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Cambridge Air Solutions

34

SA-Series Technical Manual

TROUBLESHOOTING INSTRUCTIONS

TROUBLESHOOTING GUIDE

Problem

Possible Cause

Corrective Action

X. ERRATIC OR

PULSATING FLAME

1. High Pressure Regulator

a) Vent undersized

b) Defective regulator

a) Enlarge vent piping size or reduce vent

piping length

b) Replace regulator

2. Amplifier

a) Hunting

b) Temperature control system out of

calibration

c) Defective amplifier

a) Adjust sensitivity control dial counter-

clockwise

b) Perform appropriate calibration procedure

(page 17)

c) Replace amplifier

3. Space Temperature Selector

(CE-Smart

TM

)

a) Induced voltage in field wiring

a) Utilize shielded, twisted pair wiring

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Summary of Contents for Blow-Thru SA Series

Page 1: ... and maintenance instructions thoroughly before installing or servicing this equipment FOR YOUR SAFETY The use and storage of gasoline or other flammable vapors and liquids in open containers in the vicinity of this appliance is hazardous FOR YOUR SAFETY If you smell gas 1 Open windows 2 Don t touch electrical switches 3 Extinguish any open flame 4 Immediately call your gas supplier Made in the US...

Page 2: ...Manufacturer does not warrant Products if they are abused improperly operated or maintained subjected to abnormal wear and tear damaged due to improper gas or electric service damaged in transit or that have been repaired or modified by others without Manufacturer s written authorization Buyer shall have no right to enforce this Warranty unless it has complied with all of its obligations under the...

Page 3: ...em Overview 4 Accessory Identification 4 Heater Operation 5 Heater Configuration 5 Roof Top Mounting 6 Thru Wall Mounting 8 Under Roof Mounting 10 Gas Piping 12 Electrical Wiring 13 Start up Instructions 14 Shutdown Instructions 17 Calibration Procedure 17 Operating Instructions 19 Operating Sequence 19 TSS Controller 20 Troubleshooting Instructions 29 Troubleshooting Guide 29 Reference 35 Electri...

Page 4: ...acity It should be noted that this can be accomplished by taking into account through standard engineering methods the structure s designed infiltration rate by providing properly sized relief openings or by interlocking a powered exhaust system or by a combination of these methods If the failure or malfunction of this heater creates a hazard to other fuel burning equipment in the building e g whe...

Page 5: ...fect the desired air distribution pattern of the heater WARNING It is recommended the heater mounting structure be reviewed and approved by a qualified structural engineer and the roof manufacturer before installing this equipment WARNING To prevent contaminated air from being drawn into the heater install the heater s inlet at least 10 feet from any building exhaust process exhaust sewer stacks o...

Page 6: ...CATION Roof Top Mounting RH UNIT AMS MC DE DD Thru Wall Spiral Mounting Thru Wall Mounting RH IC UNIT DE AMS Adjustable Mounting Stand DD Discharge Duct DE Directional Elbows IC Inlet Collar IT Inlet Transition MC Mounting Curb RH Rain Hood Component Identification Under Roof Mounting IT UNIT DE ...

Page 7: ...e heaters on and off in response to the rise and fall of the space temperature The heater will discharge air at the temperature selected up to 160ºF The operating thermostat is typically located near the perimeter of the building in a location which is out of the direct path of the heated discharge air insulated from cold surfaces and shielded from cold drafts created by air infiltrating the build...

Page 8: ...of manufacturer s recommendations IMPORTANT The roof curb and mounting stands should be installed so that the heater will mount level Cambridge recommends mounting the heater 24 off the roof surface in areas where snow accumulation could impact heater operations 3 Lower the discharge duct through the mounting curb and the roof opening and secure the counterflashing to the mounting curb 4 Use a cra...

Page 9: ...CLOSURE ADJUSTABLE MOUNTING STAND BLOWER ACCESS PANEL CONTROL WIRING CONDUIT REMOTE CONTROL STATION THERMOSTAT CONTROLS INCOMING POWER BY OTHERS SA250 SA350 BLOWER ACCESS PANEL SA250 TYPICAL INSTALLATION ROOF TOP MOUNTING NOTES TREATED TIMBER REQUIRED UNDER MOUNTING CURB AND STAND TO SECURE AND LEVEL UNIT SECURE MOUNTING STAND TO TIMBER WITH WOOD LAG SCREWS AS SHOWN MOUNTING STAND CONSTRUCTION 12 ...

Page 10: ...e hanging brackets on the unit Locate the hanging rods so that the weep holes provided in the rain hood are located a minimum of 3 beyond the outside wall surface 4 Install the hanging brackets on the heater 5 Use a forklift or comparable lifting device to raise and position the heater Take precautions to prevent equipment damage dents and or scratches when the heater is being lifted into position...

