Combustion Research Omega II User manual

COMBUSTION RESEARCH CORPORATION
Issue Date: 7/15/2008 Revision Date: 2/16/2017 Rev. 4a Bulletin OM080715
TM TM
Pre Engineered Packages
Gas fired, Low Intensity Infrared Unitary
Infrared Heating Systems
Installation, Operating, Maintenance
and Parts Manual
Combustion Research Corp.
2516 Leach Rd.
Rochester Hills, MI 48309-3555
Telephone: [phone]
Fax: [phone]
www.combustionresearch.com
WARNING
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.
!
Installer
Please take 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 serviceman with the necessary information.
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.
!

Omega II®Installation, Operation & Service
Combustion Research Corporation
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.
2. Check clearances given on the outside of each burner to
make sure the product is suitable for your application.
3. Installer must be a trained, experienced service
technician.
4. All service must be performed only by a trained service
technician or representative
5. After installation is complete, check system operation as
provided in these instructions.
Combustibles: Failure to maintain the specified minimum
clearances to combustibles could result in a serious fire
hazard. Do not locate flammable or combustible materials
within this distance. Signs must be posted near thermostat
and in storage areas to specify maximum stacking height to
maintain required clearances to combustibles. Do not locate
in hazardous atmospheres containing flammable vapors or
combustible dust.
United States: Installations in public garages or airplane
hangars are permitted when in accordance with NFPA-88
(latest edition) and NFPA-409 (latest edition) Codes.
Canada: Installation in public garages and airplane hangars
is permitted when in accordance with CAN/CGA B.149.1 &
CAN/CGA B149.2.
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.
Gas Connection: There is an expansion of the radiant pipe
With each firing cycle, and this will cause the burner to move
with respect to the gas line. This can cause a gas leak
resulting in an unsafe condition if the gas connection in not
made strictly in accordance with page 13 of these
instructions.
Ignition: This appliance does not have a pilot. It is equipped
with an ignition device, which automatically lights the burner.
Do not try to light the burner by hand.
Mechanical Hazard - Vacuum Exhauster: High speed
rotating vacuum exhauster impeller/wheel can cause severe
injury. Do not operate the vacuum exhauster without
impeller. Loose clothing can be drawn into unguarded inlet
and entangle with impeller wheel. Keep hands and fingers
away from inlet and outlet. Install exhaust duct with "bird
screen" or approved vent cap on vacuum exhauster outlet.
Mechanical Hazard - Suspension: Use appropriate
suspension hardware, beam clamps (rod or perforated
strap) and turnbuckles at predetermined locations. The
weight and normal movement of the heating system may
cause support failure if the following minimum suspension
requirements are not met: Distance between combination
hangers must be 10-ft. (3 M) or less; chain size must be 3/0
minimum or equivalent.
NOTICE CAUTION
Failure to follow these instructions can cause personal injury
or property damage:
Caution must be used when running the system near
combustible materials such as wood, paper, rubber, etc.
Consideration should be given to partitions, storage racks,
hoists, building construction, etc. Page 16 & 17 outlines
minimum acceptable clearances to combustibles.
If the building has a slight negative pressure or
contaminants are present in the air, an outside combustion
air supply to the heaters is strongly recommended.
Do not use in an atmosphere containing halogenated
hydrocarbons or other corrosive chemicals. Some
compounds in the air can be drawn into the equipment and
can cause an accelerated rate of corrosion of some parts of
the radiant heat exchanger. The use of such chemical
compounds in or near the enclosure should be avoided
where a longer life of the burner, tubing and other parts is
desirable.
Failure to follow these instructions can cause damage to the
system components:
DO NOT high-pressure test the gas piping with the burners
connected. Failure to follow this procedure will exceed the
pressure rating of burner gas controls and this will require
complete replacement of these parts.
DO NOT operate a blower with an unrestricted inlet. An
unrestricted airflow will overload the motor, which can cause
burnout or failure.
This heater is designed for heating nonresidential indoor
spaces. These instructions, the layout drawing, local codes
and ordinances, and applicable standards that apply to gas
piping, electrical wiring, venting, etc. must be thoroughly
understood before proceeding with the installation.
!
!

Omega II®Installation, Operation & Service
Combustion Research Corporation
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.
TABLE OF CONTENTS
PAGE(S)
Heater Safety & Burner Label Placement 1 & 2
Warning Symbols 3
Standards, Certifications and Codes 3 & 4
Installer Qualifications & Responsibility 4
Assembly – Tube and Reflectors 5 - 7
Suspension Methods 8
Combustion Tube Installation 9
Reflector Mounting 9
Customizing System 9
Seismic Restraint Suspension 10
Burner Connection & Installation 11
Gas Supply 12
Flexible gas Connector Installation 13
Technical Data 14
System Dimensions 15
Clearance To Combustibles 16 & 17
Side Shield Installation 18
Combustion Air 19 & 20
Venting 22 – 24
Electrical Information 25
Thermostat Wiring 27
System Start-Up 28 & 29
Sequence Of Operation 29
Service & Maintenance 29 – 33
Trouble Shooting Flow Chart 34 & 35
Burner Parts List 36 & 37
Accessories & Optional Equipment 38 – 40
Warranty Statement and Terms and Conditions 41 & 42
Sample Clearance To Combustible Warning Sign 43
Omega II®heating systems DO NOT qualify for use in explosion proof installations.
Heaters SHALL NOT be used in living/sleeping areas.
2016 COMBUSTION RESEARCH CORPORATION, INC.
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.

