break-on-rise OUT )!( Diagnostic/status LED’s Adjustable operating limit range (LED’s indicate “Power”, “Call for Heat”, and “Lockout”) Fixed differential (subtractive) +42)1#$.,*70,7 Operating temperature limits 70,7 Storage temperature limits Agencies TECH SUPPORT 800-989-2275 70, 7 70, 7 570,7 +"'2'"1)!,+0.,)/.#Listed $,.+'0#"00#/+" carlincombustion.com 33 Model 99000A Commercial Boiler Control Package for On-Off Mode — Data Sheet Model 90200AL diagnostic LED’s GREEN – OFF – ON Power AMBER – OFF – ON Control call for heat Dimensions – FLASHING Lockout 4.12” Model 90200EL diagnostic LED’s GREEN – OFF – ON Power RED – OFF – ON Lockout – FLASHING Lockout Pending Electrical shock hazard: Disconnect power to appliance when wiring or servicing any electrical component. Operation (See wiring diagrams for connections) Power Indicator When power is applied to unit, the green LED is turned ON. Lockout Pending 90200EL: If a diagnostic failure occurs or the sensor temperature rises above the high limit setting, the green LED will flash for 5 seconds. If the conditiion still exists after 5 seconds, the control will enter lockout requiring manual reset. The red LED turns ON and the limit contact opens. (If the condition corrects before 5 seconds, the green LED will return to normal). Lockout Indicator Lockout Indicator 90200AL: When a diagnostic failure occurs, the LED blinks and the contact opens. The control will reset when the failure is removed and power is cycled. Call for Heat 90200AL: When the temperature at the sensor is at or below set point minus fixed differential, the control powers the limit relay (break-on-rise contact closes). The Amber LED turns ON. When temperature is at or above set point, the contact opens. 2.12” 6.75” J-Box Terminal Strip 90200EL EZ-Temp SENSOR INPUT S S1 S S1 S1 DOUBLE S2 SENSOR Sensor Well: Located on JBox back center knockout. 5.25” ** Conduit connection. Locate at any knockout. 90200AL ** J-Box Terminal Strip EZ-Temp SENSOR INPUT TO BURNER PRIMARY CONTROL L2 (BREAK ON TEMPERATURE RISE). To Wht B2 To Blk B1 To Red / Wht BL1 120 VAC NEUTRAL OUT. 120 VAC LIMIT OUT. 120 VAC FEED OUT. (IF NEEDED) L1 S S2 S S2 N H LWCO Limit, if used SERVICE SWITCH TECH SUPPORT 120 Vac Power to Appliance G HOTLINE 800-989-2275 Carlin Combustion Technology, Inc. 70 Maple Street e-mail us at: © Copyright 2010 — Carlin Combustion Technology, Inc. East Longmeadow, MA 01028 [email protected] Phone 413–525–7700 Fax 413–525–8306 vist our website: www.carlincombustion.com Carlin part number MN99000AC Rev. 01/27/10 34 EZ-Temp™ Model 99000B Lo-Hi-Lo Mode of Operation Data sheet Specifications s The EZ-Temp Commercial Boiler Package controls are provided as an assembled package. Pre-assembled and pre-wired operating limit, manual reset high limit temperature and two position step modulating controls for commercial boilers and similar applications. Includes EZ-Temp model 90200AL operating temperature limit control, EZ-Temp model 90200EL manual reset high limit temperature control, and EZ-Temp model 90200GL two position step modulating Lo-Hi-Lo temperature control, mounted and wired on a three-gang J-box with terminal strips, one triple sensor, 3/4” immersion well (1.55” length) and mounting hardware. s Carlin’s model 90200AL, 90200EL, and 90200GL microprocessor-operated temperature controls are UL Listed. Each control provides a single contact (break-on-rise). Microprocessor-operated (Processor coordinates limit and diagnostic functions) 90200AL Operating limit control 8 "0%!*.-0)1%#.-2!#2 8 %+%#20.-)#1%-1.0 8.#*.32.-$)!'-.12)#&!)+30% 8%1%2&0.,+.#*.324)!/.5%0#6#+% 90200EL Manual reset high limit control 8 "0%!*.-0)1%#.-2!#2 8 %+%#20.-)#1%-1.0 8.#*.32.-$)!'-.12)#&!)+30%!-$+),)2!#2).8!-3!+0%1%2&0.,+.#*.32 8.0%1%2&0.,/.5%0)-2%003/2).- 90200GL Two position step modulating Lo-Hi-Lo control 8 "0%!*.-0)1%#.-2!#2 8 %+%#20.-)#1%-1.0 8.#*.32.-$)!'-.12)#&!)+30% 8%1%2&0.,+.#*.324)!/.5%0#6#+% Easy Remote Sense (Electronic sensors, wired to control) Break-on-Rise Operation Self-checking Program (Control locks out on diagnostic failure) Control model Contacts Diagnostic/status LED’s AL EL !#2).-.-2%,/%0!230%0)1% Contact Rating (LED’s indicate “Power”, “Call for Heat”, and “Lockout”) "0%!*.-0)1% "0%!*.-0)1% VAC Locked rotor 3 3 120 VAC%320!+ %$ ()2% Break-on-rise OUT +!#* Modulating IN 4 ()2% 120 VAC.2.0 ),)2 Adjustable operating limit range "0%!*.-0)1% VAC Full load Quantity Wires GL VAC Power input 92.9 Fixed differential (subtractive) +!#*0%%- 92.9 92.9 -64!+3%&0.,92. 9 Operating temperature limits 92. 9 Storage temperature limits 792. 9 Agencies TECH SUPPORT 800-989-2275 -$)4)$3!+#.-20.+1!0%Listed &.0-)2%$2!2%1!-!