Page 11: ...nual 9 Cambridge Air Solutions TYPICAL INSTALLATION THRU WALL MOUNTING HANGING ROD DETAIL HANGING BRACKET DETAIL HANGING ROD WASHER WASHER NUT SHIPPING POSITION DOUBLE NUT SA250 SA350 HANGING RODS NUTS AND WASHERS BY OTHERS ...

Page 12: ...ss exhaust sewer stacks or other sources that would allow contaminants to be drawn into the heater Consult local codes for additional references 1 Install the accessories for roof intake by others 2 Install the hanging brackets on the heater 3 Install hanging rods to adequate ceiling supports and align with the hanging brackets on the heater 4 Use a forklift or comparable lifting device to raise a...

Page 13: ...OTHERS INCOMING POWER BY OTHERS HANGING ROD THERMOSTAT CONTROLS REMOTE CONTROL STATION CONTROL WIRING CONDUIT BY OTHERS INSULATED INLET DUCT BY OTHERS INSULATED INLET ELBOW BLOWER ACCESS PANEL SA350 SA250 TYPICAL INSTALLATION UNDER ROOF MOUNTING HANGING ROD DETAIL HANGING BRACKET DETAIL SA250 SA350 HANGING RODS NUTS AND WASHERS BY OTHERS HANGING ROD WASHER WASHER NUT SHIPPING POSITION DOUBLE NUT ...

Page 14: ...the gas piping to the unit in accordance with local codes or in their absence in accordance with the National Fuel Gas Code ANSI Standard Z223 1 or the CAN CSA B149 Installation Codes IMPORTANT A 1 8 NPT tap is supplied with the heater for measuring the gas supply pressure If the gas supply pressure exceeds that indicated on the nameplate the installer must install a 1 8 NPT tap and high pressure ...

Page 15: ...cause infiltration air can affect the sensor when the door is closed and the sensor may not adequately sense the temperature when the door is open In this application the sensor should be located on the first column in from the outside wall CAUTION Observe special notes and instructions on Wiring and Connection Diagrams regarding sensor installation The wiring for any temperature sensors mounted r...

Page 16: ...the unions in the gas piping located at the burner and just external to the heater housing are tight 8 If inlet ducting is utilized determine the time required to purge it with four 4 air changes and select a pre purge time that will accommodate this time Utilize jumper settings on the Multi functional PC Board to set the Purge Timer to 2 4 8 16 or 32 seconds as applicable ADJUSTMENT TIMER PREPURG...

Page 17: ...rner service switch to the LOCAL position After a delay for prepurge and igniter warm up the burner will light Allow 15 seconds for the low fire start to time out 9 Observe the manometer reading and compare to the manifold pressure determined Step 7 If the manifold pressure reading does not equal this value adjust the control regulator until the proper manifold pressure is obtained 10 Turn the blo...

Page 18: ...ls 21 and 22 The dial should be set to 160 F IMPORTANT The heater access doors must be closed for the remaining portion of this test 3 Turn the blower and burner service switches to the LOCAL position After a delay for prepurge and igniter warm up the burner will light Allow 15 seconds for the low fire start to time out 4 Monitor the discharge temperature until it stabilizes Do not rush through th...

Page 19: ...ner ignition after a delay for pre purge and igniter warm up 5 Reset the thermostat to the desired space temperature 6 Reinstall jumper to Normal Mode 7 Service switches should be in REMOTE FINAL HEATER PREPARATION 1 Perform visual inspection of all wiring and gas valve plugs to ensure they have been properly replaced 2 Remove all test instrumentation 3 Replace and fasten all covers and panels Clo...

Page 20: ... Periodic belt adjustments may be required Indications of loose belts include barking or squealing when blower starts BLOWER CLEANING The blower wheel should be examined for accumulation of dust on the blades These surfaces must be kept clean Dirt accumulation will result in significant air flow reduction and or possible imbalance of the blower wheel CAUTION Prolonged imbalance can result in catas...

Page 21: ...tinues to run until turned off HEATING MODE 1 Mode switch in HEATING position CE Smart only 2 Thermostat or interlock calls for heat 3 Optional motorized inlet damper opens 4 Blower motor starts 5 Airflow switch closes 6 Entering air thermostat closes when inlet temperature is below setpoint after the prepurge delay 7 Igniter warm up timing 8 Gas valve opens 9 Burner lights 10 Igniter is de energi...

Page 22: ...tic adjustment for Daylight Saving Time Nine Holiday Setback Periods for temporary setback operation Temperature Calibration for accurate temperature control Capacitor backup maintains current time and day of week for power loss of up to 96 hours EEPROM storage maintains schedules and temperature settings indefinitely The thermistor enclosure SH 1 is packed inside the Remote Control Station for sh...

