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State Industries STC-074 User's Manual

1. 22 Control Board Diagnostic LED Interpretation and Troubleshooting 120 Check to Flealter a cuo eeu gere era Ee ccr s 23 Polarity CH GCK o c iiie eee te 24 Continuity Check of High Limit 2 25 Upper Temperature Probe Check 26 Check ACE TTD t 27 Blower Prover Low Gas Pressure Circuit Check 28 HSI Voltage and Continuity Check 29 Igniter and Gas Valve Circuit Check 30 Gas Valve Coil Continuity 31 Flame Prover Checks oru apta cipe cca appen ser o qe ERR 32 Water Temperature Circuit 33 Technical Training Department 1 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TABLE OF CONTENTS Troubleshooting Conditions esee 34 LED Troubleshooting aucun citi ceo Orio SE De ba bx ra nus sid d e nna 36 e 38 General Questions and Answers eese 41 Electrical Information ciconia ecd Cu Ed ua DO MH RA rud eR 44 Draft Proving Pressure Switch Table 44 SBN Service Handbook Introduction This s
2. Phillips head screwdriver standard screwdrivers 3 8 and 7 16 inch open end wrench set of marked drill bits electrical multimeter tester capable of measuring continuity AC voltage and DC voltage gas pressure gauge or manometer gauge pt no 8099 2 water pressure gauge pt no 4798 e thermometer pt no 4870 range 0 220 degrees F 1 2 inch socket with extension for removal of the clean out cover 1 1 16 inch socket with extension for anode removal Custom Commercial Storage Tank Model Number Break Down UG v 6 6 01500 V 125 E a a ECCE eret U Unjacketed Warranty J Jacketed ASME Glass Lined Black Steel Cement SPECIAL NOTE model number appearing on rating plate and carton labels will be compressed Example UGV6601500VA125 Technical Training Department 3 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK INSTALLATION CONSIDERATIONS This portion of the handbook reviews some often overlooked installation considerations clearances air supply gas pressure requirements and venting taking note of necessary installation requirements for SBN The installation manual covers most of these items in detail Clearances A 24 inch clearance for all serviceable parts is recommended Clearances may vary between models See instruction manual or the label on the heater for clearances applic
3. SERVICE HANDBOOK When vents are combined the area of the com bined vent should be equal to area of the largewst NINE RULES FOR single vent plus 50 of area of all others joining GOOD VENTS EXAMPLE To combine two 6 vents with an 8 vent the area of a combined vent should be one half area of two 6 inch vents 14 14 plus area of 8 inch vent 50 or 78 sq inches Referring to char 78 Sq inches require 10 diam eter vent Area in Square Inches Vent Size Square Inches 79 113 454 1 The vent pipe should ALWAYS 201 be the same size as the outlet of 254 the draft diverter or factory supplied vent reducer e Model SBN 120 are supplied with a 6 to 5 reducer e Models SBD 250 251 and 275 are supplied with a 8 to 6 reducer 2 The diameter of a vent pipe should NEVER be reduced no matter what the circumstances Technical Training Department 13 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK 90 AVOID WHERE POSSIBLE 3 In some cases it may be necessary to run a vent larger than the draft diverter outlet zi 4 Take the maximum vertical rise possible immediately 6 Horizontal pipe should be sloped above the draft diverter upward at a minimum of 74 per foot 5 MAXIMUM 75 OF VERTICAL RISE ABOVE CONNECTION 7 Horizontal elements should be limited to 75 of the vertical rise of the vent above the connection 2003 14 Tec
