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 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.
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 this equipment. Improper installation, service or maintenance can cause death, injury and/or property damage. Vehicles: Minimum clearances must be maintained from vehicles parked, below the heater. Ensure that adequate clearance is maintained where vehicles are in operation or being serviced. 2.
Omega II® Installation, Operation & Service INSTALLER PLEASE TAKE TIME TO READ AND UNDERSTAND THESE INSTRUCTIONS PRIOR TO ANY INSTALLATION. Contact your representative or the factory if you have any questions OWNER Retain this manual in a safe place to provide your serviceman with information if the situation arises.
Omega II® Installation, Operation & Service This Page Intentionally Left Blank Combustion Research Corporation
Omega II® Installation, Operation & Maintenance HEATER SAFETY Please take time to familiarize yourself this manual as your safety is important is important to us. This symbol is used throughout this manual to notify you of possible fire, electrical, burn hazards or other safety issues. Pay special attention when reading this manual and follow the warnings. will also help in reducing the transfer of dirt and oils to the surface of the reflectors.
Omega II® Installation, Operation & Maintenance Venting Instructions Label Side Panel Rating Plate Label P/N 900.2601 Clearance to Combustibles Label P/N 900.2730 Side Panel Operating Instructions Label P/N 900.
Omega II® Installation, Operation & Maintenance WARNING SYMBOLS ! WARNING Warning indicates a potentially hazardous situation which, if not avoided, could result in death or injury. ! CAUTION Caution indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Notice indicates a potentially hazardous situation which, if not avoided, could result in property damage.
Omega II® Installation, Operation & Maintenance required clearance to combustibles. A temporary sample sign can be found at the end of the manual. ELECTRICAL GROUNDING The burner and blower unit must be electrically grounded in accordance with the following codes: United States: Refer to National Electrical Code®, ANSI/NFPA 70 (latest edition). Wiring must conform to the latest edition of National Electrical Code®, local ordinances, and any special diagrams furnished.
Omega II® Installation, Operation & Maintenance STRAIGHT & "U" TUBE ASSEMBLY ! Combustion Tube 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. Wear protective gloves when installing and handling and cutting radiant tubes. Failure to follow these instructions will result in personal injury. 1. Remove the Reflector(s), tubes and hanger from the shipping carton.
Omega II® Installation, Operation & Maintenance 10’ SYSTEM 3.5” STRAIGHT TUBE SYSTEM Note: Install Reflector inside hanger as shown.
Omega II® Installation, Operation & Maintenance 5’ “U” 10’ TUBE LENGTH 3.5” “U” TUBE SYSTEM 44” - TURBULATOR 10’ “U” 20’ TUBE LENGTH - BURNER END - HANGER E - REFLECTOR EXANSION JOINT 66” 15’ “U” 30’ TUBE LENGTH 66” 66” 20’ “U” 40’ TUBE LENGTH 66” 66” Note: Install Reflector inside hanger as shown. 66” 25’ “U” 50’ TUBE LENGTH E 66” 66” 66” 66” 15’ “U” 30’ TUBE LENGTH 4.
Omega II® Installation, Operation & Maintenance STRETCH OR INSTALL CHAIN OTHER THAN IN A VERTICAL FASHION WHEN INITIALLY INSTALLED (BURNER NOT FIRING). SUSPENSION ! WARNING COLLAPSE, FIRE AND EXPLOSION HAZARD If chain is not supplied by Combustion Research Corp., 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.
Omega II® Installation, Operation & Maintenance assembly – see page 9. It is necessary that the weld seam on this combustion tube be positioned so that it is on the bottom when installed. COMBUSTION TUBE INSTALLATION The first section or radiant tube downstream of the burner is a heavy wall 16 Ga. heat-treated aluminized steel tube. This tube is referred to as the combustion tube. One end of this tube is swaged to fit inside the next spiral radiant tube.
Omega II® Installation, Operation & Maintenance SEISMIC RESTRAINT SUSPENSION METHODS For standard seismic restraint such as earthquake prone areas, install seismic restraint chain or cable as shown below. If high winds can be encountered in the building, such as found in airplane hangers where opposing doors are simultaneously open, or system is installed near or below the door opening, additional support of the radiant tube and reflector network will be required.
Omega II® Installation, Operation & Maintenance CONNECTING BURNER ASSEMBLY TO RADIANT TUBE/REFLECTOR ASSEMBLY Iron, Uni-strut, etc. and then suspend the chain so that it hangs vertically. ! ! WARNING WARNING FIRE OR EXPLOSION HAZARD FIRE OR EXPLOSION HAZARD IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE DEATH, SEVERE INJURY AND/OR PROPERTY DAMAGE.
