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Spec Air Series Technical Manual

37

Cambridge Air Solutions

BONNET SCREW

Indicates parts supplied

in ASCO Rebuild Kit.

CAUTION

Do not damage

valve seat

Locate bleed hole in

core/diaphragm sub---

assembly approximately

30° from valve inlet

BLEED HOLE

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

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Disassembled View of ASCO Valve

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Содержание SPEC AIR Series

Страница 1: ...ng 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 ...

Страница 2: ...r Acknowledgement For questions regarding Limited Warranty contact Cambridge Air Solutions Customer Service Group at 1 800 473 4569 Copyright 2022 Cambridge Air Solutions All Rights Reserved Cambridge Air Solutions 760 Long Road Crossing Dr Chesterfield MO 63005 Phone 636 532 2233 800 899 1989 Fax 636 530 6133 www cambridgeair com ...

Страница 3: ...uctions 7 Mounting Location 7 Horizontal Mount Mounting Curb 8 Horizontal Mount Roof Top Preparation 9 Gas Piping 11 Electrical 12 START UP INSTRUCTIONS 13 OPERATING INSTRUCTIONS Operating Sequence 20 Electronic Thermostat 23 TSS Controller 25 MAINTENANCE INSTRUCTIONS Bearing Lubrication 34 Belt Tensioning 34 Blower Cleaning 35 Burner Cleaning 35 Gas Valve Cleaning 35 ASCO Gas Valves 36 Filters 38...

Страница 4: ...V30 41 Electrical Wiring Diagrams 42 Series 44 Temperature Setback System Temperature Averaging 42 Connection Diagram 43 Gas Control Systems 44 Remote Control Station Components 45 Individual Unit Component Descriptions 46 Damper Motor Replacement Adjustment 51 Troubleshooting Guide 52 ANSI ASHRAE IESNA STANDARD 90 1 57 MAINTENANCE LOG 58 QR CODE 59 SPEC AIR SERIES TECHNICAL MANUAL CONTENTS ...

Страница 5: ...red exhaust system or by a combination of these methods If the failure or malfunction of this unit creates a hazard to other fuel burning equipment in the building e g when the unit is providing the ventilation air to a boiler room the unit is to be interlocked to open inlet air dampers or other such devices If the unit is installed such that an inlet duct is utilized the duct system must be purge...

Страница 6: ...termines the minimum discharge temperature the unit will deliver 40 F to 80 F The MAX dial setting determines the maximum discharge temperature the unit will deliver 80 F to 140 F MAXITROL SERIES 44 TAMPER PROOF The Maxitrol Series 44 Tamper Proof temperature control system is similar to the Maxitrol Series 44 controls above except the adjustable Space Temperature Selector control is replaced by t...

Страница 7: ...NT ROOF TOP CONFIGURATION Standard Unit with Optional Accessories UNIT ACCESSORY WEIGHTS Horizontal Mount Weights Shown In Pounds Model Component V18 V20 V25 V30 Base Unit1 1275 1260 1750 2270 Rain Hood Dual 120 150 210 310 Filters 20 30 45 60 V Bank Filter Section 200 215 275 395 Discharge Duct 50 65 80 95 110 Discharge Nozzles 20 25 35 50 Discharge Damper 20 25 30 40 Curb 14 100 120 180 210 3HP ...

Страница 8: ...r mechanical exhaust fans via an optional dry contact interlock An entering air thermostat acts as an economizer by deactivating burner operation during mild weather TYPICAL SYSTEM OVERVIEW UNIT OPERATION BLOWER ASSEMBLY BURNER VIEWPORT PROFILE DAMPER BLADES BURNER ASSEMBLY MANIFOLD PRESSURE MEASURING PORT MANUAL SHUT OFF VALVE MODULATING GAS VALVE REGULATOR SAFETY SHUT OFF VALVE SSV ELECTRICAL GA...

Страница 9: ...ted such that it would affect the rated airflow through the unit or affect the desired air distribution pattern of the unit If upon review of the proposed installation a problem is discovered which may be considered detrimental to the performance of the unit or restricts its serviceability or deviates from the instructions or drawings which may be provided it is the responsibility of the installer...