4. Pin 10 A i No Power to igniter Note Flash code of LED pur UO 1H 113 Continuity Test Check E1 pin 10 24V oae Voltage check and continuity check of hot surface igniter circuit Continuity check Power off Plug removed from E4 receptacles Nominal 80 VAC check Plug in E4 Power On check wiring and connection from E4 plug to HSI receiving plug replace HSI Assembly continuity is present resistance should be between 11 and 20 Ohms P at a temperature of 77 F voltage is not present between E4 Pin 2 replace ignition board to ground voltage is present continue voltage is not present between E4 Pin 4 to ground replace HSI HSI should work 2003 32 Technical Training Department Ashland City Tennessee continuity is not indicated between E4 plug pin 2 to 4 SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 8 IGNITER HEATS NO MAIN BURNER Conditions Plugs in receptacle Igniter energizes gets red No main burner or main shuts off within 5 seconds Note flash code of LED E1 Plug Pin 9 E1 Plug Pin 12 Plug in Receptacle Plug in Receptacle Test of Igniter and gas valve circuit MH e check for 24V from E1 Pin 12 to ground during 4 normal Approximate 20 seconds second trial warm up no ignition Yes Continue No Replace Igntion Board no voltage present E4 Pin 12 to replace ignition board ground 24 Volt was p
5. Tank is at a set temperature of 2 F Tank has cooled Push the manual below 120 F reset button Preceded by ECO Troubleshoot for Open indication why the ECO opened n No power Check the breaker Technical Training Department 37 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK LED INDICATORS ON HOT SURFACE IGNITION HSI USING FLASHING RED LED ON HSI HOT SURFACE IGNITION LED STATUS INDICATION ACTION TO BE TAKEN 3 Flashes 2003 System is in lockout Draft proving pressure switch closes at 2 10 0 01 inches W C negative pressure failed to open within 5 seconds at the end of the last cycle Draft proving pressure switch failed to close within 5 seconds after the inducer was started Open on high temperature limit switch ECO 115 volt supply power connection is indicating reversed polarity 38 Interrupt power to reset Heater had not sensed the flame check gas supply and igniter condition Test for defective switch or a pressurized room condition that may be forcing air through the inducer Check the draft The low gas pressure switch closes at 5 2 inches W C may have remained open Verify the supply gas pressure while the gas is flowing Check temperature control operation Verify that a neutral to ground check results in 0 volts and a hot to ground check results in 115 125 VAC
6. heat 2 Inducer fan starts and provides draft 3 Hot surface igniter 20 sec warmup 4 Main gas valve opens 4 sec trial for ignition Maximum 5 trials 5 Main burner ignites and proves 6 Thermistors reach the temperature setting 7 Main burners OFF Auto restart after 60 min 20 sec blower interpurge between trials Top View Draft proving pressure switch Exhaust outlet Optional hat water outlet 2003 Inducer Fan Thermistors probes Hot Surface Igniter Draft Proving Pressure Switch Table Pressure Setting To 5 Close Switch Inches _ SBN Models W C 1 120 199 250 194411 3 2 40 10 400 154 180 199 194411 4 2 60 10 18 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK FRONT VIEW OFWATER HEATER Temperature Display Adjustment LEDs Dial Integrated Heater Diagnostic ETC 5 Indicator E NEN also called red LED b 1 NES Thermostat HSI Ignition Control Board ON OFF Switch Technical Training Department Ashland City Tennessee 2003 SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK WHITE ROGERS INTEGRATED WATER HEATER CONTROL PART NO 194393 0 ALSO CALLED THERMOSAT Display LED Label Display LEDs gt 72 Temperature Adjustment Dial To Upper O Push Reset T L WHITE
7. ies eu EMERSOM ELECTRIC oo 4 Manual To HSI Control Board To Lower Fuse Pin Number Temp Probe Label 2003 20 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK HSI INTEGRATED IGNITION CONTROL BOARD PART NO 194392 Diagnostic pa e Indicator Flash Code LED 7 Control To ON OFF 1 Low Gas Switch 4 2 To HSI 2 Flame Probe 3 1 To Blower 3 6 From Heater Control 7 10 Draft Prower Switch E4 8 Ground 9 12 To Gas Valve E1 Technical Training Department 21 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK LOWER FRONT VIEW OF SBN WATER HEATER Rollout shield Radiation shield Main burner with mounted strips on SBN Models only Part Number 194405 Volts AC Nominal 80 VAC Ohms Resistance 11 0 20 0 77 F 25 2003 22 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK WIRING DIAGRAM Upper 24V ritur dan BOO oput Prote BLOWER PRIMER PRESS STTCH TO EARTH b l GROUND 1309 Reim HOT i120 VAC EARTH GOURD 1 LOWER PROBE a FACTORY ET aie BY MSTAL
