Interrupted duty ignition

Recycle on flame failure

(flame failure lockout version also available)
Serviceman reset protection
(Latch-up after three consecutive lockouts (1))
Diagnostic & flame indicator LED’s
Pre-purge and post-purge
(contact Carlin for available timings)
2-second ignition establishment period
4-second TFI (trial for ignition)(other timings available)
(1.3-second flame failure response time (FFRT))
Alarm contacts Installing and wiring
Flame signal test jack Warning — The 60200FR control must be installed and serviced only by
Thermostat/aquastat compatible a qualified service technician.
(2) 1. Always disconnect power source before wiring to avoid electrical shock
SMC Technology or damage to the control. All wiring must comply with applicable codes
and ordinances.
2. Thermostat terminals (T–T) provide a current source. Never apply
external power to these terminals under any circumstances.
3. Alarm terminals provide a 24 vac-rated dry contact, suitable for use
with security/fire alarm systems such as Carlin SecureHeat™.

Mounting
• The control may be mounted on a 4” x 4” junction box in any convenient
location on the burner, furnace or wall. The location must not exceed
the ambient temperature limit, 140°F.

Wiring
• Wiring must comply with local and national electrical codes, and in
accordance with the wiring diagram above.

Field checks
1. Safety timing (TFI) test — Disconnect flame rod wire from control.
Start burner. After the pre-purge period, the control activates ignitor.
Control should lockout within TFI timing plus 2 seconds. Replace wire
(1) Latch-up mode shuts down the control after three consecutive lockouts, and requires a after test.
special procedure to reset. This ensures the owner will call in a technician to troubleshoot
burner problems. 2. Flame failure/recycle test — Start burner. After flame is established
(after TFI period), close the gas supply hand valve. This will cause a
(2) The 60200FR provides two motor relays. Carlin’s patented SMC technology (Safety flame failure sequence as described on the reverse side of this Data
Monitoring Circuit ) monitors the contacts of both motor relays and the gas valve relay. sheet. The control should recycle (restart after 65 seconds).
No start-up is allowed if a motor relay contact is found closed when it should be open —
or — if the gas valve relay contact shows power when the control starts up. The second 3. If control does not operate as described, check the wiring.
motor relay ensures motor shutdown even if the first motor relay fails.

Te ch s u p p ort 800-989-2275 carlincombustion.com

Model 60200FR Microprocessor flame rod gas primary control — Data sheet — Operation/Troubleshooting

Start-up & operation Model 60200 diagnostic LED’s

Do not start the burner if the combustion chamber contains residual gas. – Amber OFF – Red OFF – Green OFF
Allow gas to disperse.
– Amber ON – Red ON – Green ON
Per UL requirements, the control will not turn on if the flame rod senses
flame during the self-test. If the flame rod senses flame, the green LED – Amber FLASHING – Red FLASHING
turns on. The control will remain in self-test mode until the flame rod
no longer senses flame. The amber LED will remain on, but blink off – Amber BLINKING (blinks off momentarily every 3 to 4 seconds)
momentarily every 3 to 4 seconds.
Check 60200FR control label for trial for ignition (TFI), pre-purge and
post-purge timings.