Omega II® Installation, Operation & Maintenance In industrial installations where the natural gas pressure at the meter is available at higher pressure than the standard 7" TO 14" W.C., it may be possible to cut down on gas piping costs (when local codes and the Fire Marshal approve) by running high pressure gas lines inside the building or on the outside of the building. In no case should the pressure exceed 10% of the service supply pressure.
Omega II® Installation, Operation & Maintenance Install the flex connector as shown in the diagram below. This gas connector accommodates the normal expansion of the system. Before connecting the gas connector verify that all high-pressure testing has been completed. The gas connector shut off valve must be parallel to the gas inlet on the burner. A 2” (5cm) cold displacement for initial setup is shown. This displacement may reduce when the system is fired.
Omega II® Installation, Operation & Maintenance GAS PRESSURE AT MANIFOLD GAS INLET PRESSURE Natural Gas: 3.5" W.C. LP Gas: 10.0" W.C. 1/2" NPT Gas Connector Size Natural Gas: LP Gas: 6.0" W.C. Minimum 14.0"W.C. Maximum 11.0" W.C. Minimum 14.0" W.C. Maximum ALTITUDE ELECTRICAL RATING Systems 0922 through 0910 (40k - 100k Btu/hr input) 0 - 4,500 Ft. (0 - 1370 m) No de-rating required. 115VAC, 60 Hz., 1.8 Amp Systems 0926 through 0945 (105k - 200k Btu/hr input) 0 - 2,000 Ft.
Omega II® Installation, Operation & Maintenance 3.5" OMEGA II® PART NUMBER BTU/Hr INPUT A ("U" TUBE SYSTEM) B (STRAIGHT TUBE SYSTEM) SQ. FT. RADIANT 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 50,000 10'0" / 14'8" 19'8" / 29'10" 18.3 / 27.5 0919.NG/LP 55,000 10'0" / 14'8" 19'8" / 29'10" 18.3 / 27.5 0918.NG/LP 60,000 10'0" / 14'8" 19'8" / 29'10" 18.3 / 27.5 0917.
Omega II® Installation, Operation & Maintenance ! WARNING Placement of explosive objects, flammable objects, liquids and vapors close to the heater may result in fire, explosion, death and serious injury or property damage. Do not store or use explosive objects, liquids and vapor in the vicinity the heater. In all situations the clearance to combustibles must be maintained. Failure to observe clearances to combustibles will result in death, serious injury, or property damage.
Omega II® Installation, Operation & Maintenance HORIZONTAL MOUNTING A A C C A C B1 B2 DEEP &STANDARD REFLECTOR D D DEEP & STANDARD REFLECTOR WITH ONE SIDE SHIELD A B2 DEEP & STANDARD REFLECTOR WITH TWO SIDE SHIELD A C D A C C D D B1 D B2 B2 PANEL REFLECTOR PANEL REFLECTOR WITH ONE SIDE SHIELD PANEL REFLECTOR WITH TWO SIDE SHIELD 30 DEGREE ANGLE MOUNTING A A C1 C1 D C B1 B1 DEEP & STANDARD REFLECTOR WITH ONE SIDE SHIELD DEEP & STANDARD REFLECTOR A A E E C C B1 B1 PAN
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 either side of the reflector. Refer to the layout plan and clearance to combustible chart on the preceding page for proper location.
Omega II® Installation, Operation & Maintenance including the space that is being heated, PROVIDED the building does not have a negative pressure and the atmosphere is not contaminated with acid fumes, fluorocarbons, corrosive substances, dirt, oil, etc., which would have an adverse effect on the blower and radiant tubing. DO NOT draw combustion air be drawn from an attic space.
Omega II® Installation, Operation & Maintenance OUTSIDE AIR SUPPLY ® When two OMEGA II systems are controlled by one thermostat a common combustion air supply can be used. This duct must be a minimum of six-inch (6") diameter and should not exceed fifty feet (50') in length. A Maximum of two (2) 90° elbows may be used. Maintain a minimum of six feet (6') between the exhaust port and the fresh air intake. Maintain a minimum of six inches (6") between the inlet hood and the exterior wall.
Omega II® Installation, Operation & Maintenance GENERAL NOTES 9. If condensation within the flue becomes a problem, the flue should be shortened or insulated. VENTING EQUIPMENT ! WARNING IMPROPER INSTALLATION CAN CAUSE DEATH, SEVERE INJURY AND/OR PROPERTY DAMAGE. Improper venting and insufficient ventilation may result in health problems, carbon monoxide poisoning and death. Vent enclosed spaces and buildings according to national, state, provincial and local codes.