Omega II®Installation, Operation & Service
Combustion Research Corporation
This Page Intentionally Left Blank

Omega II®Installation, Operation & Maintenance
Combustion Research Corporation Page 1
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.
Read this manual carefully before installation, operation or
service of this equipment.
Protective gear (including safety glasses) is to be worn
during installation, set up and service. Sheet metal
components, including the aluminum reflectors and field cut
radiant tubes used on this system as well as various
venting components have sharp edges. The use of gloves
will also help in reducing the transfer of dirt and oils to the
surface of the reflectors.
If additional Installation, Operation and Service Manuals are
needed, contact your Combustion Research Corporation
independent representative or Combustion Research
Corporation. The IOM’s can also be found at
www.combustionresearch.com.
In order to help prevent personal injury and damage to the
heater components, at least two persons will be required for
installation.
SAFETY LABELS AND THEIR LOCATION
Product safety signs or labels should be replaced by the
end user or servicing contractor when they are no longer
legible or have been damaged. Please contact Combustion
Research Corp. or your Combustion Research Corp.
independent representative to obtain signs or labels.
Gas Connector Label
P/N 900.2712
Logo Label
P/N 900.2708
Bottom Panel
Wiring Schematic located inside Bottom Panel
P/N 900.27D

Omega II®Installation, Operation & Maintenance
Page 2 Combustion Research Corporation
Operating Instructions Label
P/N 900.2701
Rating Plate Label
P/N 900.2601 Clearance to Combustibles Label
P/N 900.2730
Side Panel
Side Panel
Venting Instructions Label

Omega II®Installation, Operation & Maintenance
Combustion Research Corporation Page 3
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.
CHECKING SHIPMENT
Upon receipt of shipment, check shipment against Bill of
Lading for shortages. Also check for external damage to
cartons or tube bundles. Shortages and/or external
damage to cartons or tubes must be noted on the Bill of
Lading in the presence of delivery trucker. The delivery
trucker should acknowledge any shortages or damage by
initialing this "noted" Bill of Lading.
Claims for damaged material, or shortages that were not
evident upon receipt of shipment must be reported to
carrier and Combustion Research Corporation Sales
Representatives within 72 hours.
Before starting to assemble the heater, make sure
that all optional and accessory items are accounted
for and are available for assembly. It is also
important to verify that the correct gas burner is
supplied for the gas service, i.e., natural gas burner
for natural gas supply.
IMPORTANT
WARNING
IMPROPER INSTALLATION
CAN CAUSE DEATH, SEVERE
INJURY AND/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.
These instructions, the layout drawing, local codes and
ordinances, and applicable standards such as apply to gas
piping and electrical wiring must be thoroughly understood
before proceeding with the installation.
TESTED UNDER STANDARDS
AMERICAN STANDARDS – Z83.20 (current standard)
CANADIAN STANDARDS – CSA 2.34 (current standard)
GAS FIRED BROODERS - CAN 1-2.20-M85
BUILDING CODES
In the absence of local codes, the installation must conform
to the latest edition of:
United States: National Fuel Gas Code, ANSI Z223.1
(NFPA 54).
Canada: CAN/CGA B149.1 and .2, Canadian Electrical
Code C22.1
AIRCRAFT HANGERS
Heaters for use in aircraft hangers must be installed in
accordance with;
United States: Refer to Standard for Aircraft Hangars,
ANSI/NFPA 409 (latest edition).
In Canada: Refer to Standard CAN/CGA B149.1 and
B149.2 and applicable Standards for Aircraft Hangars.
Basic guidelines are as follows:
1. Suspended heaters in aircraft storage or service areas
shall be installed at least ten feet (10') above the upper
surface of wings or engine enclosures of the highest aircraft
which may be housed in the hanger. This should be
measured from the bottom of the heater to the wing or
engine enclosure; whichever is highest from the floor.
2. In other sections of aircraft hangers, such as shops or
offices communicating with airplane storage or servicing
area, heaters shall be installed in accordance with their
listings and mounted not less than eight feet (8') above the
floor.
3. Heaters installed in aircraft hangers shall be located so
as not to be subject to injury by aircraft, cranes, moveable
scaffolding or other objects. Provisions shall be made to
ensure accessibility to suspended heaters for recurrent
maintenance purposes.
PUBLIC GARAGES
Heaters for use in public garages must be installed in
accordance with:
United States: Standard for Parking Structures NFPA 88A
(latest edition) or the Code for Motor Fuel Dispensing
Facilities and Repair Garages NFPA 30A (latest
edition).
Canada: Refer to CAN/CGA B149.1 and B149.2:
Installation Codes for Gas Burning Appliances and
applicable Standards for Public Garages.:
Basic guidelines are as follows:
1. Heaters shall be installed in accordance with their listings
and not be mounted less than eight feet (8') above the
floor. Minimum clearances to combustibles must be
maintained from vehicles parked below the heater.
2. When installed over hoists, clearance to combustible
material must be maintained from upper most point of the
hoist, or provided as insulating or reflective barrier on the
hoist (consult representative or factory for guidance).
!
!
!

