Component Testing

Carlin Combustion Technology, Inc.70 Maple StreetEast Longmeadow, MA 01028Tech Service Hotline: 1-800-989-2275

Carlin Ignitor Testing Procedure

This test procedure consists of three tests. The first test should be the ignitor spark test. The second test is a secondary coil resistance test. The third test consists of an input current test. The following is a step by step procedure to perform these tests. It is important that all three of these tests be performed.

41000 Ignitor Spark Test

1. Turn off the power to the burner/appliance. 2. Disconnect the ignitor wires in the burner junction box. 3. Release the ignitor hold down screws or clips. 4. Swing the ignitor plate fully open. 5. Bend the copper ignitor clips until the clip ends are from 5/8” to ¾” apart (see

figure 1). 6. Connect a test power cord with a switch to the ignitor leads in the burner

junction box. 7. Turn on the test power cord switch to power the ignitor. 8. Check for spark across the ignitor clip ends (see Figure 1). 9. If spark occurs, proceed the secondary coil test below. 10. If spark does not jump the gap, or if the spark jumps intermittently, ignitor is

defective and should be replaced. 11. Turn off power to the ignitor.

41000 Secondary Coil Resistance Test

1. Turn off the power to the burner/appliance. 2. Release the ignitor plate hold down screws or clips. 3. Swing the ignitor plate fully open. 4. Use an ohmmeter to check the resistance from electrode to ground for each of

the electrodes (Figure 2 and 3). 5. The secondary coils are good if the difference between the two readings is less

than 10%. 6. If the difference in the electrode-to-ground resistance is more than 10%, the

secondary coil may be failing. Replace the ignitor. 7. If the difference between electrode-to-ground is within 10%, proceed with the

input current test.

Figure 1

41000 Input Current Test

1. Turn off the power to the burner/appliance. 2. Disconnect the ignitor wires in the burner junction box. 3. Release the ignitor hold down screws or clips. 4. Swing the ignitor plate fully open. 5. Bend the copper ignitor clips or springs until the clip ends are ½” apart. 6. Set a multimeter to read AC milliamps. 7. Using a test power cord with a switch, wire the ignitor blue lead to one of the

multimeter leads. Wire the other lead of the multimeter to the hot side of the test cord. Wire the white ignitor wire to the neutral side of the test cord. (Figure 4)

8. Insure the multimeter is set for AC milliamps and turn on the test power cord switch to power the ignitor. If there is no spark, replace the ignitor.

9. Monitor the input current with the multimeter set on AC milliamps for 5 minutes.

10. If at any time the reading drops below 300 milliamps AC, the ignitor should be replaced.

11. Turn off the power to the ignitor. 12. Remove the power test cord. 13. Readjust ignitor clip spacing (1 inch ± 1/8 inch). 14. Wire the ignitor in its original condition (per burner wiring diagram). 15. Replace all components to normal condition.

Figure 2 Figure 3

Figure 4

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Field testing oil valves

Always disconnect power source before wiring to avoid electrical shock or damage to electrical com-ponents.

Checking SVC-10FF coil resistance

• You can determine whether the oil valve coil is normal by measuring the resis-tance across the coil.

• Disconnect power to the burner. Then disconnect one of the oil valve wires in the junction box.

• Measure the resistance from one coil wire to the other. If the coil is good, the resistance should be between 494 and 526 ohms. If not, replace the oil valve.

Check A2VA-3006 oil valve coil resistance

• You can determine whether the oil valve coil is normal by measuring the resis-tance across the coil.

• Disconnect power to the burner. Then remove the power lead to the A2VA-3006

coil.

• Measure the resistance

between the bottom two terminals of the coil. The resistance

should be be-tween 350 and

550 ohms. If not, replace the oil valve.

OilValves

Application tips

1. Carlin solenoid oil safety shut-off valves help to provide years of safe, effi cient oil burner performance while adding reliability to the burner and oil delivery system.

2. Carlin’s SVC oil valves are direct-act-ing, two-way, normally-closed. Use on single or two-pipe oil systems to isolate the fuel pump, preventing the possibility of oil tank siphoning.

3. Carefully review the burner instruc-tion manual when applying to en-sure the oil valve is correctly wired and the burner fuel lines are cor-rectly installed.

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coil is normal by measuring the resis-tance across the coil.

• Disconnect power to the burner. Then remove the power lead to the A2VA-3006

coil.

• Measure the resistance

between the bottom two terminals of the coil. The resistance

should be be-tween 350 and

550 ohms. If not, replace the oil valve.

Carlin SVC-10FF

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Field testing

Nozzle line heaters

• You can check the integrity of a nozzle line heater using your Carlin multimeter.

• Disconnect power to the burner and appli-ance. Make sure the burner and all internal parts are cool to the touch.

• Separate the nozzle line heater at its disconnet.

• Insert the probes of your multimeter into the nozzle line heater connector sockets.

• Set the meter for ohms and read the resistance.

• The heater is accept-able if the resistance is between 600 ohms and 1,500 ohms.

• Replace the heater if the resistance is less than 600 ohms or more than 1,500 ohms.