Omega II® Installation, Operation & Maintenance Approved Vent Cap (Check Local Codes) Flashing Min. 24" Roof Omega II Exhaust Min. 1" Clearance (Combustible Roof) Min. 4" Double Wall Vent (Check Local Codes) All Joints Sealed 4" Vent Approved Vent Cap (Check Local Codes Flashing Min. 24" Roof Min. 1" Clearance (Combustible Roof) Min. 6" Vent Double Wall Vent For Roof Penetration (Check Local Codes) ® Omega II Exhaust Omega II® Exhaust All Joints Sealed 4" Vent COMMON VENTING 1.
Omega II® Installation, Operation & Maintenance HORIZONTAL VENTING, NON-COMBUSTIBLE WALLS Seal penetrations Vent Cap P/N 1810.VT.400 or P/N 1811.VT.400 Omega II® Exhaust 4” Single wall vent pipe Use 4” Type “B” Vent pipe for wall penetration Min. 6” Max. 18” HORIZONTAL VENTING, COMBUSTIBLE WALLS 4” ingle wall vent pipe Wall thimble 18” Omega II® Exhaust 4” Type “B” Vent pipe Combustion Research Corporation Vent Cap PN 1811.VT.
Omega II® Installation, Operation & Maintenance UNVENTED OPERATION Although the OMEGA II® units are approved for un-vented operation, THIS IS NOT A RECOMMENDED OPTION. The reason being that when the products of combustion are discharged into the heating space, ventilation of this heating space is required. For proper ventilation, code requires that a positive air displacement of 4 CFM per 1000 BTU/Hr input of gas input be provided for insulated buildings.
Omega II® Installation, Operation & Maintenance GENERAL electrical supply problems are caused by voltage drop due to long runs, or low voltage supplied by the utility. The requirements and practices described below are based on the National Electrical Code ANSI/NFPA No. 70 (current standard) and the Canadian Electric Code.
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
Omega II® Installation, Operation & Maintenance LINE VOLTAGE THERMOSTAT WIRING LOW VOLTAGE THERMOSTAT WIRING 115V – 60Hz L1 (H) L2 (N) G Black R C White Black T W G Y Brown Low voltage thermostat (PN 5483.00) COIL 6 5 3 2 COIL 4 1 (BOTTOM VIEW) (TOP VIEW) White Red SPDT Transformer relay (P/N 5541.
Omega II® Installation, Operation & Maintenance GENERAL SAFETY INFORMATION Follow all local electrical and safety codes, as well as the National Electrical code (NEC) and the Occupational Safety and Health Act (OSHA). 1. OMEGA II® BURNER ASSEMBLY must be securely and adequately grounded. This can be accomplished by wiring with a grounded, metal-clad raceway system, by using a separate ground wire connected to the bare metal of the blower frame, or other suitable means. 2.
Omega II® Installation, Operation & Maintenance TO START SYSTEM ! WARNING FIRE OR EXPLOSION HAZARD RESETTING THE IGNITION CONTROL The OMEGA II® BURNER ASSEMBLY is equipped with an automatic lockout control which is activated after 60 seconds if a burner should fail to ignite. If your burner should lock out, it should be reset by the following method: 1. Turn off the disconnect switch located near the burner or turn down the thermostat to stop the entire system. 2.
Omega II® Installation, Operation & Maintenance CHECK SAFETY SHUTDOWN PERFORMANCE Radiant Tubing: NOTE: Read steps 1-7 below before starting safety shutdown or safety lockout tests for the direct ignition (DI) module. ! WARNING FIRE OR EXPLOSION HAZARD 1. Turn gas supply off. 2. Set the thermostat or controller above room temperature to call for heat. 3. Watch for ignition spark immediately or following prepurge. See ignition module specifications. 4. Time length of ignition operation.
Omega II® Installation, Operation & Maintenance ELECTRODES.) Check to see if high voltage leaks occur at porcelains and high voltage leads. 4. If ignition arc is not present or sporadic, turn off power and check gap. It should be approximately .10 inch. (DO NOT TRY TO MEASURE HIGH VOLTAGE OUTPUT.) High voltage wire should not touch casing as grounding can occur when wires are wet. 5.