Omega II®Installation, Operation & Maintenance
Page 4 Combustion Research Corporation
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.
Canada: Refer to Canadian Electrical Code CSA C22.1
Part 1 (latest edition).
GAS INPUT LINES
The method of pipe sizing must conform to the U.S.
National Standards: ANSI Z223.1 (current standard)
National Fuel Gas Code or CAN 1-B149.1 Installation
Code, and should be installed in accordance with all
National and Local Codes and ordinances.
CLEARANCES AND ACCESSIBILITY
Inlet air assemblies are to be installed with the air opening
pointing toward the ground to protect against rain and
snow. Inlet is provided with a bird screen. Adequate
clearance must be provided around the inlet air assembly
opening to provide an unobstructed entry for the
combustion air. The air should be taken from outside the
building. Clearances must be sufficient to provide
accessibility for servicing. The air inlets must be a
minimum of six feet (6') from the exhaust port.
AGRICULTURAL INSTALLATIONS
In agricultural installations Omega II®heating systems must
be installed as vented systems only.
HAZARDOUS LOCATIONS
Where there is the possibility of exposure to combustible
airborne materials or vapor, consult the local Fire Marshal,
the fire insurance carrier, or other authorities for approval of
the proposed installation. Omega II®heating systems DO
NOT qualify for use in explosion proof installations.
INSTALLER QUALIFICATIONS
Only firms or individuals qualified to perform work in
accordance with the applicable specifications should be
engaged to install a Omega II®system. Consult local
Building Inspectors, Fire Marshals, or the local applicable
Combustion Research Corporation representative for
guidance.
INSTALLER RESPONSIBILITY
Omega II®systems are installed on the basis of information
given in a layout drawing. Together with these instructions
and the cited codes and regulations comprise the
information needed to complete the installation. The
installer must furnish all needed material that is not
furnished as standard Omega II®equipment, and it is his
responsibility to see that such materials, as well as the
installation methods he uses result in a job that is workman
like and in keeping with all applicable codes.
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. A temporary
sample sign can be found at the end of the manual.
GENERAL CONSIDERATIONS
Combustion Research Corporation Factory
Representatives are experienced in the application of this
equipment and can be called on for suggestions about
installation which can give the owner of the building a more
satisfactory and economical installation.
When installing the Omega II®system, take maximum
advantage of the building upper structure, beams, Joists,
purloins etc. from which to suspend the system. Mount
units at minimum height for ease of installation and
maintenance but of specified height to fully utilize the
building.
The general lay out of the Omega II®heating system has
been established by the engineering drawing. The Omega
II®heaters are used to heat building structures as well as
localized areas that would include doors, loading docks and
isolated workstations throughout the building. The location
of the Omega II®heaters should be such that the area is
covered uniformly, in that the heat is positioned on the
perimeter or to each side of the area to be heated, rather
than directly overhead. This will give a better comfort
condition for workers who would be in these areas. Consult
with your representative or the factory for additional
guidance in designing the optimum layout for your project.
Omega II®is a suspended system, which requires that
consideration be given to the factors that determine its
stability, flexibility, safety, and satisfactory operation.
Before installation, the contractor should inspect the
building along with the owner (or engineer) responsible for
the building to check on the use of the building. Inspection
of the building including the use of floor space for storage
and height of materials stored in the building must be noted
so that there are no problems with clearances to
combustibles. Particular care should be taken over doors
and high objects such as busses, trucks, cranes, car lifts,
etc. Whenever possible use side wall penetrations for
combustion air inlets to burners and exhaust venting.
DO -
Maintain specified clearances to combustibles, and
to heat sensitive material, equipment, and
workstations.
Provide approved heat radiation shielding or
barriers if needed. Refer to the National Fuel Gas
Code for guidance.
Provide access for general servicing; provide easy
access for complete removal of burner and blower.
Familiarize yourself with local and national codes.
Develop a planned installation procedure, which will
conserve material and labor on the job. Check to
see that all material and equipment is on the job
before starting installation. Be sure to
accommodate thermal expansion of the hot tube.
Use the gas connector ONLY as shown in the
instructions.
Provide end clearance so tubing won't expand and
touch a wall or a structural member.

Omega II®Installation, Operation & Maintenance
Combustion Research Corporation Page 5
STRAIGHT & "U" TUBE ASSEMBLY
CAUTION
CUT HAZARD - SHARP EDGES.
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. Inspect for shortages and damages as
well as correct gas service for burners.
2. Assemble the tubes as illustrated making sure to apply
one to two tablespoons (15 – 30 ml) of sealer to the
inside edge of the spiral radiant tube. Use a 1” (25.4
mm) dowel or plastic tube to evenly spread the sealer
around the inside edge of the spiral radiant tube before
sliding the coupler/tube together. INSTALL
COMBUSTION TUBE WITH WELD SEAM ON
BOTTOM AND MAKE SURE THAT THE TUBE WITH
THE INTERNAL TURBULATOR IS ASSEMBLED IN
TUBES AS ILLUSTRATED ON THE FOLLOWING
PAGES.
3. Next secure joints with the self drilling and taping
screws provided (use three per joint). Clean off excess
sealer with a damp cloth.
4. Next install hangers supports by sliding them into place
and position them as illustrated. REFER TO PAGES 6
& 7 FOR PROPER LOCATION. NOTE: Do not vary the
location of the hangers anymore than +/- 4" from the
recommendations.
IMPORTANT: Slide the reflectors into place (inside
hangers) and overlap them approximately 1" to 2" and
secure no more than two together with sheet metal
screws. A reflector expansion joint (unsecured reflectors)
at every other overlap is required for expansion and
contraction of the system.
STRAIGHT TUBE SYSTEMS
“U” TUBE SYSTEMS
NOTE: The assembled tubing and reflecto
r
assembly may be too long to conveniently
install in one piece, therefore it is
recommended that the assembly be raised
into position in two pieces. Apply sealer and
secure the final
j
oint
w
hen in position.
Placement of screws @
approximately 120°
A
pply sealer sparingly to inside
edge of radiant tube, spread
with dowel or plastic tube.
Weld Seam Position on Bottom Of Tube
Combustion Tube
End View
!