Страница 10: ... 4 TYP A TYP 2 x 6 WOOD NAILER PROVIDED RAIL CROSS SECTION 5 INSULATION CANT BY OTHERS 3 7 8 TYP 14 2 x 2 WOOD NAILER PROVIDED UNIT BASE 5 INSULATION CANT BY OTHERS INSTALLATION INSTRUCTIONS CURB AND ROOF PREPARATION V18 V30 Shown for Roof Top Configuration Downblast Application Model Reference inch V18 V20 V25 V30 A 33 33 33 33 7 8 B 48 5 8 54 5 8 66 5 8 88 3 8 See page 9 for drawing references a...

Страница 11: ...must not penetrate the unit base or mounting curb Cambridge Air Solutions recommends using pitch pockets or roof boots to seal the penetrations IMPORTANT Accurate measurements are critical and will affect installation process Roof Opening Model W inch L inch V18 26 26 V20 30 30 V25 36 36 V30 42 42 2 Place exterior curb sides together as shown and secure using large Tek screws as required 3 Install...

Страница 12: ...LVE SUPPLYPRESSURETAP ORIFICE DETAIL B LIFTING PROVISIONS TYP EACH CORNER TYPICAL INSTALLATION UNIT PREPARATION AND INSTALLATION V18 V30 1 Position and install the discharge nozzles by screwing them onto the bottom of the discharge duct 2 Lower the discharge duct through the roof opening 3 Use a crane or comparable lifting device to raise and position the equipment onto the mounting curb Use a spr...

Страница 13: ...the gas piping when installed will not restrict or block the access door from fully opening 5 Install gas piping to the ventilation air unit in accordance with local codes or in their absence in accordance with the National Fuel Gas Code NFPA 54 ANSI Standard Z223 1 or the CAN CGA B149 Installation Codes IMPORTANT A 1 8 NPT tap is supplied with the unit for measuring the gas supply pressure The ta...

Страница 14: ... remote mounted temperature sensors immediately adjacent to overhead doors because the infiltration air can affect the sensor when the door is closed and may not adequately sense the temperature when the door is open In dock areas the sensor should be located on the first column in from the outside wall IMPORTANT Observe the special notes and instructions on the wiring diagrams including the follo...

Страница 15: ...1 VISUAL INSPECTION OF EQUIPMENT a Check for any physical damage from shipping or installation that could render the unit inoperable b Verify all unit accessories and filters if applicable have been properly installed c Check for loose components belts plugs terminal screws etc d Verify the access doors and controls enclosure are free from obstructions such that they can be fully opened e Verify t...

Страница 16: ...vated with the enclosure open live power is present Only experienced technicians with knowledge and respect for live power should proceed beyond this point b Turn the blower service switch to the LOCAL position The blower motor will start after the motorized damper opens Then turn the blower service switch to the OFF position and verify the blower is rotating in the proper direction See the direct...

Страница 17: ...ent at the overload relay on all three legs b Turn the blower service switch to the OFF position IMPORTANT The average amps must not exceed the motor nameplate FLA High amperage may indicate excessive blower RPM Call the Cambridge Air Solutions Customer Service Group at 800 473 4569 if unable to obtain acceptable amperage readings 7 CALCULATING AND ADJUSTING BURNER MANIFOLD PRESSURE a Turn the dis...

Страница 18: ... adjusted in Step 5 page 14 must not fall below 0 51 inches WC for natural gas units and 0 55 inches WC for natural gas with a filter section or filters in the rainhood If the pressure drop is below these values the low airflow switch will shutoff power to the burner This is an indication of low airflow or burner overfiring To correct this condition either adjust the manifold pressure regulator to...

Страница 19: ...eak check piping WARNING Any gas leak detected must be repaired before the ventilation air unit is placed into service 10 MINIMUM FIRE SETTING IMPORTANT All access doors must be closed during this procedure a For units with an A1044 amplifier Reinstall 3 wire on the amplifier that was removed in Step 7 b See page 15 b Connect a meter set to read DC microamps mA in order to verify the minimum fire ...

