Combat HVAC NRG Control Setup guide

WARNING
FOR YOUR SAFETY
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. Extinguish any open flame.
6. Leave the building.
7. Immediately call your local gas
supplier after leaving the building.
Follow the gas supplier’s
instructions.
8. If you cannot reach your gas
supplier, call the Fire Department.
Fire Hazard
Keep all flammable objects, liquids and
vapours the minimum required
clearances to combustibles away from
heater.
Some objects will catch fire or explode
when placed close to heater.
Failure to follow these instructions can
result in death, injury or property
damage.
Combat HVAC Ltd
Unit A, Kings Hill Business Park
Darlaston Road, Wednesbury
West Midlands, WS10 7SH UK
Telephone: [phone]
Fax: [phone]
Service Telephone: [phone]
Service Fax: [phone]
E-mail: [email protected]
E-mail: expor[email protected]
www.combat.co.uk
www.blackheatheaters.co.uk
WARNING
Installation must be done by an electrician qualified
in the installation and service of control systems
for heating equipment.
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or
property damage. Read the Installation, Operation
and Service Manual thoroughly before installing or
servicing this equipment.
Installer
Please take the time to read and understand
these instructions prior to any installation.
Installer must give a copy of this manual to the owner.
Owner
Keep this manual in a safe place in order to provide
your service technician with necessary information.
© 2015Combat HVAC Limited
NRG Control
Installation, Operation and Service Manual
P/N X235 Rev H1 04/15
Energy Saving Control for
Combat HVAC infrared and
warm Air Heating Equipment

© 2015Combat HVAC
Limited
All rights reserved.No part of this work covered by the copyrights herein 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 the
written permission of Combat HVAC Limited.
Printed in U.K.
TABLE OF CONTENTS
SECTION 1: Introduction........................................................ 2
1.1 Safety Labels and Their Placement .............................2
1.2 What is anNRG Control?.............................................2
1.3 General Requirements ................................................. 2
1.4 Control Location ........................................................... 2
1. 5 N e t work Installation...................................................... 2
1.6 Installation Requirements............................................. 3
1.7 Programming Details ....................................................3
SECTION 2: Specifications .................................................... 4
2.1 Material ........................................................................ 4
2.2 Keypad Layout ............................................................. 4
SECTION 3: Installation.......................................................... 6
3.1 National Standards and Applicable Codes .................. 6
3.2 Installing the NRG Control ...........................................6
3.3 Electrical Installation Requirements............................. 7
SECTION 4: Wiring.................................................................. 9
4.1 Network Wiring ............................................................ 9
4.2 LowVoltage Wiring .................................................... 10
4.3 CTU Wiring (Pektron Ignition Controller).................... 11
4.4 CTCU Wiring (Pektron Ignition Controller) ................. 11
4.5 CTU Wiring (Pactrol Ignition Controller)..................... 12
4.6 CTCU Wiring (Pactrol Ignition Controller) .................. 12
4.7 Interface Relay Wiring for Multiple Models
CTU 70 - 115.............................................................. 13
4.8 Interface Relay Wiring for Multiple Models
CTCU 11 - 32 & CTU 40 - 60 ..................................... 14
4.9 MGB/MOB Range Wiring - 1 Ø Cabinet Heaters....... 15
4.10 MGB/MOB Range Wiring - 3 Ø Cabinet Heaters ..... 16
4.11 Cabinet Heater Remote Lockout Reset Wiring
(With THERMOWATT Ignition Control) .................... 16
4.12 Cabinet Heater Remote Lockout Reset Wiring......... 17
4.13 Unitary Radiant System Wiring ................................ 17
4.14 CORAYVAC®and Multiburner Systems Wiring ........ 18
SECTION 5: Programmingand Operation .......................... 19
5.1 Stand Alone Unit........................................................ 19
5.2 Network Unit .............................................................. 19
5.3 System Language ...................................................... 19
5.4 Network Open Level User Functions ......................... 21
5.5 Manager Settings....................................................... 25
5.6 Engineer Settings ......................................................31
SECTION 6: Standard Screen Messages ............................ 39
6.1 Stand Alone Control Screen Messages .....................39
6.2 Network Control Screen Message ............................. 40
6.3 Fault Messages ......................................................... 40