Omega II®Installation, Operation & Maintenance
Page 6 Combustion Research Corporation
IMPORTANT: A reflector expansion joint (unsecured reflectors) at every other overlap is required for expansion
and contraction of the system. Failure to do so will result in reflectors buckling and system noise!
3.5” STRAIGHT TUBE SYSTEM
4.0” STRAIGHT TUBE SYSTEM
66”
55”55”118”
S
55”55”118”
S
55”55”118”
S
118”
S
118”
S
118”
S
55”55”118”
S
118”
S
118”
S
118”
S
10’ SYSTEM
20’ SYSTEM
30’ SYSTEM
40’ SYSTEM
50’ SYSTEM
55”55”118”
S
118”
S40’ SYSTEM
55”55”118”
S
118”
S30’ SYSTEM
118”
S
55”55”118”
S
118”
S50’ SYSTEM
118”
S
118”
S
55”55”118”
S
118”
S60’ SYSTEM
118”
S
118”
S
118”
S
55”55”118”
S
118”
S70’ SYSTEM
118”
S
118”
S
118”
SS
118”
118”
SS
118”
S
118”
55”55”118”
S
118”
S80’ SYSTEM
118”
S
118”
S
Note: Install Reflector inside
hanger as shown.
E
E
EE
E
E
E
E
EE
EE
EE
E
S
- TURBULATOR
- BURNER END
- HANGER
- REFLECTOR SUPPORT
E - REFLECTOR EXPANSION JOINT

Omega II®Installation, Operation & Maintenance
Combustion Research Corporation Page 7
IMPORTANT: A reflector expansion joint (unsecured reflectors) at every other overlap is required for expansion
and contraction of the system. Failure to do so will result in reflectors buckling and system noise!
3.5” “U” TUBE SYSTEM
4.0” “U” TUBE SYSTEM
44”
66”
5’ “U”
10’ TUBE LENGTH
10’ “U”
20’ TUBE LENGTH
66”
15’ “U”
30’ TUBE LENGTH
66”
66”66”
25’ “U”
50’ TUBE LENGTH
66”66”
66”66”66”
20’ “U”
40’ TUBE LENGTH
Note: Install Reflector inside
hanger as shown.
53” 53” 53”
53” 53” 53” 53”
53” 53” 53” 53” 53”
53” 53” 53” 53” 53”
53” 53” 53” 53” 53”
53” 53” 53” 53” 53”
53”
53” 53”
53” 53” 53”
E
E
E
E
E
- TURBULATOR
- BURNER END
- HANGER
- REFLECTOR EXPANSION JOINT
E
15’ “U”
30’ TUBE LENGTH
25’ “U”
50’ TUBE LENGTH
20’ “U”
40’ TUBE LENGTH
30’ “U”
50’ TUBE LENGTH
35’ “U”
50’ TUBE LENGTH
40’ “U”
50’ TUBE LENGTH

Omega II®Installation, Operation & Maintenance
Page 8 Combustion Research Corporation
SUSPENSION
WARNING
COLLAPSE, FIRE AND EXPLOSION HAZARD
Improper suspension of the tube heater may result in
collapse and being crushed. Always suspend from a
permanent and secure part of the building structure
that can evenly support the total force and weight of
entire the heating system.
Failure to maintain minimum clearance to
combustibles may result in fire and/or explosion,
property damage, serious injury or death. Always
maintain minimum clearances and post clearance
signs where needed.
Combustion Research Corporation recommends that
Omega II ®systems are hung by means of chain. Chain
and “S” hooks are supplied as an option. DO NOT
STRETCH OR INSTALL CHAIN OTHER THAN IN A
VERTICAL FASHION WHEN INITIALLY INSTALLED
(BURNER NOT FIRING).
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. This allows for system expansion and
contraction, reducing the likelihood of reflector and radiant
tube warping and/or expansion noise.
CAUTION: Infrared tube systems expand and contract
upon each call for heat. System expansion of up to 4” can
be expected.
Provisions must be made to limit lateral movement when
systems are installed in site conditions where open doors
may create a wind condition – see page 8 for guidelines.
Radiant tubes DO NOT require sloping.
For fine adjustment turnbuckles may be used.
NOTES:
SECURE TURNBUCKLES SO THAT THEY WILL NOT
UNWIND OR UN-SCREW.
CRIMP "S" HOOKS CLOSED BEFORE LEAVING JOB.
REFLECTORS ARE NOT TO BE INSTALLED ON TOP OF
COMBINATION HANGER
Beam Clamp
Threaded Rod
and Turn Buckle Secure turnbuckle
with JAM nu
t
s or wire
to prevent unwinding
Chain
Bar Clamp
Beam Clamp
Chain
Chain
Beam
Wood Beam
Concrete
Beam Eye Bolt Screw
with Washer and
Locknut
Suitable Expansion
Anchor
All ”S” Hooks MUST Be
Manually Closed By
Installer
Chain
!