$! carlincombustion.com 35 Model 99000B Commercial Boiler Control Package for Lo-Hi-Lo Mode — Data Sheet Model 90200AL diagnostic LED’s – OFF – ON Power AMBER – OFF – ON Control call for heat ** – FLASHING Lockout Model 90200EL diagnostic LED’s GREEN – OFF – ON Power RED – OFF – ON Lockout – FLASHING Lockout Pending EZ-Temp SENSOR INPUT – ON Power – OFF – ON Low Fire Calling AMBER – OFF B1 BL1 To Red / Wht 120 VAC NEUTRAL OUT. 120 VAC LIMIT OUT. 120 VAC FEED OUT. (IF NEEDED) L1 N S S2 H S S2 SERVICE SWITCH 120 Vac Power to Appliance G 90200EU – FLASHING Lockout – ON High Fire Calling Electrical shock hazard: Disconnect power to appliance when wiring or servicing any electrical component. EZ-Temp SENSOR INPUT S2 S1 S3 S S1 S S1 TRIPLE SENSOR Sensor Well: Located on JBox back center knockout. 90200GU Operation (See wiring diagrams for connections) When power is applied to unit, the green LED is turned ON. Lockout Pending 90200EL: If a diagnostic failure occurs or the sensor temperature rises above the high limit setting, the green LED will flash for 5 seconds. If the conditiion still exists after 5 seconds, the control will enter lockout requiring manual reset. (If the condition corrects before 5 seconds, the green LED will return to normal). Lockout Indicator 90200AL and 90200GL: When a diagnostic failure occurs, the LED blinks and the contact opens. The control will reset when the failure is removed and power is cycled. Call for Heat When the temperature at the sensor is below set point minus fixed differential, the control powers the limit relay (break-on-rise contact closes). On the 90200GL, the High Fire LED turns ON and the Low Fire LED turns OFF. On the 90200AL, the Amber LED turns ON. When temperature is at or above set point, the contact opens. On the 90200GL, the High Fire LED is turned OFF and the Low Fire LED is turned ON. On the 90200AL, the Amber LED turns OFF. EZ-Temp SENSOR INPUT S S3 S S3 J-Box Terminal Strip Power Indicator Lockout Indicator To Blk LWCO Limit, if used J-Box Terminal Strip – OFF AMBER (BREAK ON TEMPERATURE RISE). To Wht B2 Model 90200GL diagnostic LED’s GREEN TO BURNER PRIMARY CONTROL L2 J-Box Terminal Strip GREEN 90200AU ** Conduit connection. Locate at any knockout. ** Load Out LFOUT LFIN Feed In DRY CONTACT FOR LOW-FIRE ACTUATOR CONTROL. (CONTACT BREAKS ON TEMPERATURE RISE). Dimensions 4.12” 6.75” TECH 5.25” 6.75” SUPPORT HOTLINE 800-989-2275 Carlin Combustion Technology, Inc. 70 Maple Street e-mail us at: © Copyright 2010 — Carlin Combustion Technology, Inc. East Longmeadow, MA 01028 [email protected] Phone 413–525–7700 Fax 413–525–8306 vist our website: www.carlincombustion.com Carlin part number MN99000BC Rev. 01/27/10 36 EZ-Temp™ Model 99000C Lo-Hi-Lo Mode of Operation Data sheet Specifications s The EZ-Temp Commercial Boiler Package controls are provided as an assembled package. Pre-assembled and pre-wired operating limit and manual reset high limit and two positon step modulating control for commercial boilers and similar applications. Includes EZ-Temp model 90000CEL combination operating limit and manual reset high limit and EZ-Temp model 90200GL two position step modulating Lo-Hi-Lo temperature controls, mounted and wired on a two-gang J-box with terminal strips, one triple sensor, 3/4” immersion well (1.55” length) and mounting hardware. s Model 90000CEL and 90200GL microprocessor-operated temperature controls are UL Listed. The 90000CEL provides 2 contacts (break-on-rise) and the 90200GL provides a single contact (break-on-rise). s The 90000CE and 90200G are UL Recognized and may be purchased separately for replacement. 90000CEL Microprocessor-operated (Processor coordinates limit and diagnostic functions) 90200GL Easy Remote Sense (Electronic sensors, wired to control) Two position step modulating Lo-Hi-Lo control 8 "0%!*.-0)1%#.-2!#2 8 %+%#20.-)#1%-1.0 8.#*.32.-$)!'-.12)#&!)+30% 8%1%2&0.,+.#*.324)!/.5%0#6#+% Control model CEL !#2).-.-2%,/%0!230%0)1% Contact Rating "0%!*.-0)1% "0%!*.-0)1% VAC Full load VAC Locked rotor Quantity 3 4 120 VAC%320!+ Self-checking Program (Control locks out on diagnostic failure) GL VAC Power input Contacts Break-on-Rise Operation Combination operating limit and manual reset high limit control 8"0%!*.-0)1%#.-2!#21 8%+%#20.-)#1%-1.01 8.#*.32.-$)!'-.12)#&!)+30%!-$+),)2 !#2).8!-3!+0%1%2&0.,()'(+),)2+.#*.32 8.0%1%2&0.,/.5%0)-2%003/2).8)'(+),)22%12&3-#2).- Wires ()2% 120 VAC.2 ),)2 %$ ()2% Break-on-rise OUT +!#* Diagnostic/status LED’s +!#*0%%- Adjustable operating limit range 92.9 92.9 (LED’s indicate “Power On”, “Call for Heat”, “Lockout”, “High fire Calling” and “Low Fire Calling”) Fixed high limit range 92.9 .-% Fixed differentials (subtractive) Modulating IN Operating temperature limits Storage temperature limits Agencies TECH SUPPORT 800-989-2275 -64!+3%&0.,92. 9 92. 9 792. 9 -$)4)$3!+#.-20.+1!0%Listed &.0-)2%$2!2%1!-!