TABLE OF FIGURES
Figure 1: Keypad Layout ...........................................................4
Figure 2: Remote Sensors ........................................................ 5
Figure 3: Cover Detail ............................................................... 6
Figure 4: Mounting Hole Layout ................................................ 6
Figure 5: Cable Entry ................................................................7
Figure 6: Control Terminals and Relay Use............................... 7
Figure 7: Ferrite EMC Filter.......................................................7
Figure 8: Sensor Mounting Plate - Warm Air ............................8
Figure 9: Remote Temperature Sensor - Radiant .....................8
Figure 10: Sports Hall Sensor ................................................... 8

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Product Approval
Combat HVAC appliances have been tested and CE certified as complying with the
essential requirements of the Gas Appliance Directive, the Low Voltage Directive, the
Electromagnetic Compatibility Directive and the Machinery Directive for use on natural gas, LPG
and fuel oil when installed, commissioned and maintained in accordance with these instructions.
These instructions refer to appliances designed to operate in the European Union.
Appliances designed for other countries (non European Union) are available on request.
This appliance must be installed in accordance with the local and national codes in force and used
only in a sufficiently ventilated space, as specified in these instructions.
Before installation, check that the local gas distribution systems, nature of gas and pressure, and
adjustment of the appliance are compatible.

SECTION 1: INTRODUCTION
Your Safety is Important to Us!
This symbol is used throughout
the manual to notify you of
possible fire, electrical or burn
hazards. Please pay special
attention when reading and fol-
lowing the warnings in these
sections.
Installation, service and annual inspection of
controller must be done by an electrician qualified in
the installation and service of control systems for
heating equipment.
Installation, service and annual inspection of heater
must be done bya contractor qualified in the
installation and service of gas or oil fired heating
equipment.
Read this manual carefully before installation,
operation, or service of this equipment.
The equipment must be applied and operated under
the general concepts of resonable use and installed
using best building practices.
This equipment is not intended for use by persons
(including children) with reduced physical, sensory
or mental capabilities, or lack of experience and
knowledge, unless they have been given
supervision or instruction concerning use of the
appliance bya person responsible for their safety.
Children should be supervised toensure that they
do not play with the equipment.
For optimum heater performance and safe heating
conditions, inspect and maintain heater(s) before
every heating season and as necessary.Also, know
and maintain heater clearances tocombustibles,
see heater Installation, Operation and Service
Manual for further details. If you require additional
manuals, contact Combat HVAC at [phone]
7700 or at www.combat.co.uk.
1.1 Safety Labels and Their Placement
Product safety signs or labels should be replaced by
product user when theyare no longer legible.
Please contact Combat HVAC Limited or your
Combat HVAC independent distributor to obtain
replacement signs or labels.
1.2 What is a Combat HVAC NRG Control?
The Combat HVAC NRG Control is a micro
processor based controller designed for efficient
control of Combat HVAC warm air and radiant
products. Each control is intended for operation ofa
single zone of heating but is designed so that
individual controls may be linked toform a network
that will allowinformation and settings tobe
available at one or any of the units dependent upon
site configuration. Controls will operate the following
products:
COMBAT HVAC NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL
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• Warm air heaters On/Off operation
• Unitary BLACKHEAT®radiant systems
• BLACKHEAT®multi burner systems on a single
zone*
•CORAYVAC
®systems on a single zone*
•Heaterswith two stage High/Lowoperation
•Heaterswith modulating burners requiring a 0-
10V DC input
*For safe use of multiburner and CORAYVAC®systems with up
to four zones operating with a single shared fan, additional
use of Combat HVAC System Control will be required with a
Combat HVAC NRG Control installed for each zone.
1.2.1 Features of the Combat HVAC NRG
Control.
• Coded access to set up and network functions to
prevent unauthorised access.
• Built in temperature sensor.
• Remote temperature sensor option.
• Self learning optimum start.
• Automatic correction for daylight saving time
changes.
• Burner lockout indication and reset for suitable
heater systems.
• Pre programmed holiday functions.
• May be connected on a network to give access
to all controls from a single point.
• Programmed in 5 languages as standard.
• Data logging of hours run and temperatures.
1.3GeneralRequirements
The Combat HVAC NRG Control is only for use
with Combat HVAC heating products. On site
commissioning is required to ensure temperature
sensor is calibrated, and that options available are
selected correctly. Before proceeding with
installation, it will be necessary to check that the
following points have been considered.
1.4 Control Location
Each control is intended tooperate a single zone of
heating. The built in sensor may be used for
temperature control. In this case, position control as
in Section 1.6.1 through Section 1.6.3.
When remote temperature sensors are required,
control may be fitted in any suitable location. If
required, two remote sensors may be installed. The
average of the two sensors will be calculated by the
control.
1.5 Network Installation
The Combat HVAC NRG Control may be installed
on a network so that all controls may be accessed
from a single control, selected controls or all
controls dependent upon howthey are configured
on site. Touse control on a network simply requires
wiring of COMS port on one control to connect to
COMS port oneach of the other controls in a
continuous loop.

