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Combustion Research Omega II Installation, Operating, Maintenance And Parts Manual

Gas fired, low intensity infrared unitary infrared heating systems
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FOR YOUR SAFTEY
If you smell gas:
1. Open windows
2. DO NOT try to light any appliance
3. DO NOT use electrical switches
4. DO NOT use any telephone in your
building
5. Leave the Building
6. Immediately call your local gas
supplier after leaving the building.
Follow gas supplier's instructions.
7. If you cannot reach your gas
supplier, call the fire department.
!
WARNING
Fire Hazard
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
Some objects will catch fire or explode
when placed near this heater.
Failure to follow these instructions can
result in death, injury or property
damage.
Read and understand these installation, operating and maintenance
instructions thoroughly before installing or servicing this equipment.
Only trained, qualified gas installation and service personnel may
install or service this equipment.
A gas-fired appliance could expose you to substances in fuel or fuel
combustion, which has been determined by the State of California to
cause cancer, birth defects, or other reproductive harm. Contact
factory for further information.
Please take time to read and understand these
instructions prior to any installation. Installer must
give a copy of this manual to the owner
Keep this manual in a safe place in order to provide
your serviceman with the necessary information.
Combustion Research Corp.
2516 Leach Rd.
Rochester Hills, MI 48309-3555
Telephone: 248.852.3611
Fax: 248.852.9165
www.combustionresearch.com
Issue Date: 7/15/2008
COMBUSTION RESEARCH CORPORATION
Gas fired, Low Intensity Infrared Unitary
WARNING
!
Installer
Owner
Revision Date: 2/16/2017
Pre Engineered Packages
Infrared Heating Systems
Installation, Operating, Maintenance
Rev. 4a
and Parts Manual
TM
TM
Bulletin OM080715

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Summary of Contents for Combustion Research Omega II

  • Page 1 COMBUSTION RESEARCH CORPORATION FOR YOUR SAFTEY If you smell gas: 1. Open windows 2. DO NOT try to light any appliance 3. DO NOT use electrical switches Pre Engineered Packages 4. DO NOT use any telephone in your building 5. Leave the Building Gas fired, Low Intensity Infrared Unitary 6.
  • Page 2 ® Omega II Installation, Operation & Service WARNING FIRE OR EXPLOSION HAZARD Can cause death, severe injury and/or property damage. 1. Read this manual carefully before installing or servicing Vehicles: Minimum clearances must be maintained from this equipment. Improper installation, service vehicles parked, below the heater.

  • Page 3: Table Of Contents

    All rights reserved. No part of this work covered by the copyrights hereon in may be reproduced or copied in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval systems - without written permission of COMBUSTION RESEARCH CORPORATION, Inc.
  • Page 4 ® Omega II Installation, Operation & Service This Page Intentionally Left Blank Combustion Research Corporation...

  • Page 5: Heater Safety & Burner Label Placement 1

    Please contact Combustion radiant tubes used on this system as well as various Research Corp. or your Combustion Research Corp. venting components have sharp edges. The use of gloves independent representative to obtain signs or labels.
  • Page 6 ® Omega II Installation, Operation & Maintenance Venting Instructions Label Side Panel Rating Plate Label Clearance to Combustibles Label P/N 900.2601 P/N 900.2730 Side Panel Operating Instructions Label P/N 900.2701 Page 2 Combustion Research Corporation...

  • Page 7: Warning Symbols

    2. In other sections of aircraft hangers, such as shops or carrier and Combustion Research Corporation Sales offices communicating with airplane storage or servicing Representatives within 72 hours.

  • Page 8: Installer Qualifications & Responsibility

    Code, and should be installed in accordance with all building. National and Local Codes and ordinances. ® The general lay out of the Omega II heating system has CLEARANCES AND ACCESSIBILITY been established by the engineering drawing. The Omega ®...

  • Page 9: Assembly - Tube And Reflectors

    ® Omega II Installation, Operation & Maintenance Combustion Tube STRAIGHT & "U" TUBE ASSEMBLY End View CAUTION CUT HAZARD - SHARP EDGES. Weld Seam Position on Bottom Of Tube Apply sealer sparingly to inside edge of radiant tube, spread with dowel or plastic tube.
  • Page 10 ® Omega II Installation, Operation & Maintenance 10’ SYSTEM 3.5” STRAIGHT TUBE SYSTEM Note: Install Reflector inside hanger as shown. 66” 20’ SYSTEM - TURBULATOR - BURNER END 118” 55” 55” - HANGER 30’ SYSTEM - REFLECTOR SUPPORT 118” 118”...
  • Page 11 ® Omega II Installation, Operation & Maintenance 5’ “U” 3.5” “U” TUBE SYSTEM 10’ TUBE LENGTH 44” - TURBULATOR 10’ “U” - BURNER END 20’ TUBE LENGTH - HANGER - REFLECTOR EXPANSION JOINT 66” 15’ “U” 30’ TUBE LENGTH 66”...