$! carlincombustion.com 37 Model 99000C Commercial Boiler Control Package for On-Off Mode — Data Sheet Model 90000CEL diagnostic LED’s GREEN – OFF – ON Power RED – OFF – ON Lockout – OFF – FLASHING (Fast) Hi-Test – ON Call for Heat Model 90200GL diagnostic LED’s GREEN – OFF – ON Power AMBER – OFF – ON Low Fire Calling AMBER – OFF N SERVICE SWITCH 90000CEU – FLASHING Lockout EZ-Temp SENSOR INPUT – ON High Fire Calling ** L2 J-Box Terminal Strip AMBER – FLASHING (Slow) Latch-up TO BURNER PRIMARY CONTROL (BREAK ON TEMPERATURE RISE). To Wht B2 LWCO Limit, if used B1 BL1 To Blk To Red / Wht H G 120 VAC NEUTRAL OUT. 120 VAC LIMIT OUT. 120 VAC FEED OUT. (IF NEEDED) L1 S2 S2 S S1/S2 S1 S1 S2 S1 S3 TRIPLE SENSOR Sensor Well: Located on JBox back center knockout. 90200GU Electrical shock hazard: Disconnect power to appliance when wiring or servicing any electrical component. Power On When power is applied to unit, the green LED turns ON. Lockout 90000CEL: When the temperature at the High-Limit sensor reaches the High-Limit set point or a diagnostic fault occurs, the control goes into Lockout. The red LED turns ON and both contacts open. The control will automatically reset when all diagnostic faults are removed. Manual reset is required to resume operation after an over temperature High-Limit Lockout. Lockout 90200GL: When a diagnostic fault occurs, the control goes into Lockout. The green LED starts flashing and the contact opens putting the control into Low Fire. The control will automatically reset when all faults are removed. Call for Heat 90000CEL: When the temperature at the Operating-Limit sensor is below the Operating-Limit set point minus the fixed differential, the control powers the operating relay and it’s break-onrise contact closes. The Amber “Call for Heat” LED turns ON. J-Box Terminal Strip EZ-Temp SENSOR INPUT Operation (See wiring diagrams for connections) S S3 S S3 ** Load Out LFOUT LFIN Feed In DRY CONTACT FOR LOW-FIRE ACTUATOR CONTROL. (CONTACT BREAKS ON TEMPERATURE RISE). ** Conduit connection. Locate at any knockout. Dimensions 4.12” When the temperature is above the set point, the contact opens and the Amber LED Turns OFF. High-Fire Calling 90200GL: When the temperature at the sensor is below the Low-Fire Calling Low-Fire set point minus the fixed differential, the control powers the relay and the break-on-rise contact closes. The Amber High-Fire Calling LED turns ON and the Amber Low-Fire Calling LED turns OFF. High-Fire Calling When the temperature is above the set point, the contact opens. Low-Fire Calling The Amber High-Fire Calling LED turns OFF and the Amber Low Fire Calling LED turns ON. Latch-up (90000CEL) If the 90000CEL locks out three consecutive times, it enters latch-up. Reset from latch-up requires a special procedure, intended to require licensed serviceman intervention. During latch-up, the red LED stays on and the green LED slow flashes. Reset as follows: 2.12” After boiler is less than high limit setting minus differential: . . . . . . . . . . . . Hold reset button at least 10 seconds. The green LED flashes faster. . . . . . . . . . . . . Continue holding button another 20 seconds. The control resets and the red LED turns off. 6.75” High Limit Test “Hi-Test” mode (90000CEL ONLY), used to test “High Limit Reset” at operating boiler temperature. Start test with system operational and calling for heat. Turn setpoint full clockwise to HiTest position. Green LED flashes fast. The setpoint now adjusts both the high and operating limits. Turn setpoint slowly counter clockwise until Lockout occurs. Now the setpoint temperature equals the hi-limit sensor temperature. Test is complete, adjust setpoint to the desired operating limit. Remove from lockout. TECH SUPPORT HOTLINE 5.25” 800-989-2275 Carlin Combustion Technology, Inc. 70 Maple Street e-mail us at: © Copyright 2010 — Carlin Combustion Technology, Inc. East Longmeadow, MA 01028 [email protected] Phone 413–525–7700 Fax 413–525–8306 vist our website: www.carlincombustion.com Carlin part number MN99000CC Rev. 01/27/10 120 Vac Power to Appliance 38 EZ-Temp™ Model 99000D Proportional Mode of Operation Data sheet Specifications s The EZ-Temp Commercial Boiler Package controls are provided as an assembled package. Pre-assembled and pre-wired operating limit, manual reset high limit temperap ture and proportional control for commercial boilers and tu ssimilar applications. Includes EZ-Temp model 90200AL operating temperature limit control, EZ-Temp model o 90200EL manual reset high limit temperature control, and 9 EZ-Temp model 90200HL proprotional control, mounted E and wired on a three-gang J-box with terminal strips, a one triple sensor, 3/4” immersion well (1.55” length) and o mounting hardware. m s Carlin’s model 90200AL, 90200EL, and 90200HL microprocessor-operated temperature controls are described below. The 90200AL and 90200EL each provide a single contact (break-on-rise). The 90200HL provides a proportional modulating control output. 90200AL Temperature limit control 8 "0%!*.-0)1%#.-2!#2 8 %+%#20.-)#1%-1.0 8.#*.32.-$)!'-.12)#&!)+30% 8%1%2&0.,+.#*.324)!