Страница 20: ... manifold differential pressure above blower pressure Voltage to the modulating valve of 9 to 11 Volts DC for the M611 valve and 10 to 13 Volts DC for the Maxitrol MR212 valve Flame length of 3 to 5 The Low Fire Start function lasts for 15 seconds before returning to the control of the temperature control system It is important that the flame travels across the burner length fast enough within 2 s...

Страница 21: ...on c 1 If the Remote Control Station utilizes a thermostat refer to the Operating Instructions for the Electronic Thermostat page 23 or the TSS Controller page 25 to set the thermostat at its highest setting c 2 If another device in the Remote Control Station controls the operation of the unit activate this device c 3 If the ventilation air unit is not equipped with a Remote Control Station activa...

Страница 22: ...rgized 10 Low Fire Start is de energized after 15 seconds 11 Unit runs and modulates discharge temperature to maintain space temperature set point 12 Repeat steps 2 through 12 HEAT UNOCCUPIED 1 Mode switch in HEAT and state switch in UNOCCUPIED 2 Unit does not run For operating thermostat with manual occupancy switch control system POWER ON 1 Control transformer energized 2 Operator must select SU...

Страница 23: ... POWER ON 1 Control transformer energized 2 Operator must select SUMMER VENT or HEAT mode 3 Operator must set a HEAT schedule for the OCCUPIED and UNOCCUPIED state 4 Operator must set a SUMMER VENT schedule for the OCCUPIED and UNOCCUPIED state 5 Operator may also use the override timer dial to set the state to OCCUPIED SUMMER VENT OCCUPIED 1 Mode switch in SUMMER VENT and state OCCUPIED 2 Damper ...

Страница 24: ... and state switch in UNOCCUPIED 2 Thermostat calls for heat 3 Damper motor optional opens and activates the end switch 4 Blower motor starts 5 Low airflow switch closes 6 If inlet temperature is above entering air thermostat set point skip to step 13 7 After the purge delay continue with igniter warm up timing 8 Gas valve opens 9 Burner lights 10 Igniter is de energized 11 Low Fire Start is de ene...

Страница 25: ...f output relay Separate settings for HEAT ON and HEAT OFF settings Temperature Calibration for accurate temperature control EEPROM storage maintains temperature settings indefinitely in case of power loss The thermistor enclosure SH 1 is packed inside the Remote Control Station for shipment It can be mounted on the exterior sides or bottom of the Remote Control Station or a remote location within ...

Страница 26: ...il the desired temperature for the unit to turn ON is displayed 2 Press and hold the HEAT OFF button while pressing the UP or the DOWN button until the desired temperature for the unit to turn OFF is displayed TEMPERATURE CALIBRATION To compensate for lead wire resistance it may be necessary to make an adjustment to the displayed temperature to correct it to the temperature measured at the thermis...

Страница 27: ...omatic 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...

Страница 28: ...old 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 o...

Страница 29: ...t when the 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 unit 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 unit will turn...

Страница 30: ...d 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 ...

Страница 31: ...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 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 ...

Страница 32: ...ress 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 onc...

Страница 33: ...quired 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...

Страница 34: ...ng 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 ...

Страница 35: ... allows 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 wi...

Страница 36: ...D6185 Annual Motor Operation Recommended Lubrication Interval NEMA 215T Frame or smaller NEMA 254 Frame or larger Intermittent Operation 5000 hours 5 years 3 years Continuous Operation Standard Service 2 years 1 year Seasonal Service Motor is idle for 6 months or more 1 year 1 year Continuous Operation Severe Service High ambient dirty or moist location high vibration 6 months 6 months BELT TENSIO...

Страница 37: ...e oxidation 5 Remove the fasteners that secure the burner to the housing The burner will then be free to slide out CAUTION Be sure to take necessary safety precautions such as wearing eye protection etc before attempting this step 6 Clean the burner by back flushing using high pressure air 40 80 PSI Continue back flushing until dust particles are completely expelled from the burner 7 Re install th...

Страница 38: ...re assembly and the diaphragm assembly when lubricating the pilot disc 6 Replace the body gasket and the core diaphragm sub assembly with the closing spring attached Locate the bleed hole in the core diaphragm sub assembly approximately 30 CCW from the valve inlet 7 Replace the valve bonnet and the bonnet screws 6 Torque the screws in a crisscross manner to 100 10 in lbs Replace the solenoid and m...