  • Page 12: Suspension Methods

    SUSPENSION VERTICAL FASHION WHEN INITIALLY INSTALLED (BURNER NOT FIRING). If chain is not supplied by Combustion Research Corp., WARNING furnish a chain with a minimum 90 lb. workload (trade size #3 or larger). A minimum of 12" (30 cm) of hanging chain is recommended.

  • Page 13: Combustion Tube Installation

    – see the illustration below. The panel hangers may also be suspended horizontally or ® The Omega II system reflectors can be suspended at a 30° angle – see illustration below. horizontally or at a 30° angle. The combination hanger is...

  • Page 14: Seismic Restraint Suspension

    ® Omega II Installation, Operation & Maintenance tube and reflector network will be required. See the SEISMIC RESTRAINT SUSPENSION METHODS “Seismic Suspension For High Wind Applications” below for details. If there are any questions regarding what method For standard seismic restraint such as earthquake prone...

  • Page 15: Burner Connection & Installation

    ® Omega II Installation, Operation & Maintenance Iron, Uni-strut, etc. and then suspend the chain so that it CONNECTING BURNER ASSEMBLY TO hangs vertically. RADIANT TUBE/REFLECTOR ASSEMBLY WARNING WARNING FIRE OR EXPLOSION HAZARD FIRE OR EXPLOSION HAZARD IMPROPER INSTALLATION, ADJUSTMENT,...

  • Page 16: Gas Supply

    LP gas pipe work. piping. ® When leak testing the gas piping system, the Omega II  Support all gas piping with suitable suspension burners must be isolated from the gas piping system. High- materials and in accordance with local codes pressure compressed air used in the leak test will damage ...

  • Page 17: Flexible Gas Connector Installation

    MANIFOLD MAY CAUSE DAMAGE. ALWAYS USE United States - Use only the stainless steel flexible gas TWO (2) WRENCHES WHEN MAKING PIPING connector as supplied by Combustion Research CONNECTIONS TO THE BURNER. DO NOT APPLY Corporation. PIPE DOPE TO FLARE NUT FITTINGS OF THE Canada –...

  • Page 18: Technical Data

    ® Omega II Installation, Operation & Maintenance GAS PRESSURE AT MANIFOLD GAS INLET PRESSURE Natural Gas: 3.5" W.C. Natural Gas: 6.0" W.C. Minimum 14.0"W.C. Maximum LP Gas: 10.0" W.C. LP Gas: 11.0" W.C. Minimum 14.0" W.C. Maximum 1/2" NPT Gas Connector Size...

  • Page 19: System Dimensions

    ® Omega II Installation, Operation & Maintenance ® 3.5" OMEGA II SQ. FT. RADIANT PART NUMBER BTU/Hr INPUT ("U" TUBE SYSTEM) (STRAIGHT TUBE SYSTEM) SURFACE AREA 0922.NG/LP 40,000 5'0"/10'0" 10'0"/19'8" 9.2 / 18.3 0921.NG/LP 45,000 5'0"/10'0" 10'0"/19'8" 9.2 / 18.3 0920.NG/LP...

  • Page 20: Clearance To Combustibles 16

    A temporary sign can be found at the end of assure that adjacent materials are protected from this manual. Contact your sales representative or degradation. Combustion Research Corporation for this self adhesive label – P/N 5566.006. UNVENTED END CLEARANCE ROOF Min.
  • Page 21 ® Omega II Installation, Operation & Maintenance HORIZONTAL MOUNTING DEEP &STANDARD REFLECTOR DEEP & STANDARD REFLECTOR DEEP & STANDARD REFLECTOR WITH ONE SIDE SHIELD WITH TWO SIDE SHIELD PANEL REFLECTOR PANEL REFLECTOR PANEL REFLECTOR WITH ONE SIDE SHIELD WITH TWO SIDE SHIELD 30 DEGREE ANGLE MOUNTING DEEP &...