/.5%0#6#+% 90200EL Manual reset high limit control 8 "0%!*.-0)1%#.-2!#2 8 %+%#20.-)#1%-1.0 8.#*.32.-$)!'-.12)#&!)+30%!-$+),)2!#2).8!-3!+0%1%2&0.,+.#*.32 8.0%1%2&0.,/.5%0)-2%003/2).- 90200HL Proportional modulating control 8 %+%#20.-)#1%-1.0 8.#*.32.-$)!'-.12)#&!)+30% 832.0%1%2&0.,+.#*.325(%-&!3+20%,.4%$ Microprocessor-operated (Processor coordinates limit and diagnostic functions) Easy Remote Sense (Electronic sensors, wired to control) Break-on-Rise Operation Control model AL EL Self-checking Program Contacts (Control locks out on diagnostic failure) Contact Rating "0%!*.-0)1% !#2).-.-2%,/%0!230%0)1% (LED’s indicate “Power”, “Call for Heat”, and “Lockout”) Wires .-% Full load Locked rotor Quantity Diagnostic/status LED’s HL Power input 3 3 120 %320!+ ()2% 120 .2 ),)2 %$()2% Break-on-rise OUT 5 +!#* %++.5()2% Low Fire Common %++.5%$ High Fire %++.5+!#* Adjustable operating limit range 92.9 Fixed differential (subtractive) 92.9 92.9 92. 9 -64!+3%&0.,92. 9 92.9 Operating zone limits Operating temperature limits Storage temperature limits Agencies TECH SUPPORT 800-989-2275 92. 9 792. 9 -$)4)$3!+#.-20.+1!0%Listed &.0-)2%$2!2%1!-!$! carlincombustion.com 39 Model 99000D Commercial Boiler Control Package for Lo-Hi-Lo Mode — Data Sheet Model 90200AL diagnostic LED’s GREEN – OFF – ON Power – FLASHING Lockout AMBER – OFF – ON Control Call for heat 90200A ** TO BURNER PRIMARY CONTROL J-Box Terminal Strip L2 Model 90200EL diagnostic LED’s GREEN RED – OFF – OFF – ON Power – FLASHING Lockout Pending – ON Lockout LWCO Limit, if used B1 BL1 S EZ-Temp SENSOR INPUT To White B2 S To Black To Red / White (BREAK ON TEMPERATURE RISE). 120 VAC NEUTRAL OUT. 120 VAC LIMIT OUT. 120 VAC FEED OUT. (IF NEEDED) L1 N S2 H SERVICE SWITCH S2 120 Vac Power to Appliance G Model 90200HL diagnostic LED’s – OFF – ON Power – FLASHING Lockout AMBER – OFF Low Fire – ON High Fire – FLASHING % High Fire J-Box Terminal Strip 90200E GREEN Electrical shock hazard: Disconnect power to appliance when wiring or servicing any electrical component. EZ-Temp SENSOR INPUT Power When power is applied to unit, the green LED is turned ON. Lockout 90200EL: If a diagnostic failure occurs or the sensor temperature rises above the limit setting, the green LED will flash for 5 seconds. If the conditiion still exists after 5 seconds, the control will enter lockout. (If the condition corrects before 5 seconds, the green LED will return to normal). Lockout 90200EL: When the sensor temperature reaches the limit set point or a diagnostic failure occurs, the LED turns ON and the contact opens. Manual reset required to resume operation. If lockout was from a diagnostic failure, the control will reset automatically when failure is removed. Lockout When a diagnostic fault occurs, the control goes into Lockout and the green LED starts flashing. On the 90200AL, the contact opens. On the 90200HL, the output goes to full Low Fire. Either control will automatically reset when all faults are removed from it. Call for Heat 90200AL: When the temperature at the sensor is below set point minus fixed differential, the control powers the limit relay (break-onrise contact closes). The Amber LED turns ON. When temperature is at or above set point, the contact opens. The Amber LED turns OFF. High Fire 90200HL: When the temperature is at or below the operating temperature minus 1/2 the zone temperature, the control is requesting High Fire and the LED is ON. When the temperature is at or above the operating temperature plus 1/2 the zone temperature, the control is requesting Low Fire and the LED is OFF. In between the control modulates the motor to a position proportional to the sensor temperature. The LED blinks with an ON time proportional to this position. Low Fire S S1 S S1 TRIPLE SENSOR Sensor Well: Located on J-Box back center 90200H EZ-Temp SENSOR INPUT J-Box Terminal Strip Operation (See wiring diagrams for connections) S2 S1 S3 S S3 S S3 ** Conduit connection. Locate at any knockout. OUTPUT TO 135 PROPORTIONAL ACTUATOR ** Wht To White lead Red To Red lead Blk To Black lead SUPPORT WIPER COMMON HIGH FIRE Dimensions 5.25” 4.12” 6.75” TECH LOW FIRE HOTLINE 6.75” 800-989-2275 Carlin Combustion Technology, Inc. 70 Maple Street e-mail us at: © Copyright 2010 — Carlin Combustion Technology, Inc. East Longmeadow, MA 01028 [email protected] Phone 413–525–7700 Fax 413–525–8306 vist our website: www.carlincombustion.com Carlin part number MN99000DC Rev. 01/27/10 40 EZ-Temp™ Model 99000E Full Proportional Mode of Operation Data sheet Specifications s The EZ-Temp Commercial Boiler Package controls are provided as an assembled package. Pre-assembled and pre-wired operating limit and manual reset high limit and proportional modulating control for commercial boilers and similar applications. Includes EZ-Temp model 90000CEL combination operating limit and manual reset high limit and and EZ-Temp model 90200HL proportional modulating temperature controls, mounted and wired on a two-gang J-box with terminal strips, one triple sensor, 3/4” immersion well (1.55” length) and mounting hardware. s Model 90000CEL and 90200HL microprocessor-operated temperature controls are UL Listed. The 90000CEL provides 2 contacts (break-on-rise). The 90200HL provides a 135 ohm proportional modulating control output. s The 90000CE and 90200H are UL Recognized and may be purchased separately for replacement. 