Omega II®Installation, Operation & Maintenance
Combustion Research Corporation Page 9
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.
The end that is un-swaged is coupled to the burner
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.
This applies for both straight tube and “U” tube systems.
When the systems are mounted on a 30° angle the weld
seam should always be on the bottom.
TUBE & REFLECTOR HANGING METHODS
The Omega II®system reflectors can be suspended
horizontally or at a 30° angle. The combination hanger is
designed so that the reflector angle will be horizontal when
suspended from the top loop or at a 30° angle when
suspended from the offset loop – see the illustration below.
The panel hangers may also be suspended horizontally or
at a 30° angle – see illustration below.
CUSTOMIZING SYSTEMS
A maximum of two 90° or four 45° elbows may be installed
after THE SECOND tube. The tube couplers that have
been factory installed will have to be removed to
accommodate the installation of any elbows. Any additional
elbows, radiant tube and reflector is optional equipment.
DO NOT INSTALL OR JAM TURBULATORS IN ELBOWS
OR "U" BENDS. CONSULT YOUR REPRESENTATIVE
OR THE FACTORY FOR PROPER INSTALLATION &
GUIDANCE.
Reflector Elbow
Secure To Connecting Reflector
With Sheet Metal Screws
Horizontal Mounting With
“Combination” Hanger 30° Mounting With “Combination” Hanger Horizontal Mounting With “Panel” Hanger 30° Mounting With “Panel” Hanger
Install Combustion Tube
with Weld Seam On Bottom ! IMPORTANT !

Omega II®Installation, Operation & Maintenance
Page 10 Combustion Research Corporation
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. See the
“Seismic Suspension For High Wind Applications” below for
details. If there are any questions regarding what method
is best suited for your application consult your sales
representative or contact the factory. If the system is a
straight system (no elbows or tee's), apply an anti sway
chain or wire rope which is parallel to the radiant tube at
approximately the middle of the run.
SEISMIC RESTRAINT FOR HIGH WIND APPLICATION
In high wind conditions it is recommended that seismic
restraints and reflector retention wire be installed. See
details below for recommended installation of seismic
restraint and anti sway retention chains (wire rope). The
vertical threaded rod shall be attached and suspend the
reflector hangers at intervals of eight to ten feet (8' - 10').
At least one vertical threaded rod shall be placed at every
elbow and/or tee connection. The threaded rod is used to
prevent the system from lifting during high wind conditions,
the chain or wire rope will keep the system from swaying
from side to side. When connecting threaded rod to "Z"
purlin use beam clamp or drill a hole through "Z" purlin and
secure with two 3/8" nuts and a lock washer. If the system
is a straight system (no elbows or tee's), apply an anti sway
chain or wire rope which is parallel to the radiant tube at
approximately the middle of the run.
Punch or drill a small hole (approximately 1/8”) in the reflector near the
reflector hanger. Insert an appropriate length of 14 Ga. galvanized
wire through this hole and encircle the combination hanger. Maintain
a loose loop around the hanger, this will allow for expansion of the
system. Twist the ends of the wire together and trim as required. This
retention wire may be installed on either sides, or edges of the
reflector for severe wind conditions.
30° MIN.
45
°
MAX.
30° MIN.
45
°
MAX.
Seismic Restraints
Use chain or min. 1/8”
aircraft cable 30° Min.
45° Max. 30° Min. 45° Max.
Install the cable clamp
approximately 3” from the
edge of the reflector.
Clamp tight to prevent
chains or cables from
sliding on hanger
30° Min.
45° Max. 30° Min.
45° Max.

Omega II®Installation, Operation & Maintenance
Combustion Research Corporation Page 11
CONNECTING BURNER ASSEMBLY TO
RADIANT TUBE/REFLECTOR ASSEMBLY
WARNING
FIRE OR EXPLOSION HAZARD
IMPROPER INSTALLATION, ADJUSTMENT,
ALTERATION, SERVICE OR MAINTENANCE
CAN CAUSE DEATH, SEVERE INJURY
AND/OR PROPERTY DAMAGE.
There Is expansion of the radiant pipe with each firing
cycle and this will cause the burner to move with
respect to the gas line. This can cause an unsafe
condition if the gas pipe connection is not done in strict
accordance to the instructions.
1. Remove the burner assembly from its shipping carton
and using chain or threaded rod, hang the burner so that it
butts up to the 16 Ga. tube of the tubing and reflector
assembly, and connect the two with the draw band coupler
provided. IMPORTANT NOTE - THE WELD SEAM OF
THE 16GA. TUBE MUST BE POSITIONED SO THAT IT
IS ON THE BOTTOM. Position draw band bolting
assembly on the TOP SIDE of the tube assembly as shown
- DO NOT APPLY SEALER TO THE DRAW- BAND
COUPLER. After tightening the coupler, check to make
sure the burner is lined up squarely - reposition as may be
required, and re-tighten the draw band coupler. Secure
with 2 sheet metal screws. See illustration below. Install
reflector end cap at the burner end of the reflector. Fasten
to reflector with sheet metal screws.
2. Connect the thermostat, gas and electrical supplies and
hook up the exhaust flue and combustion air supply as it
outlined in this manual.
3. The system is now ready to be fired. Refer to the START
UP section of this manual.
NOTES: Heater must be independently supported and not
rely on the gas or electrical line for any of its support.
If there is not a convenient point for suspending the
hanging chain above the heater DO NOT try to "stretch" the
span by having severe angles on the chain. Rather build a
bridge between the existing building structure using Angle
Iron, Uni-strut, etc. and then suspend the chain so that it
hangs vertically.
WARNING
FIRE OR EXPLOSION HAZARD
IMPROPER INSTALLATION, ADJUSTMENT,
ALTERATION, SERVICE OR MAINTENANCE
CAN CAUSE DEATH, SEVERE INJURY
AND/OR PROPERTY DAMAGE.
To insure proper burner performance the burner head
assembly MUST be mounted vertically even when tube
and reflector assembly is angle mounted. Failure to do
so may result in erratic pressure switch operation.
NOTE: On “U” tube systems, install exhaust end of radiant
tube preferably on the motor side of burner assembly. This
will allow easy access to burner controls and is necessary
for proper burner operation for un-vented systems.
Install exhaust on
motor side of burner
assembly
Reflector Mounted at
30° angle. Keep burner
assembly vertical
Suspension
Point
Drawband Coupler
Mount Bolt Assembly
On Top Of Tube
Install Reflector End
Cap On This Side
Of Drawband
Coupler
Secure With Sheet
Metal Screws
! !