Страница 39: ...ambridge Air Solutions BONNET SCREW Indicates parts supplied in ASCO Rebuild Kit CAUTION Do not damage valve seat Locate bleed hole in core diaphragm sub assembly approximately 30 from valve inlet BLEED HOLE Disassembled View of ASCO Valve ...

Страница 40: ...ilter section only CLEANING AND REPLACEMENT Shut down the unit and turn off the blower before servicing the filters Remove the filters from the rainhood or filter section Handle carefully to prevent debris from being dislodged from the filter into the unit Permanent filters can be cleaned using a stream of water or soap and water Back flush the filters until the water comes out clean If soap is us...

Страница 41: ...rence inch Discharge Opening Discharge Duct Size Model A B C D E F V18 19 7 8 18 1 4 13 1 4 63 23 1 2 60 V20 23 7 8 24 5 8 13 1 4 57 27 1 2 62 1 4 V25 31 1 8 31 1 4 18 3 4 62 1 2 33 65 1 4 V30 36 36 5 8 18 5 8 57 39 65 5 8 UNIT DISCHARGE DIMENSIONS Horizontal Mount DIMENSIONS ALLOW FOR 1 CLEARANCE ON EACH SIDE UNIT DISCHARGE AREA UNIT BOTTOM C A B D UNIT INLET E E F ...

Страница 42: ...ambridge Air Solutions 40 Spec Air Series Technical Manual REFERENCE GAS TRAIN DRAWING Horizontal Mount 400 MBH High Pressure CSA Certified ELECTRIC SHUT OFF VALVE SOV ELECTRIC SAFETY SHUT OFF VALVE SSV ...

Страница 43: ...Spec Air Series Technical Manual 41 Cambridge Air Solutions REFERENCE ELECTRICAL CONTROL ENCLOSURE ISOMETRIC DRAWING NOTE Component location and or orientation may differ from that shown above ...

Страница 44: ...S OVERRIDE CLOCK 24V TIME MODE VENT OTS V SW3 3 4 2 1 Z1 O H HEAT FAN RELAY R2X2 6 5 SW3 Z2 7 5 V 8 6 H O 8 1 23 X2 X1 H2 H1 CLASS 2 24V 40VA T2 208v T1 FU1 H1 H2 X4 X2 X1 FU2 120v 24v N2 7 X1F X3 X3F DISC CUSTOMER CONNECTION IN UNIT TERM BLOCK 1 SYMBOL DESCRIPTION AFL Air Flow Switch Low AFH Air Flow Switch High AMP Amplifier Solid State AX1 Auxiliary Contact AX Auxiliary Contact CR1 Control Rela...

Страница 45: ...ation 21 21 STS Temperature Sensor Space Modulation 22 22 Relief Damper Contact E1 Relief Damper Contact Isolated contact optional E2 INCLUDES Non fused disconnect switch Wiring by others 24 VAC Class 2 wiring 18 AWG minimum up to 250 Run separate from power wiring Shielded twisted pair wiring 18 AWG minimum up to 350 Run separate from all AC wiring Ground shield at control end only Refer to wirin...

Страница 46: ...ial setting determines the minimum discharge temperature the unit will deliver 40 F to 80 F The MAX dial setting determines the maximum discharge temperature the unit will deliver 80 F to 140 F Intermittent Continuous Control ITC The Intermittent Continuous Control allows the burner input to be modulated to be operated continuously at modulating discharge temperature for ventilation air see Maxitr...

Страница 47: ...tback System TSS The temperature setback system is a combination seven day programmable timer with independent programs for summer ventilation heating modes and integral electronic thermostat with separate selectable day night setback temperatures see page 25 The thermostat contact is wired between Z1 and Z2 The TSS exists in a lockable NEMA 1 enclosure 9 wide x 14 high x 5 deep equipped with a th...

Страница 48: ...FH AFL The air flow switches sense the pressure drop across the burner profile plate They are factory set and not adjustable They are designed to prevent burner operation if the pressure drop across the burner drops below 0 40 inch WC or increases above 0 75 inch WC for natural gas applications AMPLIFIER AMP The amplifier creates a voltage output to drive an electronic proportioning gas valve to m...