90000CEL Combination operating limit and manual reset high limit control 8"0%!*.-0)1%#.-2!#21 8%+%#20.-)#1%-1.01 8.#*.32.-$)!'-.12)#&!)+30%!-$+),)2!#2).8!-3!+0%1%2&0.,()'(+),)2+.#*.32 8.0%1%2&0.,/.5%0)-2%003/2).8)'(+),)22%12&3-#2).- 90200HL Proportional modulating control 8 %+%#20.-)#1%-1.0 8.#*.32.-$)!'-.12)#&!)+30% 832.0%1%2&0.,+.#*.325(%-&!3+20%,.4%$ Microprocessor-operated (Processor coordinates limit and diagnostic functions) Control model Power input Easy Remote Sense (Electronic sensors, wired to control) Contacts Wires Break-on-Rise Operation HL "0%!*.-0)1% .-% Full load Locked rotor 3 5 !#2).-.-2%,/%0!230%0)1% Contact Rating CEL Quantity 120 %320!+ ()2% 120 .2 ),)2 %$()2% Break-on-rise OUT +!#* %++.5()2% Self-checking Program Low Fire (Control locks out on diagnostic failure) Common %++.5%$ High Fire %++.5+!#* 92.9 Diagnostic/status LED’s (LED’s indicate “Power On”, “Call for Heat”, “Lockout”, and High Fire Calling”) Adjustable operating limit range 92.9 Fixed high limit range 92.9 .-% Adjustable band range 92. 9 -64!+3%&0.,9 2. 9 92.9 Fixed differentials (subtractive) Operating temperature limits Storage temperature limits Agencies TECH SUPPORT 800-989-2275 92. 9 792. 9 -$)4)$3!+#.-20.+1!0%Listed &.0-)2%$2!2%1!-!$! carlincombustion.com 41 Model 99000E Commercial Boiler Control Package for Full Proportional Mode of Operation — Data Sheet Model 90000CEL diagnostic LED’s GREEN – OFF – ON Power RED – OFF – ON Lockout AMBER – OFF – ON Call for Heat Dimensions – FLASHING (Slow) Latch-up 4.12” – FLASHING (Fast) Hi-Test Model 90200HL diagnostic LED’s GREEN – OFF – ON Power – FLASHING Lockout AMBER – OFF Low Fire – ON High Fire – FLASHING % High Fire Electrical shock hazard: Disconnect power to appliance when wiring or servicing any electrical component. Operation (See wiring diagrams for connections) Power On When power is applied to unit, the green LED turns ON. Self Test 90200HL: When the fault log display is complete, the self test checks the sensor and the microprocessor and verifies that all systems are operational. This test lasts up to 15 seconds before the control becomes fully operational. During the self test, the green LED blinks at a rate of 3 seconds per blink. Lockout 90000CEL: When the temperature at the High-Limit sensor reaches the High-Limit set point or a diagnostic fault occurs, the control goes into Lockout. The red LED turns ON and both contacts open. The control will automatically reset when all diagnostic faults are removed. Manual reset is required to resume operation after an over temperature High-Limit Lockout. Lockout 90200HL: When a diagnostic fault occurs, the control goes into Lockout. The green LED starts flashing and the control goes into Low Fire. The control will automatically reset when all faults are removed. Call for Heat 2.12” 6.75” 90000CEL: When the temperature at the Operating-Limit sensor is below the Operating-Limit set point minus the fixed differential, the control powers the operating relay and it’s break-on-rise contact closes. The Amber “Call for Heat” LED turns ON. When the temperature is above the set point, the contact opens and the Amber LED Turns OFF. 5.25” High-Fire Calling 90200HL: When the temperature is at or below the operating temperature minus 1/2 the band temperature, the control is requesting High Fire and the LED is ON. When the temperature is at or above the operating temperature plus 1/2 the band temperature, the control is requesting Low Fire and the LED is OFF. In between, the control modulates the motor to a position proportional to the sensor temperature. The LED blinks with an ON time proportional to this position. (90000CEL) If the 90000CEL locks out three consecutive times, it enters latchup. Reset from latch-up requires a special procedure, intended to require licensed serviceman intervention. During latch-up, the red LED stays on and the green LED slow flashes. Reset as follows. ** B2 LWCO Limit, if used B1 120 Vac Power to Appliance 120 VAC NEUTRAL OUT. 120 VAC LIMIT OUT. To Red / White L1 S2 EZ-Temp SENSOR INPUT S S2 S2 S1 S3 S1 & 2 S1 S1 TRIPLE SENSOR Sensor Well: Located on JBox back center knockout. After boiler is less than high limit setting minus differential: High Limit Test “Hi-Test” mode (90000CEL ONLY), used to test “High Limit Reset” at operating boiler temperature. Start test with system operational and calling for heat. Turn setpoint full clockwise to Hi-Test position. Green LED flashes fast. The setpoint now adjusts both the high and operating limits. Turn setpoint slowly counter clockwise until Lockout occurs. Now the setpoint temperature equals the hi-limit sensor temperature. Test is complete, adjust setpoint to the desired operating limit. Remove from lockout. 