Omega II®Installation, Operation & Maintenance
Page 12 Combustion Research Corporation
GAS SUPPLY
WARNING
FIRE OR EXPLOSION HAZARD
IMPROPER INSTALLATION, ADJUSTMENT,
ALTERATION, SERVICE OR MAINTENANCE
CAN CAUSE DEATH, SEVERE INJURY
AND/OR PROPERTY DAMAGE.
Follow these warnings exactly.
1. Disconnect power supply before wiring to prevent
electrical shock or equipment damage.
2. To avoid dangerous accumulation of fuel gas, turn
off gas supply at the appliance service valve before
starting installation, and perform Gas Leak Test
after completion of installation.
3. Always install sediment trap in gas supply line to
prevent contamination of gas control.
Meter and service must be large enough to handle all the
burners being installed plus any other connected load.
When gas piping is not included in the layout drawing, the
local gas supplier will usually help in planning the gas
piping.
Support all gas piping with suitable suspension
materials and in accordance with local codes
Use wrought iron or wrought steel pipe and malleable
iron fittings. All pipe and fittings should be new and free
from defects. Ream the pipe ends and tubing ends to
remove obstructions and burs.
Use LP-gas resistant joint compound on all threads.
Apply only to male end of piping.
Check all piping, fittings and connections for leaks before
placing heating equipment into service. Use only soap and
water solution for checking for gas leaks, NEVER use and
open flame.
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.
When using a high pressure gas distribution system each
heating zone should be equipped with a pounds to inches
service regulator with soft seat, positive 100% lock-up.
Allowing high gas pressure on the downstream side of the
regulator will damage the control valve in the gas train. The
outlet pressure of the service regulators should be set at 7"
W.C. for natural gas and 11" W.C. for LP gases/propane
gases. If it is not practical to regulate in "zones", each
burner may be equipped with its own regulator.
To meet the requirements of 100% positive lock-up and
internal relief vent must be piped to the outside of the
building. It is recommended that an intermediate service
regulator, such as a Maxitrol 325 Series or approved equal
be used.
The typical discharge pressure on the down stream side of
the gas meter furnished by the gas company is usually 5
P.S.I.G. while the discharge pressure of the regulator on the
propane tank is usually set at 15 P.S.I.G.
Proper sizing of low and high pressure piping distribution
systems for natural gas should be made in accordance with
the National Fuel Gas Code, ANSI Z223.1 (current
standard) NFPA No. 54. Consult the supplier of the
propane tank and vaporizing system for the sizing of the
piping system for LP gas pipe work.
When leak testing the gas piping system, the Omega II®
burners must be isolated from the gas piping system. High-
pressure compressed air used in the leak test will damage
the control valve in the burner gas train, which will result in
unsafe operation of the burner(s). For proper and safe test
procedures, observe the provisions of Part #4, of the
National Fuel Gas Code, ANSI Z223.1 (current standard) -
Inspection, Testing and Purging or refer to equivalent local.
In Canadian see gas code CAN/CGA-B149.1- M91.
NOTE: It is important that the entire system, up to the burner
gas connection, be checked for leaks, prior to start up.
GAS PIPE SIZING CHART
NATURAL GAS LP / PROPANE GAS
Pipe
Size Total Length of Pipe (feet) Pipe Size Total Length of Pipe (feet)
20’ 40’ 60’ 80’ 100’ 150’ 200’ 20’ 40’ 60’ 80’ 100’ 150’ 200’
½” 120 82 66 57 50 40 35 ½” 275 129 103 89 78 63 54
¾” 250 170 138 118 103 84 72 ¾” 567 267 217 185 162 132 112
1” 465 320 260 220 195 160 135 1” 1071 504 409 346 307 252 209
1-¼” 848 600 517 427 380 310 268 1-¼” 2205 1039 834 724 630 511 439
1-½” 1316 931 801 661 588 480 416 1-½” 3307 1559 1275 1086 976 787 665
PIPE CAPACITY - MBTU/HR
½” W.C. P.D. WITH 7.0” SUPPLY PRESSURE PIPE CAPACITY - MBTU/HR ½” W.C. P.D. WITH 11.0” SUPPLY PRESSURE
!