  • Page 22: Side Shield Installation

    ® Omega II Installation, Operation & Maintenance INSTALLATION PROCEDURE 0812.00 REFLECTOR & 0367.00 SIDE SHIELD The P/N 0366.00 side shield is used o the deep reflector. The PN 0367 side shield is designed for use on standard, and panel reflectors. This side shield may be installed on Field fab relief either side of the reflector.

  • Page 23: Combustion Air 19

    ® Omega II Installation, Operation & Maintenance including the space that is being heated, PROVIDED COMBUSTION AIR SUPPLY the building does not have a negative pressure and the atmosphere is not contaminated with acid fumes, fluorocarbons, corrosive substances, dirt, oil, etc., which...
  • Page 24  Maintain a minimum of six inches (6") between the inlet hood and the exterior wall. ® When two OMEGA II systems are controlled by one  thermostat a common combustion air supply can be used. Install 4" diameter flex nearest inlet trunk.

  • Page 25: Venting

    Vent enclosed spaces and buildings according Temperature Silicone Adhesive Sealant or equivalent. to national, state, provincial and local codes. Use Combustion Research Corp. P/N 1810.VT.400 (Metalbestos 4RV-RT) or P/N 1811.VT.400 (Simpson Dura Vent 4GVVTH) vent caps. Heater vent must be installed in accordance with the National Fuel Gas Code, ANSI Z223.1 (current standard)
  • Page 26 ® 1. The total stack length from the OMEGA II exhaust to 4. Connections to a common stack should be staggered so the point where it terminates should be a minimum of as to avoid direct opposition between streams of three feet (3') and a maximum of twenty feet (20').
  • Page 27 ® Omega II Installation, Operation & Maintenance HORIZONTAL VENTING, NON-COMBUSTIBLE WALLS Vent Cap Seal penetrations P/N 1810.VT.400 or P/N 1811.VT.400 ® Omega II Exhaust 4” Single wall vent pipe Use 4” Type “B” Min. 6” Vent pipe for wall Max. 18”...
  • Page 28 This will insure that both the heaters and the ventilation operate simultaneously. ® Although the OMEGA II units are approved for un-vented DO NOT USE UNVENTED SYSTEMS IN AGRICULTURAL operation, THIS IS NOT A RECOMMENDED OPTION. The APPLICATIONS.

  • Page 29: Electrical Information

    ® OMEGA II Burner Assembly. ® The OMEGA II Burner Assembly shall be connected to a power supply branch circuit fused at not more than the value appropriate for the rating of any control or device included in the circuit.
  • Page 30 ® Omega II Installation, Operation & Maintenance INTERNAL WIRING DIAGRAMS !! WARNING !! DO NOT ATTEMPT TO RE-WIRE INTERNAL BURNER WIRING 24 VOLT TRANSFORMER IS NOT TO BE USED FOR ANY THERMOSTAT OPERATION Page 26 Combustion Research Corporation...

  • Page 31: Thermostat Wiring

    ® Omega II Installation, Operation & Maintenance LINE VOLTAGE THERMOSTAT WIRING LOW VOLTAGE THERMOSTAT WIRING 115V – 60Hz L1 (H) L2 (N) Black White Black W G Y Brown Low voltage thermostat COIL COIL (PN 5483.00) (BOTTOM VIEW) (TOP VIEW)

  • Page 32: System Start-Up 28

    PRECONDITIONS TO BE CHECKED BEFORE BURNER SYSTEM STARTUP 1. System has been installed to Combustion Research Corporation recommendations in Installation Manual and nameplate data. 2. the system must be installed with adequate clearance to combustibles as outlined in this manual.