90200H ** Conduit connection. Locate at any knockout. EZ-Temp SENSOR INPUT J-Box Terminal Strip . . . . . . . . . . . . Continue holding button another 20 seconds. The control resets and the red LED turns off. SUPPORT To White To Black H G 120 VAC FEED OUT. (IF NEEDED) BL1 . . . . . . . . . . . . Hold reset button at least 10 seconds. The green LED flashes faster. TECH TO BURNER PRIMARY CONTROL (BREAK ON TEMPERATURE RISE). L2 J-Box Terminal Strip Latch-up N SERVICE SWITCH 90000CE S S3 S S3 OUTPUT TO 135 PROPORTIONAL ACTUATOR ** Wht To White lead Red To Red lead Blk HOTLINE To Black lead LOW FIRE WIPER COMMON HIGH FIRE Reverse Low Fire and High Fire leads to reverse motor direction. 800-989-2275 Carlin Combustion Technology, Inc. 70 Maple Street e-mail us at: © Copyright 2010 — Carlin Combustion Technology, Inc. East Longmeadow, MA 01028 [email protected] Phone 413–525–7700 Fax 413–525–8306 vist our website: www.carlincombustion.com Carlin part number MN99000EC Rev. 01/27/10 42 TM EZ-Temp Microprocessor Temperature Controls Instruction Manual E-Clamp Style with red sensor retainer plug Installer/servicer — Except where specifically stated otherwise, this manual must be used only by a qualified service technician. Read and follow all instructions in this manual and in the appliance manual. Failure to comply with this or other requirements in this manual could result in severe personal injury, death or substantial property damage. This symbol calls out a hazard that could cause severe personal injury, death or substantial property damage if the instructions given are not followed. Wiring: Refer to EZ-Temp data sheet for wiring information. Verify ratings: Verify the ratings of the control meet the requirements of the appliance as specified in the appliance instructions. Refer to the EZ-Temp control data sheet for required electrical supply and load ratings. Verify that the controls, wiring and installation comply with all applicable codes. Electrical shock hazard: Disconnect power to appliance when wiring or servicing any electrical component. Scald hazard: Water hotter than 130°F can cause serious burns or death. Follow water heating appliance manufacturer’s guidelines when installing temperature limit controls - DO NOT install a control that can be set at a higher temperature than specified. Also verify that the installation includes all water temperature regulating means needed to ensure the safety of building occupants, in compliance with all applicable codes. Verify operation: Test the controls/appliance to verify the appliance operates as specified in the appliance manual before leaving the installation. © Copyright 2008 — Carlin Combustion Technology, Inc. Carlin Combustion Technology, Inc. 70 Maple Street Ph 413-525-7700 TECH SUPPORT 800-989-2275 East Longmeadow, MA 01028 Fx 413-525-8306 carlincombustion.com 43 EZ-Temp Microprocessor Temperature Control — Instruction manual Install sensor(s) Configurations To install a new immersion well: Carlin EZ-Temp components are available in the following configurations, allowing use with existing wells in addition to EZ-Temp wells. 1. Turn off power to the appliance and close isolation valves. 2. Follow appliance instructions to drain the appliance so water line is below the insertion tapping. 3. Remove existing well and sensor. Apply a small amount of pipe dope to the new well and secure in tapping. 4. Insert EZ-Temp sensor into well and secure sensor in place as described in the following. 5. Refill appliance with water, following appliance manual procedures. When routing sensor wires, avoid sharp edges and use strain relief bushings at penetrations to prevent movement or electrical shorting of the sensor. Sensor wires are not low voltage, and must be routed in conduit. Configuration A: Sensor and well only 1. Insert the sensor into well (1) until the sensor (2) tip bottoms in the well socket. 2. EZ-Temp well: Slide the rubber retainer (3) over the sensor wires until it firmly contacts the sensor casing. Slide the retainer washer (4) and the jam nut (5) over the wires. Thread the jam nut into the well until snug. 3. Existing well: Press the sensor retainer plug (11) into the well until it securely holds the sensor wires, to prevent movement of the sensor. Surface-mount sensors are also available. s Control kits EZ-Temp controls mount to a standard 4x4 J-box or can be panel mounted. Control kits include the control and sensor(s) (item 2) plus hardware needed for mounting to an existing well (items 10 and 11). To obtain an EZ-Temp well and hardware, obtain an EZ-Temp well kit, below. s Well kits EZ-Temp wells are available in the sizes shown below. Well kits include a well (item 1), rubber sensor retainer (item 3), retainer washer (item 4), jam nut (item 5), and J-box lock washer (item 8). s Sensor Kits Sensor kits include only the sensor (item 2). Sensors are available in single and dual configurations (two sensors in the same assembly). For controls that use multiple sensors, obtain separate sensor kits or a sensor kit and a dual sensor. Configuration B: Sensor, EZ-Temp well and J-box 1. Insert the sensor into well (1) until the sensor (2) tip bottoms in the well socket. 