Power ON Open all manual gas line valves. Close the line switch. (If Red LED turns Service & Troubleshooting
on constant , control is in lockout. See below to reset.)
Burner (control) will not come on
Self-test 1 The control performs a “boot-up” test to verify internal operation each
time power is applied to the red/white wire. About 4 seconds after power No power to control
application, the amber LED turns on. The test continues for about 6
• Check line voltage to the control (at least 95 vac).
more seconds. If the test fails, the control turns the amber LED off and
repeats this test sequence until successful. • Check all electrical connections.
Stand-by (No call for heat) If Self-test 1 is successful, amber LED turns off and Control is in lockout
control waits for heat call.
• Red LED will be on. Press the reset button for 1 second.
Call for heat Set thermostat (or limit) to call for heat. Thermostat circuit must be   • If the control returns immediately to lockout: Use a voltmeter
closed and power coming to black wire from limit circuit. to check power to the gas valve. (Also check the power to the
Self-test 2 The amber LED turns on. For the first 3 to 4 seconds, the control per- valve after resetting control and attempting another start.)
forms a self-test. If the flame rod senses flame, the green LED turns on. The control may have detected power on the valve relay
The control repeats the self-test until flame is no longer detected (green contact. If the gas valve wire shows 120 vac, check wiring
LED would turn off). During this time, the amber LED will remain on, but to make sure wiring is correct and there is no external power
blink off momentarily every 3 to 4 seconds. If the control detects feed to the valve. Correct wiring if needed. If the voltmeter
motor contacts closed, no start-up is allowed. shows no power to the valve, the circuit may have an internal
Burner on After the self-test, the amber LED turns off. The motor starts.
control problem. Replace the control.
Flame rod sensing flame
Pre-purge The ignitor starts after the pre-purge period. Two seconds later, the gas
valve opens. The 2-second delay (ignition establishment period) helps • Amber LED blinks off each 3 to 4 seconds; green LED on.
ensure a stable spark is in place when the gas valve opens (to compen- Remove flame rod lead from rod.
sate for sluggish response of some AC ignition transformers).
If the amber LED remains on with a wire detached, the
TFI After gas valve opens, the flame rod must sense flame within the TFI control is defective.
time lmit (trial for ignition). The green LED turns on at the end of If amber and green LED’s go off , control is OK, and either
the TFI if the flame rod senses flame.
the rod is defective or there is a problem with the rod wiring.
Run The burner continues firing during call for heat if the flame rod senses To troubleshoot:
flame. Amber and red LED’s are off during normal running.
• Check flame rod by using an ohmmeter to check resistance
Lockout If flame rod does not sense flame within the TFI time limit after gas from flame rod to ground — should be at least 1 megohm.
valve activation (TFI), lockout occurs. The control turns the red LED on
• Connect a flame simulator to the control flame rod lead. If
constant, and closes the alarm contact. Green LED is off.
green LED turns on, flame rod assembly is defective. Replace
To Reset Push in and hold reset button for 1 second, then release. assembly.
Latch-up If the control locks out 3 times during a single call for heat, latch-up oc-
curs. The control turns on both the amber and red LED’s constant. You Repeated flame failures ( flashing red LED)
must use the special procedure below to reset the control after latch-up.
Check for:
Reset after latch-up — Only a qualified service technician should • Defective flame rod assembly
attempt to reset the control after latch-up. The problem that caused
the repeated burner problems must be corrected before returning the • Excessive airflow or draft causing flame to leave burner
burner to normal operation. head — Check for proper air band setting and draft.
Push in and hold the reset button for about 10 seconds. The amber and • Excessive back pressure causing flame to be erratic — Check
red LED’s will begin to flash alternately. appliance and flue for sooting/plugging.

After the LED’s begin flashing, continue to hold the reset button for
about another 20 seconds. The LED’s will turn off. Release the reset but- Control locks out after TFI ( red LED on)
ton and the control will restart. (Releasing the button before the LED’s Check for:
turn off will cause the control to remain in latch-up.)
• No gas to burner — Check gas supply and lines. Verify gas
The 60200FR control will not reset from lockout or latch-up if power is pressure is no higher than allowed for gas valve (usually ½
interrupted. psig maximum).
Flame failure If the flame rod loses flame signal during operation (after the TFI), the • Shorted electrode — Inspect for cracked porcelain and
red LED flashes. The gas valve closes within 2 seconds. The motor replace as needed.
remains on for the motor delay off period, then shuts off. Recycle: • Poor spark — Check electrode spacing and condition per
Control waits for 65 seconds (with red LED flashing), then begins again
burner manual. Replace or realign if necessary.
at Self-test 2. Red LED goes off .
(NOTE: Controls with non-recycle feature will lockout on flame failure. • Airflow too high — Check air band setting.
Model 60200FRN only.) • Ignitor module defective — Replace if no spark.
Post-purge Set thermostat (or aquastat) to stop call for heat. The gas valve will turn • Flame rod defective or shorted to burner chassis.
off within 2 seconds. The motor remains on for the post-purge period, • Gas valve stuck in closed position. Check wiring connections.
then turns off. Replace as necessary.
Stand-by Control remains in stand-by mode until limit circuit sends power to the • Reversed 120 vac polarity — Make sure the hot and neutral
black wire and thermostat circuit closes (call for heat). lines are not reversed at power entrance.

© Copyright 2011 — Carlin Combustion Technology, Inc. Carlin part number MN60200FRC Rev. 10/03/11