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.
Serengeti-IR™ 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
Serengeti-IR™ Installation, Operation & Service 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 dirt and oils to the surface of the reflectors.
Serengeti-IR™ Installation, Operation & Service Mounting Height Information Label P/N 900.2705 Side Panel Venting Instructions Label Rating Plate Label P/N 900.2601 Clearance to Combustibles Label P/N 900.2702 Warning Label P/N 900.2704 Side Panel Operating Instructions Label P/N 900.
Serengeti-IR™ Installation, Operation & Service WARNING SYMBOLS ! WARNING Warning indicates a potentially hazardous situation which, if not avoided, could result in death or injury. TESTED UNDER STANDARDS AMERICAN STANDARDS – Z83.20-(current standard) Z21.86-(current standard) CSA Requirement 7-89 CANADIAN STANDARDS – CSA 2.34-(current standard) CSA 2.32-(current standard) GAS FIRED BROODERS - CAN 1-2.
Serengeti-IR™ Installation, Operation & Service hoist, or provided as insulating or reflective barrier on the hoist (consult representative or factory for guidance). 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.
Serengeti-IR™ Installation, Operation & Service STRAIGHT & "U" TUBE ASSEMBLY ! ASSEMBLY: TUBE & REFLECTOR Burner Tube End View CAUTION CUT HAZARD - SHARP EDGES. Weld Seam Position 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.
Serengeti-IR™ Installation, Operation & Service ASSEMBLY: TUBE & REFLECTOR 10’ SYSTEM STRAIGHT TUBE SYSTEM NOTE: Install Reflector inside hanger as shown 66” 40” 20’ SYSTEM S - TURBULATOR 118” - BURNER END 55” 21” 55” - HANGER S S 118” 118” S - INTERMEDIATE SUPPORT 30’ SYSTEM 55” 21” 55” 5’ “U” 10’ TUBE LENGTH “U” TUBE SYSTEM 21” 44” 10’ “U” 20’ TUBE LENGTH Note: Install Reflector inside hanger as shown.
Serengeti-IR™ Installation, Operation & Service VERTICAL FASHION WHEN INITIALLY INSTALLED (BURNER NOT FIRING). SUSPENSION ! ASSEMBLY: 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.
ASSEMBLY: INSTALLATION GUIDELINES Serengeti-IR™ Installation, Operation & Service 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.
Serengeti-IR™ Installation, Operation & Service 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 SUSPENSION: SEISMIC RESTRIANT network will be required.
ASSEMBLY: BURNER CONNECTION CONNECTING BURNER ASSEMBLY TO RADIANT TUBE/REFLECTOR ASSEMBLY Serengeti-IR™ Installation, Operation & Service Angle 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.
Serengeti-IR™ Installation, Operation & Service GAS LINE INSTALLATION 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.
Serengeti-IR™ Installation, Operation & Service BURNER GAS CONNECTION 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.
Serengeti-IR™ Installation, Operation & Service TECHNICAL DATA 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 0922R through 0918R (40k - 60k Btu/hr input) 0 - 4,500 Ft. (0 - 1370 m) No derating required. 115VAC, 60 Hz., 1.8 Amp HONEYWELL GAS VALVE PN 5285.06 (NG) & 5285.
Serengeti-IR™ Installation, Operation & Service SYSTEM DIMENSIONS 3.5" SERENGETI-IR™ PART NUMBER BTU/Hr INPUT A ("U" TUBE SYSTEM) B (STRAIGHT TUBE SYSTEM) SQ. FT. RADIANT SURFACE AREA 0922R.NG/LP 40,000 5'-0"/10'-0" 10'-0"/19'-8" 9.2 / 18.3 0921R.NG/LP 45,000 5'-0"/10'-0" 10'-0"/19'-8" 9.2 / 18.3 0920R.NG/LP 50,000 10'-0" / 14'-8" 19'-8" / 29'-10" 18.3 / 27.5 0919R.NG/LP 55,000 10'-0" / 14'-8" 19'-8" / 29'-10" 18.3 / 27.5 0918R.NG/LP 60,000 10'-0" / 14'-8" 19'-8" / 29'-10" 18.
Serengeti-IR™ Installation, Operation & Service CLEARANCE TO COMBUSTIBLES ! 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.
Serengeti-IR™ Installation, Operation & Service CLEARANCE TO COMBUSTIBLES HORIZONTAL MOUNTING A A C C A C B1 B2 D D DEEP & STANDARD REFLECTOR WITH ONE SIDE SHIELD DEEP &STANDARD REFLECTOR A DEEP & STANDARD REFLECTOR WITH TWO SIDE SHIELD A C D B2 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 C C1 D C B1 B1 DEEP & STANDARD REFLECTOR DEEP & STANDARD REFLECTOR WITH ONE SIDE SHIELD
Serengeti-IR™ Installation, Operation & Service INSTALLATION PROCEDURE SIDE SHIELD INSTALLATION 0363.00 REFLECTOR & 0366.00 SIDE SHIELD The P/N 0367.00 side shield to be used on P/N 0812.00 panel reflectors and P/N 0366.00 side shield is for use on the P/N 0363.00 Reflector. 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.
Serengeti-IR™ Installation, Operation & Service COMBUSTION AIR SUPPLY COMBUSTION AIR SUPPLY NOTICE Air that is not contaminated must be ducted to the heater if chlorinated or fluorinated contaminants, high humidity, other contaminants, or if negative pressure is present in the area where the heater is installed. 1. Combustion air is a factory preset opening. 2. It is recommended that outside combustion air be used.
Serengeti-IR™ Installation, Operation & Service OUTSIDE AIR SUPPLY ™ When two SERENGETI-IR 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.