Omega II®Installation, Operation & Maintenance
Combustion Research Corporation Page 13
FLEXIBLE GAS CONNECTOR
WARNING
FIRE OR EXPLOSION HAZARD
IMPROPER INSTALLATION, ADJUSTMENT,
ALTERATION, SERVICE OR MAINTENANCE
CAN CAUSE DEATH, SEVERE INJURY
AND/OR PROPERTY DAMAGE.
There Is expansion of the radiant pipe with each firing
cycle and this will cause the burner to move with
respect to the gas line. This can cause an unsafe
condition if the gas pipe connection is not done in
strict accordance to the instructions.
United States - Use only the stainless steel flexible gas
connector as supplied by Combustion Research
Corporation.
Canada – Use approved gas connector as outlined in
B149 Codes; Type 1, minimum 36” long. See chart
below for sizing. This hose is to be supplied by the
Installer contractor.
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.
Do not high pressure test the gas piping with the burner
connected. Failure to follow these instructions can result
in property damage.
Check the pipe and tubing ends for leaks before placing
heating equipment into service. When checking for gas
leaks, use a soap and water solution, never use an
open flame. The loop of the gas flex MUST BE parallel
or in line with the gas inlet pipe on the burner.
The displacement as shown is for cold, non-firing
condition. This displacement will vary as system heats
up.
Install drip leg in accordance with all applicable codes.
EXCESSIVE TORQUE ON THE BURNER GAS INLET
MANIFOLD MAY CAUSE DAMAGE. ALWAYS USE
TWO (2) WRENCHES WHEN MAKING PIPING
CONNECTIONS TO THE BURNER. DO NOT APPLY
PIPE DOPE TO FLARE NUT FITTINGS OF THE
FLEXIBLE GAS CONNECTOR.
Gas Connector Description Used With Inputs of P/N
½” Flexible Stainless Steel Gas Connector (US Models) – 36” L 40K through 150K 0317.01
¾” Flexible Stainless Steel Gas Connector (US Models) – 36” L 155K through 200K 0417.00
½” Flexible Type 1 Rubber Hose (Canada Only) – 36” L 40K through 175K Supplied by Installer
¾” Flexible Type 1 Rubber Hose (Canada Only) – 36” L 180K through 200K Supplied by Installer
INCORRECT POSITIONS
IMPORTANT: Use two wrenches when connecting gas connector and fittings.
Gas Connecto
r
Shut-Off Valve Shut-Off Valve must be parallel to the gas inlet on the burner. A 2” (5 cm)
cold displacement for initial setup is shown. This displacement may
reduce when the s
y
stem is fired.
3” (8 cm) – Cold Displacement
12”
(
30 cm
)
Flexible Gas Connector – Form connector into a lazy
“U” bend as shown. DO NOT make sharp bends.
!

Omega II®Installation, Operation & Maintenance
Page 14 Combustion Research Corporation
GAS PRESSURE AT MANIFOLD
Natural Gas: 3.5" W.C.
LP Gas: 10.0" W.C.
1/2" NPT Gas Connector Size
ELECTRICAL RATING
115VAC, 60 Hz., 1.8 Amp
GAS INLET PRESSURE
Natural Gas: 6.0" W.C. Minimum 14.0"W.C. Maximum
LP Gas: 11.0" W.C. Minimum 14.0" W.C. Maximum
ALTITUDE
Systems 0922 through 0910 (40k - 100k Btu/hr input)
0 - 4,500 Ft. (0 - 1370 m) No de-rating required.
Systems 0926 through 0945 (105k - 200k Btu/hr input)
0 - 2,000 Ft. (0 - 610 m) No de-rating required
2,000 - 4,500 Ft. (610 - 1,370m) De-rating required.
NOTE: Gas pressures must be measured with a water or red oil manometer - NOT A DIAL GAUGE. All measurements must
be made when this heater and all other gas burning equipment connected to the gas supply system are operating at maximum
capacity. It should be assured by test that the gas pressure at the burner inlet is not greater than the figures given above.
Maximum inlet pressure is 1/2 lb. or 14.0" W.C.
The installer must provide a 1/8" N.P.T. (3.2mm) plugged tapping, accessible for test gauge connection, immediately upstream
of the gas supply.
1/8" NPT (3.2mm)
Manifold Pressure Tap
Manifold Pressure
Adjustment
(Under Cap)
Inlet Pressure Tap
1/8" NPT (3.2mm)
0
1
2
3
4
5
6
7
0
1
2
3
4
5
6
7
7
6
5
4
3
2
1
7
6
5
4
3
2
1
3.5” W.C.
Natural Gas 10.0” W.C. Propane Gas
HONEYWELL GAS VALVE
PN 5285.06 (NG) & 5285.06LP (LP)