Page 23: ... the DAY OF WEEK button while pressing the UP or the DOWN button until the light for the current day is illuminated 2 Press and hold the TIME button while pressing the UP or the DOWN button until the current time is displayed 3 Press and hold the MONTH DAY button while pressing the UP or the DOWN button until the current date is displayed 4 Press and hold the YEAR button while pressing the UP or t...

Page 24: ...he OFF time schedule is in effect See SETTING SCHEDULES for instructions on setting the ON and OFF schedules With the keyswitch in the SUMMER VENTILATION position the heater fan will run based on the time schedule with no temperature control HEATING MODE ON Time Schedule The HEATING mode requires two temperature settings When the temperature drops below the HEAT ON setting the heater will turn on ...

Page 25: ...by the VENT MODE light on the TSS Controller being illuminated Before attempting to program the schedule determine the planned time periods for HEAT ON and SETBACK OFF for the HEATING mode and the planned ON and OFF time periods for the Ventilation mode The time that it takes to recover from the SETBACK temperature to the HEAT temperature must also be taken into consideration for the ON time in th...

Page 26: ... 4 On 5 Off 5 On 6 Off 6 On 7 Off 7 On 8 Off 8 On 9 Off 9 On 10 Off 10 On 11 Off 11 On 12 Off 12 On 13 Off 13 On 14 Off 14 SUMMER VENTILATION SCHEDULE Cycle Time AM PM Day On M F Off M F On 1 Off 1 On 2 Off 2 On 3 Off 3 On 4 Off 4 On 5 Off 5 On 6 Off 6 On 7 Off 7 On 8 Off 8 On 9 Off 9 On 10 Off 10 On 11 Off 11 On 12 Off 12 On 13 Off 13 On 14 Off 14 ...

Page 27: ...s and bold the TIME button while pressing the UP or the DOWN button to scroll to the desired OFF time for Monday through Friday 6 If Monday through Friday is the only schedule required proceed to Step 14 If any additional programming is required proceed with the following steps Remember that subsequent program cycles must not overlap with the ON and OFF times set above 7 Press the UP button once t...

Page 28: ...red program cycles have been entered 14 Press the SETBACK SCHEDULE EXIT button to exit the scheduling program 15 Verify that the correct current time and light for day of the week are still displayed HOLIDAY SETBACK SCHEDULE The Holiday Setback Schedule overrides the normal schedule and holds the space at the SETBACK temperature The TSS Controller allows up to nine holiday periods Holiday Start Da...

Page 29: ...the UP or the DOWN button to scroll to the desired holiday start date 4 Press the UP button once to step to the first holiday end date cycle HEd1 5 Press and hold the MONTH DAY button while pressing the UP or the DOWN button to scroll to the desired holiday end date NOTE Holiday end date must be at least one day after holiday start date 6 Repeat steps 2 5 until all required holiday cycles have bee...

Page 30: ...lows the displayed temperature to be offset either above or below the actual sensed temperature Be sure to use an accurate temperature meter for making this correction 1 Press and hold the HEAT ON and HEAT OFF buttons while pressing the UP or the DOWN button until the correct temperature is displayed A period after the F will indicate the Calibration Mode 2 Pressing the UP or the DOWN button will ...

Page 31: ...ge b Blown control fuse c Defective transformer a Check disconnect and supply fusing b Replace control fuse c Replace transformer 7 Class II Transformer a No output voltage b Defective transformer a Check supply voltage b Replace transformer 8 Multi Functional PC Board a No input voltage on Terminal G RCS b Improper wiring c Defective board a Check voltage in RCS b Check wiring c Replace multi fun...

Page 32: ...pickup ports e Replace switch 5 Flame Safeguard Relay a No input voltage b Defective FSR a Check wiring b Replace FSR III BLOWER RUNS NO HEAT FLAME SAFETY RELAY LOCKS OUT 1 Igniter a No current open igniter b No voltage During trial for ignition a Check igniter current b Check FSR output to igniter 2 High Limit a High limit tripped a See Problem Number VI page 32 3 Gas Valve a No input voltage b G...

Page 33: ...imum fire on modulating valve c Tighten all ground points d Remove jam nuts from Flame Rod Reassemble with terminal located between jam nuts on Flame Rod e Replace burner 5 Flame Safeguard Relay a Defective FSR a Replace FSR 6 High Limit a High limit contact intermittent a Replace high limit V BLOWER RUNS UNIT HEATS SHORT CYCLES WITHOUT RESETTING 1 Air Flow Switch a Blower running backwards SA350 ...