SECTION 1: INTRODUCTION
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It will then be possible to set program times and
temperatures for all controls from one location and
copy programs from one control to another.
It will also be possible to read the current status of
all controls from a single station.
1.6 Installation Requirements
1.6.1 Radiant Tube Heaters
The Combat HVAC NRG Control can operate up to
ten burners providing that the electrical load on
each relay does not exceed 7 A inductive.
Mount Combat HVAC NRG Control (or remote
sensor if fitted) on a wall or column at a height of
approximately 1.5 to 1.8 metres from the floor.
The Combat HVAC NRG Control, or sensor, should
be in a position to monitor an average radiant
temperature. Keep clear of cold draughts, direct
sunlight, direct radiant field heaters and areas of
little air movement such as corners. For larger
systems, use two remote sensors to provide closer
temperature control.
1.6.2 Warm Air Heaters
The Combat HVAC NRG Control can operate a
single warm air heater. However up to four heaters
may be controlled from each control if each heater
is provided with interface relays See Page 13,
Section 4.7.
Mount Combat HVAC NRG Control, or remote
sensor, on a wall or column at a height of
approximately 1.5 to1.8 metres from floor. The
Combat HVAC NRG Control, or sensor, should be
positioned where it will monitor an average room
temperature. Keep clear of cold draughts, direct
sunlight, path of warm air from heater and areas of
little air movement such as corners.
1.6.3 Multiple Unit Considerations
When using control to operate more than one
radiant or warm air heater, careful consideration
should be given to position of control or remote
temperature sensor because single temperature
monitoring point controls all heaters that are
connected. The use of tworemote sensors may
provide closer temperature control.
For warm air heaters, the interface relay D 258
must be installed, in accordance with Page 13,
Section 4.7, adjacent to each heater to ensure that
the electrical supply at each heater is isolated for
maintenance.
For larger air heaters, it may not be practical to
operate more than one heater from a single control
due to the larger area covered by these heaters.
Contact Combat HVAC Limited for further advice
on control location and application.
1.6.4 Installation Materials
Shielded cable Belden 8451, General Cable C
2514, or equivalent rated for up to 300 V must be
used for sensors, modulating 0-10 V output, 12 V
DC inputs and network bus connections. Maximum
cable length for each sensor is 100 m. Maximum
cable
length for network is 1,000 m. Keep control cables
away from high current mains circuits to prevent
signal interference.
1.6.5 Electrical Requirements
The controller must have a 230 V 50 Hz
power supply wired with the Ferrite EMC filter. See
Page 7, Figure 7 in accordance with relevant wiring
diagram from Page 9, Section 4.
1.7ProgrammingDetails
Every control is programmed with default settings
and may be reconfigured to suit the needs of the
installation. See Page 33, Section 5.6.3 and Page
34, Table 1.
When supplied, each Combat HVAC NRG Control
is configured as a stand alone unit.
Each unit must be configured tooperate heating
equipment it is controlling. See Page 33, Section
5.6.3 and Page 34, Table 1.
Programming for stand alone units and network
units is similar. However, for network units, they
must be network configured first. See Page 31,
Section 5.6.1.
DANGER
Electrical Shock Hazard
Disconnect electric before service.
Controller must be properly grounded to an
electrical source.
Failure to follow these instructions can
result in death or electrical shock.