Omega II®Installation, Operation & Maintenance
Combustion Research Corporation Page 15
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.NG/LP 65,000 10'0" / 14'8" / 19'11" 19'8" / 29'10" / 39'4" 18.3 / 27.5 / 36.2
0916.NG/LP 70,000 10'0" / 14'8" / 19'11" 19'8" / 29'10" / 39'4" 18.3 / 27.5 / 36.2
0915.NG/LP 75,000 10'0" / 14'8" / 19'11" 19'8" / 29'10" / 39'4" 18.3 / 27.5 / 36.2
0914.NG/LP 80,000 10'0" / 14'8" / 19'11" 19'8" / 29'10" / 39'4" 18.3 / 27.5 / 36.2
0913.NG/LP 85,000 10'0" / 14'8" / 19'11" 19'8" / 29'10" / 39'4" 18.3 / 27.5 / 36.2
0912.NG/LP 90,000 10'0" / 14'8" / 19'11" 19'8" / 29'10" / 39'4" 18.3 / 27.5 / 36.2
0911.NG/LP 95,000 14'8" / 19'8" / 24'10" 29'10" / 39'4" / 49'1" 27.5 / 36.2 / 45.1
0910.NG/LP 100,000 14'8" / 19'8" / 24'10" 29'10" / 39'4" / 49'1" 27.5 / 36.2 / 45.1
4" OMEGA II®
BURNER
PART NUMBER BTU/Hr INPUT A ("U" TUBE SYSTEM) B
(STRAIGHT TUBE SYSTEM) SQ. FT. RADIANT
SURFACE AREA
0926.NG/LP 105,000 14'8" / 19'11" / 24'9" 29'10" / 39'4" / 49'1" 31.2 / 41.1 / 51.2
0927.NG/LP 110,000 14'8" / 19'11" / 24'9" 29'10" / 39'4" / 49'1" 31.2 / 41.1 / 51.2
0928.NG/LP 115,000 14'8" / 19'11" / 24'9" 29'10" / 39'4" / 49'1" 31.2 / 41.1 / 51.2
0929.NG/LP 120,000 19'11" / 24'9" / 29'9" 39'4" / 49'1" / 58'11" 41.1 / 51.2 / 61.7
0930.NG/LP 125,000 19'11" / 24'9" / 29'9" 39'4" / 49'1" / 58'11" 41.1 / 51.2 / 61.7
0931.NG/LP 130,000 19'11" / 24'9" / 29'9" 39'4" / 49'1" / 58'11" 41.1 / 51.2 / 61.7
0932.NG/LP 135,000 19'11" / 24'9" / 29'9" 39'4" / 49'1" / 58'11" 41.1 / 51.2 / 61.7
0933.NG/LP 140,000 19'11" / 24'9" / 29'9" 39'4" / 49'1" / 58'11" 41.1 / 51.2 / 61.7
0934.NG/LP 145,000 19'11" / 24'9" / 29'9" 39'4" / 49'1" / 58'11" 41.1 / 51.2 / 61.7
0935.NG/LP 150,000 19'11" / 24'9" / 29'9" 39'4" / 49'1" / 58'11" 41.1 / 51.2 / 61.7
0936.NG/LP 155,000 19'11" / 24'9" / 29'9" / 34'9" 39'4" / 49'1" / 58'11" / 68'8" 41.1 / 51.2 / 61.7 / 71.8
0937.NG/LP 160,000 19'11" / 24'9" / 29'9" / 34'9" 39'4" / 49'1" / 58'11" / 68'8" 41.1 / 51.2 / 61.7 / 71.8
0938.NG/LP 165,000 19'11" / 24'9" / 29'9" / 34'9" 39'4" / 49'1" / 58'11" / 68'8" 41.1 / 51.2 / 61.7 / 71.8
0939.NG/LP 170,000 19'11" / 24'9" / 29'9" / 34'9" 39'4" / 49'1" / 58'11" / 68'8" 41.1 / 51.2 / 61.7 / 71.8
0940.NG/LP 175,000 19'11" / 24'9" / 29'9" / 34'9" 39'4" / 49'1" / 58'11" / 68'8" 41.1 / 51.2 / 61.7 / 71.8
0941.NG/LP 180,000 24'9" / 29'9" / 34'9" 49'1" / 58'11" / 68'8" 51.2 / 61.7 / 71.8
0942.NG/LP 185,000 24'9" / 29'9" / 34'9" 49'1" / 58'11" / 68'8" 51.2 / 61.7 / 71.8
0943.NG/LP 190,000 24'9" / 29'9" / 34'9" 49'1" / 58'11" / 68'8" 51.2 / 61.7 / 71.8
0944.NG/LP 195,000 24'9" / 29'9" / 34'9" / 39'9" 49'1" / 58'11" / 68'8" / 78'5" 51.2 / 61.7 / 71.8 / 82
0945.NG/LP 200,000 24'9" / 29'9" / 34'9" / 39'9" 49'1" / 58'11" / 68'8" / 78'5" 51.2 / 61.7 / 71.8 / 82
11.25”
22.5” “A”
17”
22.5” “B”

Omega II®Installation, Operation & Maintenance
Page 16 Combustion Research Corporation
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. In storage areas where stacking of
materials may occur, the installer must provide
signs, which specify the maximum stacking height so
as to maintain the required clearance to
combustibles. 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. Consideration must be
given when running the radiant tube next to wood, paper,
storage racks, hoists, building construction, etc. For
building personnel safety, the system shall not be
mounted lower than 9' from the floor unless fitted with
protective screens. The following illustrations and
information give minimum acceptable clearance to
combustibles.
Minimum clearances to combustibles must be maintained for
wall, floor, ceiling temperatures. The stated clearance to
combustibles represents a surface temperature of 90ºF
(32ºC) above room temperature. Building materials with
a low heat tolerance (such as plastics, vinyl siding,
canvas, tri-ply, etc.) may be subject to degradation at
lower temperatures. It is the installer’s responsibility to
assure that adjacent materials are protected from
degradation.
Clearances must also be maintained from vehicles parked
below as well as storage racks, partitions, hoists, building
construction, etc
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. A temporary sign can be found at the end of
this manual. Contact your sales representative or
Combustion Research Corporation for this self adhesive
label – P/N 5566.006.
UNVENTED END CLEARANCE
ROOF
Vent / Diffuse
r
PN 1810.WV.400
Min. 18”
Clearance
“U” BEND OR ELBOW END CLEARANCE
ROOF
“U” Tube Reflector End
Min. 18”
Clearance
!