Page 34: ...tat in cold draft relocate a2 Thermostat not satisfied turn down b Reduce differential setting c Replace thermostat 2 Burner Service Switch a Switch in LOCAL position a Place switch in REMOTE position 3 Auxiliary Control a Auxiliary contacts closed a Check auxiliary circuit wiring and contacts 4 Misunderstood Control System Operation a Control system doesn t function as expected a Review control s...

Page 35: ...I Transformer a No voltage output to amplifier a1 Check for short in modulating valve coil a2 Replace transformer 2 Modulating Valve a Valve coil is open or shorted b Plunger jammed c Ruptured main or balancing diaphragm a Replace valve if coil resistance is less than 40 Ω or greater than 85 Ω b Replace valve c Replace valve 3 Amplifier a No output voltage to valve a With the wire removed from ter...

Page 36: ...efective regulator a Enlarge vent piping size or reduce vent piping length b Replace regulator 2 Amplifier a Hunting b Temperature control system out of calibration c Defective amplifier a Adjust sensitivity control dial counter clockwise b Perform appropriate calibration procedure page 17 c Replace amplifier 3 Space Temperature Selector CE SmartTM a Induced voltage in field wiring a Utilize shiel...

Page 37: ...SA Series Technical Manual 35 Cambridge Air Solutions REFERENCE ELECTRICAL CONTROL ENCLOSURE SA350 SA250 ...

Page 38: ...R Flame Safeguard Relay HSI Symbol Description FU1 Fuse 24 Volt Control HL High Limit IG Ignitor LFS Low Fire Start LTC Low Temperature Cutout M Motor MS Motor Starter MV Modulating Valve PCB Printed Circuit Board Symbol Description PT Purge Timer R1A B C Relays Gas Valve R1D Relay Thermostat Control RC Resistor Calibration SOV Shut Off Valve Gas SW1 Service Switch Fan SW2 Service Switch Heat T1 M...

Page 39: ...igh Limit IG Ignitor LFS Low Fire Start LTC Low Temperature Cutout M Motor MS Motor Starter MV Modulating Valve OL Overload Relay OTS Override Timer Switch PCB Printed Circuit Board PT Purge Timer R1A B C Relays Gas Valve R1D Relay Thermostat Control Symbol Description R2 Relay Makeup Air Mode RC Resistor Calibration RES Resistor Thermostat Override RTS Remote Temperature Sensor SOV Shut Off Valve...

Page 40: ...Cambridge Air Solutions 38 SA Series Technical Manual REFERENCE ELECTRICAL CONNECTION DIAGRAM ...

Page 41: ...l s Series 44 modulation controls The discharge temperature sensor which is mounted in the discharge duct transmits a resistance signal back to the amplifier that corresponds to the discharge temperature The amplifier creates a voltage output to drive the modulating valve to maintain the preselected temperature The system can be operated either intermittently as a space heater at maximum discharge...

Page 42: ...sured with a DC microammeter The reading should be steady and between 2 0 and 6 0 microamps μA FLAME SAFEGUARD RELAY FSR The flame safeguard relay supplies 24 Volts AC to the igniter for 4 seconds before the gas valve is energized If the burner does not light flame is not established within 7 seconds this control will lock out gas flow until the control is reset If flame signal is lost during burn...

Page 43: ...0 45 50 or 55 F in ventilation mode or b the gas valve fails to remain energized during a heating cycle 3 The EAT Entering Air Thermostat circuit functions automatically to turn off the burner when the outdoor temperature reaches the EAT setpoint 45 50 55 57 5 60 62 64 66 68 or 70 F 4 The PT Purge Timer circuit function is preset at the factory to provide four air changes within the heater cabinet...

Page 44: ...ses Compliance Requirements The following are required for Cambridge heaters to comply with Standard 90 1 Controls Section 6 4 3 Total airflow of all heaters less than 10 000 cfm The Cambridge CE SmartTM System will meet the standard A properly configured building DDC system with the necessary programming for zone control automatic shutdown and setback can also meet the standard Units intended to ...

Page 45: ...SA Series Technical Manual 43 Cambridge Air Solutions MAINTENANCE LOG Model No _____________ Serial No _______________________ Date Activity Technician ...

Page 46: ...Cambridge Air Solutions 44 SA Series Technical Manual MAINTENANCE LOG Model No _____________ Serial No _______________________ Date Activity Technician ...

Page 47: ...es the right to change specifications modify the design and or substitute equivalent materials without notice as the result of code requirements product enhancements ongoing research development and vendor changes beyond our control ...

Page 48: ...760 Long Road Crossing Dr Chesterfield MO 63005 Phone 636 532 2233 800 899 1989 Fax 636 530 6133 www cambridgeair com ...

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