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SECTION 2: SPECIFICATIONS
Figure 1: Keypad Layout
2.1 Material
2.1.1 Enclosure
Enclosure Material: ABS fire retardant
Weight: 1.6 kg
Dimensions: 158 mm x 62 mm x 220 mm
2.1.2 Electrical
Supply: 230 V ± 10% 50 Hz 1 Ø
Outputs: 3 single pole normally open
Rated at 10 A resistive or
7 A inductive.
Battery Back Up: 3 Months.
Built in Fuses
Main Fuse: FS1 800 mA anti-surge
PCB Protection: FS2 315 mA quick blow
12 V Output: FS3 315 mA quick blow
2.1.3 Sensors
Sensor: Built in as standard
Remote available as option
Remote Sensor:
Warm Air & Radiant 80 mm x 80 mm x 22 mm
Black Bulb Radiant 68 mm diameter x 50 mm
Sports Hall Sensor Flush Mounting
2.1.4 Program Features
Zones: One
Programs: 3 timed periods per day,
7 days per week.
Optimum Start: Selectable
Night Set Back: Selectable
Burner Modulation: Selectable (0-10 V DC output.
0 V=lowfire)
Two Stage Burner Selectable
Burner Lockout:
Indication & Reset: Available for use with suitable
heater types
Pressure Switch: Connections for fan proving
for CORAYVAC®systems
Network: Up to 32 units may be
connected together on a
network using Belden 8451
shielded cable
2.2 Keypad Layout
1. LCD Readout
2. Run button and fan button, returns to standard
screen from programming options, manual
operation of fan on warm air heaters.
3. Program button and copy button used to enter
program options areas and copy time program.
4. Override button and summer button, used to
allowoperating time to be extended and set
control in summer mode.
5. Information button and reset button shows
current setting and status plus burner lockout
reset.
6. Built in temperature sensor.
7. Delete button cancels input during
programming (move forward around network).
8. Numerical key pad for inputting information.
2
1
0
12
456
89
ENTER DELETE
INFO
RESET
3
7
OVER
SUMMER
PROG
COPY
RUN
FAN
UK • [phone]
WEB • www.combat.co.uk
DANGER - 230 V50 Hz
DISCONNECT FROM ELECTRICALSUPPLY
BEFORE REMOVING THIS COVER
3
4
5
6
789
NRG Control
10
COMBAT HVAC N RG C ONTROL I NSTALLATION , O PERATION AND S ERVICE M ANUAL
Combat HVAC

SECTION 2: SPECIFICATIONS
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9. Enter key to confirm inputs (move backward
around network).
10.Temperature adjustment (optional, between
engineer defined limits) reverts to programmed
set point at next switch on.
Figure 2: Remote Sensors
Temperature Sensor Black BulbSensor Sports Hall Sensor
Description Part Number
Temperature Sensor (Warm Air & Radiant) D247
Black Bulb Sensor (Radiant) D269
Sports Hall Sensor D270
NRG Controller (not shown) D268
Interface Relay Assembly (not shown) D258
(Wire On Site)

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SECTION 3: INSTALLATION
Installation of Combat HVAC NRG Control must be
done byan electrician qualified in the installation of
control systems for heating equipment.
3.1 National Standards and Applicable Codes
All appliances must be installed in accordance with
the latest revision of the applicable standards and
national codes. This refers also to the electric, gas
and venting installation. Note: Additional standards
for installations in public garages, aircraft hangars,
etc. may be applicable.
3.2 Installingthe Combat HVAC NRG
Control
Choose a mounting location for control. See Page
2, Section 1.4 and Section 1.6.
3.2.1 Remove cover of controller by removing four
clips and screws. See Figure 3 for cover detail.
Figure 3: Cover Detail
3.2.2 Disconnect ribbon cable from control PCB
board.
3.2.3 Position controller. Figure 4 shows mounting
hole locations.
Figure 4: MountingHole Layout
3.2.4 Remove plastic cable entry plate and carefully
cut suitable holes as required for conduit entry to
control. See Figure 5.
Do not use other entry routes or pass site wiring
over circuit board.
3.2.5 Refit cable entry plate into slot at side of panel.
DANGER
Electrical Shock Hazard
Disconnect electric before service.
Controller must be properly grounded to an
electrical source.
Failure to follow these instructions can
result in death or electrical shock.
Clip Cover
Screw
Lid Assembly
Description Part Number
Clip Cover Plastic 10000701
Screw10000700
Lid Assembly 10010500
175 mm
140 mm
4 x 5 mm dia
COMBAT HVAC N RG C ONTROL I NSTALLATION , O PERATION AND S ERVICE M ANUAL