Omega II® Installation, Operation & Maintenance ! WARNING ! WARNING FIRE OR EXPLOSION HAZARD FIRE OR EXPLOSION HAZARD IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE DEATH, SEVERE INJURY AND/OR PROPERTY DAMAGE. IMPROPER INSTALLATION, ADJUSTMENT, ALTERATION, SERVICE OR MAINTENANCE CAN CAUSE DEATH, SEVERE INJURY AND/OR PROPERTY DAMAGE. 1. Flame is lit automatically. Do not light the flame manually. 2. Before lighting burner flame, smell around the appliance for gas.
Omega II® Installation, Operation & Maintenance 5. The sensing probe detects the presence of the low fire flame and the control de-energizes the spark and the valve will remain open. Check valve outlet and other downstream pipe connections with a soap solution. 6. Turn the thermostat to a low dial setting to open contacts. The main gas flame should be extinguished. 7. For 100% shutoff check, set thermostat to low dial setting (system off). Disconnect sensing probe lead at control terminal. 8.
Omega II® Installation, Operation & Maintenance New Installation? YES NO Was burner(s) isolated during high pressure leak test? NO Replace valve. YES Turn up thermostat YES Are gas li nes purged of ai r? NO Purge gas lines until gas is present at burner inlet Does the Blower start? NO Is there power to the blower? YES Disconnect power.
Omega II® Installation, Operation & Maintenance 1 Is there spark at the igniter after a 30 second pre purge? NO Remove power from burner and check igniter and ignition cable. Are they damaged? NO Is the igniter spark gap set at 1/8"? YES Replace i gni ti on control. YES YES Carefully reset gap to 1/8" Replace igniter or ignition cable as needed. Replace ignition control. YES NO Check wires and replace as needed.
Omega II® Installation, Operation & Maintenance Page 36 Combustion Research Corporation
Omega II® Installation, Operation & Maintenance Ref. No. Part No. 1 -2 -2 3 4 -5 -5 6 -7 -7 -7 -8 -8 -9 -9 10 11 910.06A 910.04AW 910.04BW 910.03 910.05 910.18 910.19 910.16.D 910.12.A 910.11 910.12 910.40 910.40.1 925.01 926.00 5285.XX 5190.NG.XXX 5190.LP.XXX 1300.00 910.07 910.07A 1477.NY 1477.NY 1242.10 1242.00 1601.12 1641.28 5241.XX 5029.10 5060.07A2 5060.07A1 5060.07C 5082.00 910.15 910.10 910.10.2 910.10.3 910.10.4 FAN.02 910.13 925.03 1183.00 1202.03 1121.01 1090.00 1142.
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" dia., 12" long with 48" long PVC coated Aluminum Flex with two hose clamps, 6" diameter. WT. 6.0 lbs. 1810.VT.400 ROOF OR WALL VENT - 4" diameter mushroom style round vent. For single wall or “B” Vent. Wt. 0.5 lbs.
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. 0336.AS 45° ELBOW - ALUMINIZED - 3.5" dia. aluminized steel, 45° elbow. Wt. 1.5 lbs. 0436.AS 45° ELBOW - ALUMINIZED - 4.0" dia. aluminized steel, 45° elbow. Wt. 1.5 lbs. 0304.AS.HT RADIANT HEAT TUBE - ALUMINIZED/HEAT TREATED 3.5" dia.
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. wire. Wt. 0.75 lb. 0464.00 DEEP DISH COMBINATION HANGER - Heat tube & deep dish reflector hanger for 4.0" tube, plated 1/4" dia. wire. Wt. 0.75 lb. 0365.00 DEEP DISH REFLECTOR SUPPORT - Intermediate support for deep dish reflector for 3.
Omega II® Installation, Operation & Maintenance WARRANTY STATEMENT Combustion Research Corporation ("CRC") offers the end-use buyers of it's products a specific and limited three-year ® standard Warranty covering the Omega II product systems or components, the details of which are given below. This Warranty is offered only to the Buyer-For-End-Use ("Buyer") and becomes effective when the product is properly installed and maintained.
Omega II® Installation, Operation & Maintenance replacement part or parts. As with the Standard Warranty, it is not CRC's obligation to find, remove or transport the defective part or parts, or to pay for finding, removing, or transporting such part or parts, and it is not CRC's obligation to install or pay for installation of the replacement part or parts. Again, it is the Buyer's obligation to send the part or parts freight pre-paid to CRC.
Omega II® Installation, Operation & Maintenance 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 ® this label near the Reflect-O-Ray heater or by the thermostat.
COMBUSTION RESEARCH CORPORATION 2516 Leach Road, Rochester Hills, Michigan 48309-3555 Telephone No. 248.852.3611 www.combustionresearch.