Nozzle line heater

Advantages

• Start-ups are cleaner with heated oil.

• Heating the oil re-duces viscosity.

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What does cadmium sulfi de do?

• Cadmium sulfi de is an electrical conduc-tor.

• When cadmium sulfi de is exposed to visible light, its resistance changes. The stronger the light source, the lower the resistance.

• When the burner isn’t fi ring, with the cad cell inside and not exposed to any light, the cad cell has a high resistance (over 50,000 ohms).

• When the burner fl ame starts, the cad cell sees the light from the fl ame, and its resistance drops.

• The primary control (48245, 60200, for examples) knows fl ame is present be-cause it senses this resistance change.

Fixed resistance primary test

Use this method to test the performance of a primary control, removing the cad

cell as a factor.

• Remove the cad cell wires from the primary control’s “F-F” terminals.

• Connect one end of a ¼-watt, 1500 ohm (1.5 kΩ) resistor to one of the “F-F” terminals.

• Start the burner. AFTER fl ame has been established,

connect the other end of the 1.5 kΩ resistor to the other “F-F” terminal.

• If the primary control is operating cor-rectly, it should accept this resistance and operate normally. If the control does not operate correctly, replace the con-trol.

• Remove the resistor and replace the cad cel leads on the “F-F” terminals.

CadCells

Cad cell construction

A cad cell contains:

• a sensing plate coated with cadmium sulfi de.

• a metal grid on the cadmium sulfi de to supply the two connections from the sensor.

• a clear coating over the cadmium sulfi de and grid that prevents con-tamination from moisture, dirt and oil.

• a housing to mount the sensor as-sembly.

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• Remove the cad cell wires from the primary control’s “F-F” terminals.

• Connect one end of a ¼-watt, 1500 ohm (1.5 kresistor to one of the “F-F” terminals.

• Start the burner. AFTER fl ame has been established,

connect the other end of the 1.5 kΩ resistor to the other “F-F” terminal.

• If the primary control is operating cor-• If the primary control is operating cor-rectly, it should accept this resistance and operate normally. If the control does not operate correctly, replace the con-trol.

• Remove the resistor and replace the cad • Remove the resistor and replace the cad cel leads on the “F-F” terminals.

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Field testing a cad cell

Check room light resistance

1. With normal room lighting, the cad cell resistance when in the open, as at right, should be less than 10 kohms.

2. In the example shown, the resistance measured 195.1 ohms. Notice that the meter automatically adjusts the range for the best reading. In this case, the range shifted to ohms.

3. If the cad cell resistance is too high, try cleaning the cell and measure the re-sistance again. If resistance is still too high, replace the cell.

4. If the cad cell resistance is below 10 kohms, perform a dark resistance test.

Check dark resistance

1. With the cad cell mounted inside the burner, with no fl ame, the cad cell should have very little light available. The cad cell resistance should be at least 50 kohms.

2. The illustration on bottom right shows a test of dark resistance by securely covering the end of the cell. In this in-stance, the cad cell resistance measured 82.2 kohms. (The meter automatically changed the range to kilohms.)

3. If the cad cell resistance is below 50 kohms when the cad cell is mounted in-side a closed burner with no fl ame, make sure the combustion chamber is cool and there is no stray light entering the burner.

Light resistance:

Cad cell resistance in room light

Dark resistance:

Cad cell resistance with no light (or when inside burner with no fl ame)

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As air temperature changes, so does the CO2 and O2

• Once an oil burner is setup, the fan always pulls through about the same volume of air (cfm) regardless of air temperature. (Air fl ow will be reduced if the overfi re pressure increases due to a dirty heat exchanger, or if the inlet air is blocked or the blower blades are dirty or linted.)

• Air density changes with temperature. The colder the air, the more dense the air.

• The blower pulls in a constant volume of air. If the air density changes, weight of air (pounds) entering the burner changes. When the air is colder (heavier), more pounds of air enter. When the air is warm-er (lighter), less pounds of air enter.

• When combustion air comes from inside, it comes in at room temperature, so the temperature of the air doesn't change much throughout the year. But when air is ducted directly from outside, it isn't heated much before it reaches the burner. It comes in pretty close to the outside temperature. In the summer, it could come in at 90°F or higher, while coming in at below -20°F in the winter. The air temperature difference between summer and winter could easily be 100°F for some areas.

• The table at left shows the change in the amount of air (pounds) as the temperature of the air changes.

• Take the air temperature into account when you set up a burner with ducted com-bustion air.

• % CO2 rises as air temperature rises.

• % CO2 drops as air temperature drops.

If you don't consider this, burner combus-tion can become very poor as air tempera-ture changes.

• Refer to the setup temperature chart at left for suggested setup values based on enter-ing air temperature.

Combustion air temp

Air changes with temperature

Recommended combustion settings based on inlet air temperature (for locations operating with outside air temperature between -20°F and +90°F)

Combustion Air Temperature Chart

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Thermistor Resistance– EZ-Temp Sensors

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Thermistor Resistance– EZ-Temp Sensors