Страница 49: ...ate the electrical circuit to assist in troubleshooting RELIEF DAMPER EXHAUST FAN CONTACT EFC The relief damper contact is an auxiliary dry contact that is mechanically interlocked to operation of the unit s motor starter and is provided with terminals located in unit s electrical enclosure The dry contact is typically wired into an exhaust fan control circuit so that the ventilation unit drives t...

Страница 50: ...peratures in excess of 2400 F during the ignition trial It is furnished with a sleeve for shock mounting and sealing the igniter in the mounting tube LEAK TEST FACILITY SW4 The leak test facility is provided on all units over 400 000 Btu hr and consists of a momentary switch for the first safety shut off valve in the gas train and a gauge port between the first and second safety shut off valve By ...

Страница 51: ...t functions to turn off the blower in approximately 3 1 2 minutes if any of the following occurs a The inlet temperature drops below the selectable LTC setpoint 40 F 45 F 50 F or 55 F in the ventilation mode b the gas valve fails to remain energized during a heating cycle or c the high airflow switch contacts indicate the burner profile plate pressure drop is too high 3 The EAT Entering Air Thermo...

Страница 52: ...hed with a dual voltage transformer unless the primary voltage is 115 Volts The transformer furnished depends on the primary voltage 208 230 or 460 Volts This transformer provides secondary control voltages of 24 and 115 Volts Units supplied for 115 Volts are furnished with a 24 Volt secondary transformer only Secondary fusing is provided in all Class I transformer circuits to protect the downstre...

Страница 53: ...the shaft clamp using a 10mm deep socket 6 Unscrew the motor bracket screws using a 3 8 socket 7 Flip the motor bracket and unscrew the damper motor from the damper motor bracket using a Philips screwdriver 8 Attach the new damper motor using the Phillips screws 9 Attach the damper motor bracket back to the heater 10 Feed the damper wire into the junction box and as they were originally provided f...

Страница 54: ...rol fuse c Defective transformer a Check disconnect and supply fusing b Replace control fuse c Replace transformer 7 Class 2 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 functional PC board...

Страница 55: ...OWER RUNS NO HEAT FLAME SAFEGUARD 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 3 High or Low Gas Pressure Switches a Low gas pressure switch tripped b High gas pressure switch tripped c Defective gas pressure switch a Check gas supply for low...

Страница 56: ...cure FSR grounded a3 Tighten loose ground screws b Clean terminal and reinsert 4 Fluctuating Flame Current a Unit overfiring b Minimum fire set too low c Intermittent ground connection d Defective burner a Check manifold pressure b Adjust minimum fire on modulating valve c Tighten all ground points d Replace burner 5 Flame Safeguard Relay a Defective FSR a Replace FSR 6 High Limit a High limit con...

Страница 57: ...tting too wide d Defective thermostat a Check thermistor wiring and or replace thermistor b1 Thermostat in cold draft relocate b2 Thermostat not satisfied turn down c Reduce differential setting d 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 Mis...

Страница 58: ...4A a Short in sensor circuit a Replace the sensor if the resistance measure is less than 5 000 Ω for the T244A or 3 500 Ω for the TS244A and 1 950 Ω for the TS244A 7 High Airflow Switch a Pressure drop across burner too high b Defective Airflow Switch a Measure pressure drop and adjust profile damper b Replace Airflow Switch 8 Multi Functional PC Board a Temp sensor wires not seated properly in te...

Страница 59: ...s less than 10 000 cfm The Cambridge Air Solutions Temperature Setback System TSS 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 Total airflow of all units exceeds 10 000 cfm The Cambridge Air Solutions Temperature Setback System TSS with optimum start control will meet the s...

Страница 60: ...Cambridge Air Solutions 58 Spec Air Series Technical Manual M O D E L N O S E R IA L N O Date Activity Technician MAINTENANCE LOG ...

Страница 61: ...ations 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 SCAN THIS CODE TO ACCESS OUR HOW TO SERVICE VIDEOS ONLINE https www cambridgeair com parts service how to service videos ...

Страница 62: ...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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