EXHAUST METHODS GENERAL NOTES Serengeti-IR™ Installation, Operation & Service VENTING EQUIPMENT VERTICAL VENTING ! 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. Heater vent must be installed in accordance with the National Fuel Gas Code, ANSI Z223.
Serengeti-IR™ Installation, Operation & Service EXHAUST METHODS Approved Vent Cap (Check Local Codes) Flashing Min. 24" Roof Serengeti-IR 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) Serengeti-IR Exhaust All Joints Sealed 4" Vent COMMON VENTING 1.
Serengeti-IR™ Installation, Operation & Service EXHAUST METHODS HORIZONTAL VENTING – NONCOMBUSTIBLE WALLS Vent Cap P/N 1810.VT.400 or P/N 1811.VT.400 Seal penetrations 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 Page 22 Vent Cap PN 1811.VT.
Serengeti-IR™ Installation, Operation & Service GENERAL The requirements and practices described below are based on the National Electrical Code ANSI/NFPA No. 70 (current standard) and the Canadian Electric Code. Although the requirements are uniform throughout the country, local electrical codes may deviate from the National Electrical Code and the Canadian Electric Code, therefore, local inspection authorities should be consulted regarding local requirements.
Serengeti-IR™ Installation, Operation & Service INTERNAL WIRING SCHEMATIC INTERNAL WIRING DIAGRAMS STANDARD WIRING !! WARNING !! DO NOT attempt to rewire internal burner wiring. The 24-volt transformer shown above is not to be used for any thermostat operation.
Serengeti-IR™ Installation, Operation & Service THERMOSTAT WIRING INFORMATION LINE VOLTAGE THERMOSTAT WIRING Serengeti-IR Burner(s) Maximum of 8 with Thermostat P/N 5487.00 Maximum of 5 with Thermostat P/N 5484.00 LOW VOLTAGE WIRING 115V – 60Hz L1 (H) L2 (N) G BLACK R C BLACK T W G WHITE Y 5 COIL 6 LOW VOLTAGE THERMOSTAT (PN 5483.00) COIL 4 2 3 (TOP VIEW) SPDT TRANSFORMER RELAY (PN 5541.
SYSTEM START 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. SERENGETI-IR™ 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.
Serengeti-IR™ Installation, Operation & Service TO START SYSTEM ! WARNING FIRE OR EXPLOSION HAZARD SYSTEM START / MAINTENANCE & SERVICE RESETTING THE IGNITION CONTROL The SERENGETI-IR™ 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.
MAINTENANCE & SERVICE CHECK SAFETY SHUTDOWN PERFORMANCE Serengeti-IR™ Installation, Operation & Service 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.
Serengeti-IR™ Installation, Operation & Service 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.
MAINTENANCE & SERVICE ! WARNING Serengeti-IR™ Installation, Operation & Service ! 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.
Serengeti-IR™ Installation, Operation & Service 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.
Serengeti-IR™ Installation, Operation & Service TROUBLE SHOOTING 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.
Serengeti-IR™ Installation, Operation & Service TROUBLE SHOOTING 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.
BURNER PARTS LIST Page 34 Serengeti-IR™ Installation, Operation & Service Combustion Research Corporation
Serengeti-IR™ Installation, Operation & Service Ref. No. Part No. 1 2 3 4 5 6 -7 -7 8 9 10 11 910.06A 910.04AW 910.03 910.05 910.18 910.16.D 910.11 910.12 910.40 925.01 5285.XX 5190.NG.XXX 5190.LP.XXX 1300.00 910.07 1477.NY 1477.NY 1242.10 1242.00 1601.12 1641.28 5241.XX 5029.10 5060.07A2 5082.00 910.15 910.10 FAN.02 910.13 925.03 1183.00 1202.03 1121.01 1090.00 1142.08 5301.
RECCOMENDED ACESSORIES Part No. Serengeti-IR™ Installation, Operation & Service 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. 1811.VT.400 ROOF OR WALL VENT - 4" diameter - High Wind mushroom style round vent. For “B” vent. Wt. 0.5 lbs. 0317.01 STAINLESS STEEL GAS FLEX - 1/2" fittings and manual gas valve 36" long (Included with each burner – United States Only). Wt. 7.0 lbs.
Serengeti-IR™ Installation, Operation & Service Part No. OPTIONAL EQUIPMENT Description 0306.AS 90° ELBOW - ALUMINIZED STEEL - 3.5" 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. 0304.AS.HT RADIANT HEAT TUBE - ALUMINIZED/HEAT TREATED 3.5" dia. aluminized steel heat treated radiant tube, 9'9" long. Wt. 11.25 lbs. 0363.00 DEEP DISH REFLECTOR - Aluminum, 10' long. Wt. 5.75 lbs.. 0364.
Serengeti-IR™ Installation, Operation & Service Part No. Description 0367.00 SIDE SHIELD - Aluminum side shield. Used on all reflectors, 10' long. Wt. 3.0 lbs. 0342.WH REFLECTOR END CAP - Aluminum end cap. Used on 0360.00 reflector. Wt. 0.25 lbs. 5221.00 HIGH PRESSURE REGULATOR - For Natural gas, 2 lbs. to 7.0" W.C., ½" NPT Wt. 1.5 lbs. 5221.0015 HIGH PRESSURE REGULATOR - For Natural gas, 5 lbs. to 7.0" W.C., ½" NPT Wt.
Serengeti-IR™ Installation, Operation & Service WARRANTY STATEMENT 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 Serengeti-IR 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.
Serengeti-IR™ Installation, Operation & Service WARRANTY STATEMENT 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.
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Serengeti-IR™ Installation, Operation & Service 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