SECTION 3: INSTALLATION
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Figure 5: Cable Entry
3.2.6 Install electrical wiring in accordance with the
correct wiring diagram in Section 4 to wiring termi-
nals as shown in Figure 6.
Figure 6: Control Terminals and Relay Use
3.2.7 Reconnect ribbon cable to PCB board and
replace cover of control by replacing four screws and
covers as removed on Page 6, Section 3.2.1.
3.3 Electrical Installation Requirements
3.3.1 Panel must have a 230 V 50 Hz supply in
accordance with the appropriate wiring diagram from
Section 4.
3.3.2 Ensure that Live, Neutral and Earth cables are
looped three times through ferrite EMC filter as
shown.
Figure 7: Ferrite EMC Filter
3.3.3 Ensure that cables toany lowvoltage equip-
ment are Belden 8451 shielded cables with shield
connected as shown in the wiring diagrams on Page
9, Section 4.1 through Page 10, Section 4.2.
3.3.4 Lockout Reset
Facilities are available for systems that reset to Live
or reset to Neutral. Look at wiring diagram on each
heater to determine correct system to use for heater
concerned.
Failure to comply will cause permanent damage
to burner control on heater and Combat HVAC
NRG Control.
3.3.5 Network Connections
Optionally controls may linked together as
described on Page 2, Section 1.5. Site wiring is to
be connected and DIP switches set as shown on
Page 9, Section 4.1.
3.3.6 Remote Sensors
All sensors are electrically connected in the same
way. The use of remote sensors is optional.
One remote temperature sensor will operate
control. For larger heated areas, two remote
temperature sensors may be installed where
control will automatically calculate average of two
readings. See Page 8, Figure 8 through Page 8,
Figure 10.
Position remote sensor/s in accordance with Page
2,Section 1.4 and Page 3, Section 1.6.
See Page 5, Figure 2 for sensor detail.
Circuit Board
Cut suitable holes
Removable Plastic Entry Plate
12 V
Override
Press' switch
0 -10 VDC
MODULATING
OUTPUT
-
+
S
COMS
PORT
-
+
S
REMOTE
SENSORS
1
+
S
2
INPUTS
-
+
2
1
Lockout
Reset
C
N.O.
N.C.
Burner
Fan
CRV- Multi
Burner Radiant
Unitary
Radiant
Warm Air
Relay 3
Relay 2
Relay 1
Power Supply
230 V50 Hz
(From Ferrite Filter)
Lockout Signal
230 V50 Hz
L
N
Fan
Burner or
Low Fire
High
Fire
Burner
N
L

8 of 40
Figure 8: Sensor MountingPlate - Warm Air
Figure 9: Remote Temperature Sensor - Radiant
Figure 10: Sports Hall Sensor
3.3.7 Pressure Switch
For CORAYVAC®systems only, a pressure switch is
required to prove operation of system fan.
This must be connected to input terminals as shown
on Page 10, Section 4.2 and Page 18, Section 4.14
to allowcontrol to monitor correct operation of fan.
Control must also be configured to monitor pressure
switch. See Page 33, Section 5.6.3 and Page 34,
Ta b l e 1 .
Remote sensors must be fastened using
countersunk screws. Dome headed screws
will short out the board and result in failure
of the sensor.
Cover Screws
Circuit Board
Screws
Cable Entry
Cable
Connections
COMBAT HVAC NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 4: WIRING
9 of 40
SECTION 4: WIRING
4.1 Network Wiring
DANGER
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be
required to disconnect electric to the unit.
Failure to follow these instructions can result
in death or electrical shock.

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4.2 Low Voltage Wiring
COMBAT HVAC NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 4: WIRING
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4.3 CTU (Terminal block connection) Wiring(Pektron Ignition Controller)
4.4 CTCU Wiring& CTU (7 pin plug connection) (Pektron Ignition Controller)

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4.5 CTU Wiring(Terminal block connection) (Pactrol Ignition Controller)
4.6 CTCU Wiring& CTU (7 pin plug connection) (Pactrol Ignition Controller)
COMBAT HVAC NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 4: WIRING
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4.7 Interface Relay Wiringfor Multiple Models CTU 75 - 115
Description Part Number
Interface Relay Assembly D258

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4.8Interface Relay Wiringfor Multiple Models CTCU 11 - 32 & CTU 40 - 60
Description Part Number
Interface Relay Assembly D258
COMBAT HVAC NRG CONTROL INSTALLATION, OPERATION AND SERVICE MANUAL