  • Page 33: Sequence Of Operation

    5. At this time, manually shut off the gas and verify that the "flame failure shutdown" occurs. Open the manual gas ® valve and turn off the power to the OMEGA II BURNER ASSEMBLY to reset the control. FIRE OR EXPLOSION HAZARD. CAN 6.
  • Page 34 Look for cracks, holes, physical damage, etc. Replace as needed. NOTE: WARNING ® Use only approved OMEGA II tube which is specifically ® manufactured for the OMEGA II system. Use of substitute materials can result in an unsafe condition and will void any ELECTRICAL SHOCK and all warranties.
  • Page 35 ® Omega II Installation, Operation & Maintenance ELECTRODES.) Check to see if high voltage leaks TURNING OFF THE APPLIANCE occur at porcelains and high voltage leads. 4. If ignition arc is not present or sporadic, turn off power VACATION SHUTDOWN -- Set the thermostat to the and check gap.
  • Page 36 ® Omega II Installation, Operation & Maintenance WARNING WARNING FIRE OR EXPLOSION HAZARD FIRE OR EXPLOSION HAZARD IMPROPER INSTALLATION, ADJUSTMENT, IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE ALTERATION, SERVICE OR MAINTENANCE CAUSE DEATH, SEVERE INJURY CAUSE DEATH, SEVERE INJURY AND/OR PROPERTY DAMAGE.
  • Page 37 ® Omega II Installation, Operation & Maintenance 5. The sensing probe detects the presence of the low fire IGNITION CHECKOUT PROCEDURES flame and the control de-energizes the spark and the valve will remain open. Check valve outlet and other A combination voltmeter and micro-ammeter with a DC downstream pipe connections with a soap solution.

  • Page 38: Trouble Shooting Flow Chart 34

    ® Omega II Installation, Operation & Maintenance Was burner(s) isolated Replace valve. during high pressure leak New Installation? test? Purge gas lines until gas Turn up thermostat Are gas li nes purged of ai r? is present at burner inlet Disconnect power.
  • Page 39 ® Omega II Installation, Operation & Maintenance Remove power from Is there spark at the burner and check igniter Is the igniter spark gap igniter after a 30 Replace i gni ti on control. and ignition cable. Are set at 1/8"?

  • Page 40: Burner Parts List 36

    ® Omega II Installation, Operation & Maintenance Page 36 Combustion Research Corporation...
  • Page 41 ® Omega II Installation, Operation & Maintenance Ref. No. Part No. Description Qty. 910.06A Bottom Cover 910.04AW Back Plate - For 3.5" System 910.04BW Back Plate - For 4.0" System 910.03 Front Plate 910.05 Top Cover 910.18 Burner Tube - For 3.5" System 910.19...

  • Page 42: Accessories & Optional Equipment

    ® Omega II Installation, Operation & Maintenance Part No. Description 0314.00 FRESH AIR INLET ASSEMBLY - Weather Proof Inlet 4" dia., 12" long with 24" long PVC coated Aluminum Flex with two hose clamps, 4" diameter. WT. 2.0 lbs. 0614.00 FRESH AIR INLET ASSEMBLY - Weather Proof Inlet 6"...
  • Page 43 ® Omega II Installation, Operation & Maintenance Part No. Description 0306.AS 90° ELBOW - ALUMINIZED STEEL - 3.5" dia. aluminized steel, 90° elbow. Wt. 3.0 lbs. 0406.AS 90° ELBOW - ALUMINIZED STEEL - 4.0" dia. aluminized steel, 90° elbow. Wt. 3.0 lbs.
  • Page 44 ® Omega II Installation, Operation & Maintenance Part No. Description 0363.00 DEEP DISH REFLECTOR - Aluminum, 10' long. Wt. 5.75 lbs. 0364.00 DEEP DISH COMBINATION HANGER - Heat tube & deep dish reflector hanger for 3.5" tube, plated 1/4" dia.

  • Page 45: Warranty Statement And Terms And Conditions 41

    LIMITATIONS AND CONDITIONS FOR EXTENDED 10 YEAR WARRANTY The Extended Warranty is a special offer made by Combustion Research Corporation (CRC) to Buyers-For-End-use of CRC products to give them an extra term of replacement part protection. The Extended Warranty covers the infrared emitter tubing.
  • Page 46 LIMITATIONS ON STANDARD AND EXTENDED 10 YEAR WARRANTY These Warranties are the only warranties offered by Combustion Research Corporation (CRC) and are in lieu of all other warranties either express or implied. CRC shall not be liable for any special, incidental or consequential damage, such as damage to a building or persons or things within a building due to any kind of radiant energy heating system failure.

  • Page 47: Sample Clearance To Combustible Warning Sign

    In storage areas where stacking of materials may occur, the installer must provide signs that specify the maximum stacking height so as to maintain the required clearance to combustibles. The following is a temporary sign that can be used until a permanent label is obtained from your representative or Combustion Research Corporation - Request P/N 5566.006. Attach ®...
  • Page 50 COMBUSTION RESEARCH CORPORATION 2516 Leach Road, Rochester Hills, Michigan 48309-3555 Telephone No. 248.852.3611 www.combustionresearch.com...

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