2. Slide the rubber retainer (3) over the sensor wires until it firmly contacts the sensor casing. Slide the retainer washer (4) over the wires. 3. Slide the lock washer (8), J-box (7), and jam nut (4) over the wires. 4. Thread the jam nut into the well and tighten to secure the J-box and sensor in place. Configuration C: Sensor, EZ-Temp well and J-box 1. Insert the sensor into well (1) until the sensor (2) tip botoms in the well socket. 2. Slide the J-box (7) over the wires and secure the J-box in place by snapping the retainer ring (10) onto the well shoulder. 3. Press the sensor retainer plug (11) into the well until it securely holds the sensor wires, to prevent movement of the sensor. Mount the control 1. Insert sensor wire terminals into the labelled openings on the back of the control. Press into place firmly. 2. Attach the control to the 4x4 J-box or panel mount, as desired. Wire the control 1. Control wiring (including sensor wires) must be routed through conduit or electrical enclosures. Follow all applicable codes and the appliance manual. 2. Follow the burner and appliance wiring diagrams to connect the control(s) into the appliance limit circuit. 3. For specific applications, contact your Carlin supplier for further information. Set the control 1. Follow the appliance manual to set the correct limit temperature for the appliance. To adjust the EZ-Temp control: s )NSERTASCREWDRIVERINTOTHESETTINGSLOTANDROTATEUNTILTHEINDICATORPOINTS to the desired temperature. 2. Test the operation of the appliance and the new limit control(s) to verify correct operation. 3. NOTE: EZ-Temp controls have a subtractive differential — control contacts trigger when the temperature setting is reached. Contacts reset after temperature drops below setpoint minus the differential amount. –2– Carlin part number MNEZT Rev. 12/08/2008 44 TM EZ-Temp Microprocessor Temperature Controls Instruction Manual Well clamp with sensor retainer spring Installer/servicer — Except where specifically stated otherwise, this manual must be used only by a qualified service technician. Read and follow all instructions in this manual and in the appliance manual. Failure to comply with this or other requirements in this manual could result in severe personal injury, death or substantial property damage. This symbol calls out a hazard that could cause severe personal injury, death or substantial property damage if the instructions given are not followed. Wiring: Refer to EZ-Temp data sheet for wiring information. Verify ratings: Verify the ratings of the control meet the requirements of the appliance as specified in the appliance instructions. Refer to the EZ-Temp control data sheet for required electrical supply and load ratings. Verify that the controls, wiring and installation comply with all applicable codes. Electrical shock hazard: Disconnect power to appliance when wiring or servicing any electrical component. Scald hazard: Water hotter than 130°F can cause serious burns or death. Follow water heating appliance manufacturer’s guidelines when installing temperature limit controls - DO NOT install a control that can be set at a higher temperature than specified. Also verify that the installation includes all water temperature regulating means needed to ensure the safety of building occupants, in compliance with all applicable codes. Verify operation: Test the controls/appliance to verify the appliance operates as specified in the appliance manual before leaving the installation. © Copyright 2008 — Carlin Combustion Technology, Inc. Carlin Combustion Technology, Inc. 70 Maple Street Ph 413-525-7700 TECH SUPPORT 800-989-2275 East Longmeadow, MA 01028 Fx 413-525-8306 carlincombustion.com 45 EZ-Temp Microprocessor Temperature Control — Instruction manual Install sensor(s) Configurations To install a new immersion well: 1. Turn off power to the appliance and close isolation valves. 2. Follow appliance instructions to drain the appliance so water line is below the insertion tapping. 3. Remove existing well and sensor. Apply a small amount of pipe dope to the new well and secure in tapping. 4. Insert EZ-Temp sensor into well and secure sensor in place as described in the following. 5. Refill appliance with water, following appliance manual procedures. Carlin EZ-Temp components are available in the following configurations, allowing use with existing wells in addition to EZ-Temp wells. When routing sensor wires, avoid sharp edges and use strain relief bushings at penetrations to prevent movement or electrical shorting of the sensor. Sensor wires are not low voltage, and must be routed in conduit. s Well kits EZ-Temp wells are available in the sizes shown below. Well kits include a well (item 1), rubber sensor retainer (item 3), retainer washer (item 4), jam nut (item 5), and J-box lock washer (item 8). Configuration A: Sensor and well only 1. Insert the sensor into well (1) until the sensor (2) tip bottoms in the well socket. 2. EZ-Temp well: Slide the rubber retainer (3) over the sensor wires until it firmly contacts the sensor casing. Slide the retainer washer (4) and the jam nut (5) over the wires. Thread the jam nut into the well until snug. 3. Existing well: Press the sensor retainer plug (11) into the well until it securely holds the sensor wires, to prevent movement of the sensor. s Sensor Kits Sensor kits include only the sensor (item 2). Sensors are available in single and dual configurations (two sensors in the same assembly). For controls that use multiple sensors, obtain separate sensor kits or a sensor kit and a dual sensor. Surface-mount sensors are also available. s Control kits EZ-Temp controls mount to a standard 4x4 J-box or can be panel mounted. Control kits include the control and sensor(s) (item 2) plus hardware needed for mounting to an existing well (items 10 and 11). To obtain an EZ-Temp well and hardware, obtain an EZ-Temp well kit, below. A Configuration B: Sensor, EZ-Temp well and J-box 1. Insert the sensor into well (1) until the sensor (2) tip bottoms in the well socket. 2. Slide the rubber retainer (3) over the sensor wires until it firmly contacts the sensor casing. Slide the retainer washer (4) over the wires. 3. Slide the lock washer (8), J-box (7), and jam nut (4) over the wires. 4. Thread the jam nut into the well and tighten to secure the J-box and sensor in place. Configuration C: Sensor, EZ-Temp well and J-box 1. Remove the center knock-out from one side of the J-box (7). 2. Position the well clamp (10) over the end of the well (9) (sensor not yet installed) and slide the well clamp (10) toward the side of the J-box (9) engaging the keyslot opening with the well undercut. 3. Position the flat washer (13) over the open knockout and install the tensioning screw (14) through the flat washer (13) and into the well clamp (10), tighten. 4. Position the rubber retainer (12) over the sensor leads until the retainer stops at the sensor body. 5. Position the retainer spring (11) near the end of the rubber retainer as shown. 6. Slide sensor and retainer/sping assembly into well. Squeeze retainer spring ends together as the spring enters the well. The end of the spring should be within the well bore. B Sensor, J-box & EZ-Temp well C Mount the control 1. Insert sensor wire terminals into the labelled openings on the back of the control. Press into place firmly. 2. Attach the control to the 4x4 J-box or panel mount, as desired. Wire the control 1. Control wiring (including sensor wires) must be routed through conduit or electrical enclosures. Follow all applicable codes and the appliance manual. 2. Follow the burner and appliance wiring diagrams to connect the control(s) into the appliance limit circuit. 3. For specific applications, contact your Carlin supplier for further information. Sensor, J-box & existing well EZ-Temp well EZ-Temp sensor EPDM rubber retainer Retainer washer Jam nut Sensor leads J-box, 4 x 4 Set the control 1. Follow the appliance manual to set the correct limit temperature for the appliance. To adjust the EZ-Temp control: s )NSERTASCREWDRIVERINTOTHESETTINGSLOTANDROTATEUNTILTHEINDICATORPOINTS to the desired temperature. 2. Test the operation of the appliance and the new limit control(s) to verify correct operation. 3. NOTE: EZ-Temp controls have a subtractive differential — control contacts trigger when the temperature setting is reached. Contacts reset after temperature drops below setpoint minus the differential amount. –2– Lock washer Existing well Well clamp Sensor retainer spring 3.8” rubber retainer Flat washer Tensioning screw Carlin part number MNEZT5 Rev. 12/08/2008 46 / iÀÃÌÀÊ,iÃÃÌ>Vi qÊ</i«Ê-iÃÀÃ #ARLIN5n2ESIDENTIAL/IL"URNERSn0AGE 47 / iÀÃÌÀÊ,iÃÃÌ>Vi qÊ</i«Ê-iÃÀÃ #ARLIN5n2ESIDENTIAL/IL"URNERSn0AGE TECH SUPPORT HOTLINE 800-989-2275 Carlin Combustion Technology, Inc. 70 Maple Street East Longmeadow, MA 01028 Phone 413–525–7700 Fax 413–525–8306 e-mail us at: [email protected] © Copyright 2010 — Carlin Combustion Technology, Inc. vist our website: www.carlincombustion.com Carlin part number MNEZTEMP Rev. 03/26/10
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