8. 000 2t Joejo 6 6 6 6 6 154 00 616 is 61616 6 Number of Combined Input Heaters in Thousands of Btu hr 308 000 xj 462 000 PCS 616 000 MODEL SBN 81 180NE SBN 100 199NE ees es ee Se Input 180 000 190 000 and 199 000 Btu hr Total Vent Height Feet Vent Connector Size 6 inches 6 8 10 15 20 30 50 100 Input Btuh hr i Vent Connector Diameter Inches 180 000 190 000 199 000 180 000 190 000 199 000 180 000 190 000 199 000 Number of Combined Input Heaters in Thousands of Btu hr 60 000 380 000 398 000 540 000 570 000 597 000 720 000 760 000 796 000 2003 16 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK MODEL SBN 100 250NE TECHNICAL DATA VENTING Continued Input 250 000 Btu hr Total Vent Height Feet Vent Connector Size 6 inches 6 8 10 15 20 30 50 100 Btuhhr Rise Vent Connector Diameter Inches 8181717 7 e 6 2500 2r 7 7 7 71 161 61 61 6 Number Combined Input of Heaters in Thousands of Btu hr Manifold and Common Vent Diameter Inches 500 000 12 9 9 9 ea8 es8 7 7 7 75000 12 12 10 10 10 9 8 8 1000000 14 14 12 12 10 1019 9 MODEL SBN 100 275NE Input 275 000 Btu hr Total Vent Height Feet Vent Connector Size 6 inches 6 8 10 15 20 30 50 100 Input Btuhr Rise Vent Connector Diameter Inches 275 000 3 Ft Number of Combine
9. For Self Cleaning Induced Draft Multi Flue Commercial Gas Water Heaters SBN Meets Low NOx Requirements of SCAQMD Rules 1121 amp 1146 2 Part No STC 074 COMMERCIAL 20 00 Printed in the U S A 0204 The Expert s Choice SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TABLE OF CONTENTS SBN Service Handbook Introduction 2 3 Installation Considerations 4 CIB AN AICO 4 541211818 2 irene 5 SUD DY 6 Contaminated PAF echa i o dia dco rp redo 9 9 aS tative A ean 10 PERPE 11 ot ans onion once ence Uo x qs 12 Technical Data 13 14 15 AOD eu etes c kem cad oq pi o uid eem Dea p d RE 15 ood auia tanto delato asd 16 White Rogers Control fia aa a 17 FIO BROAN se 18 Wining DIG GaN 20 Electrical 5 naper Er Erans 21 Pre Service
10. LER Blur daha BK BLACK BROWN WIRING DIAGRAM FOR BTH 120 THROUGH R RED HEN EQUIPPED WITH WHITE RODGERS HSHITIORN Y YELLOW BOARD DIGITAL THERMOSTAT AND CONTROLS GHEEN BL BLUE IF ANY OF THE ORIGINAL WIRE AS SUPPLIED W WHITE MUST BE REPLACED USE ONLY 105 C THERMOPLASTES EGUIVALENT Propane series models do not have a low gas presure switch Technical Training Department 23 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK ELECTRICAL SEQUENCE OF SBNWATER HEATER OPERATION 120 VAC Power to Heater Green LED On Call for Heat Green LED On Module Self Check Low Gas Pressure Switch is Closed Draft Proving Switch I l Is Open High Limit is Closed Inducer Blower Prover Closes 1 6 to 2 60 10 W C depending on heater model Ignition Control Board 120 VAC Variable Voltage 2 80 120 3 Second Trial r HSI Off 3 Seconds to Prove Flame After HSI Off Flame Proves Minimum Millivolt for 4 25 seconds Gas Valve Open 20 Second Blower Purge Flash 7 Times Tank Heated to Set Temperature 1 Hour Auto Reset 2 More Trials To Prove Flame Gas Valve Off Call for Heat LED Off 60 Second Blower Post Purge i O Flash 8 Times On Diagnostic LED Blower Prover Opens Lock Out fo
11. RCIAL GAS WATER HEATER The outlet view of the Gas Valve shown on the right shows the Manifold Gas Outlet Connection the two 24 volt Main Valve MV Solenoid connections and the Manifold Pressure Tap The two yellow wires from the 12 pin plug on the Ignition Board attach to the MV terminals Technical Training Department Ashland City Tennessee SERVICE HANDBOOK Outlet View 24 Volt Main Valve Solenoid Connections Both Wires Manifold Pressure Tap Manifold Gas Outlet 11 2003 SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK Venting All SBN water heaters are classified by ANSI as Category non condensing negative pressure venting appliances They are approved for type B vent The draft inducer does not pressurize the exhaust Venting Atmospheric Multiple Heaters Chimney A minimum of 1 4 rise per foot of horizontal vent is required Manifold mee Consiant Sizo Manifold For larger applications SBN water heaters can be common vented together either in a tapered manifold or constant size manifold Follow the National Fuel Gas Codes requirements for sizing and installation of fan assisted products SBN Models may be common vented only with other Category appliances See the Venting Section in the National Fuel Gas Code 2003 12 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER
12. TEST2 Check from on off switch center and white wire terminals to ground 115 125 VAC is not present voltage is present white right terminal to ee reverse supply wire connections polarity is ground but not black center terminal to reversed ground TEST 3 CONTINUITY CHECK OF HIGH LIMIT ECO Conditions Power On No Hot Water Red heater control Call for Heat LED on Red ignition control board diagnostic LED 4 Flashing Note LED Flash Code before resetting heater See Description of diagnostic LED Flashes Turn Power Off Continued on next page 2003 28 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 3 CONTINUITY CHECK OF HIGH LIMIT ECO continuED TEST 3 Continuity check of ECO energ igh limi Black to Black wires of upper probe Power is off opens at 203 closes at 193 F If water is y below 193 F continuity is correct Morini dentes replace ECO sensor if water temperature is p below 193 F ereset status LED should be on water is less than 120 F ereplace heater control if control will not manually reset TEST 4 UPPER TEMPERATURE PROBE CONTINUITY CHECK Conditions Power On Water below tempera ture set point Red heater control Reset Status LED OFF Call For Heat LED off Ohms Resistance Table Upper Tempera
13. Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK LED INDICATORS ON HOT SURFACE IGNITION HSI USING FLASHING RED LED ON HSI HOT SURFACE IGNITION LED STATUS INDICATION ACTION TO BE TAKEN 7 Flashes Flame sensor reads a Verify that the main low flame signal for burner flame is in contact more than 4 25 sec with the flame e Check wiring and connection to HSI assembly Clean the flame sensor rod of soot or metal flakes 8 Flashes No ignition sensed Check igniter for lack of voltage cracks or lose connection 11 20 Ohms at 77 25 C is good Check ground connection Continuous Continuous flame Check that the gas valve Flash sensed for more than 5 is not failing to close at seconds without gas the end of a heating valve being energized cycle Continuous Internal control board Replace ignition control ON failure board Technical Training Department 39 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK PART LOCATIONS ON SBN SERIES 120 000 390 000 BTU H INPUT MODELS 120 THROUGH 400 A PARTIAL REPLACEMENT PARTS LIST AS AVAILABLE AT TIME OF PRINTING www stateind com Technical Training Department 2003 40 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK 200 Blower Assembly 194408 194408 Outlet Assembly Ex
14. Training Department 9 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK The supply gas pressure is normally measured at the gas valve inlet gas pressure tap if available when the gas is flowing The manifold gas pressure is measured at the manifold pressure tap of the gas valve when the gas is flowing Gas valves used are 24 volt AC combination step opening gas valves They incorporate the main valve and gas pressure regulator into one body The Low Gas Pressure Switch the Supply Gas Inlet and the Supply Gas Pressure Tap are shown in the Inlet View to the right The top view of the gas valve shown on the right shows the Main Gas Regulator Manifold Pressure Tap Top Knob and the Limited Bleed Vent Port The main gas regulator is found under the silver cap screw It is factory preset to 3 5 inches W C and adjusts gas pressure output from 3 0 to 5 inches water column Caution Always test the manifold pressure at the outlet when the gas is flowing 2003 Gas Valve Inlet View Low Gas Pressure Switch Clases at 5 2 30 4 WLC all ae Pressure Tap Remove oN m ressure Switch for Testing Supply Gas Inlet Top View Top Knob Manual ON OFF Gas Control ak ilis E manifold Gas Pressure Limited Bleed Vent Port 10 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMME
15. able to your specific model Top and Front Views of Minimum Clearances To Combustibles Minimum Clearances To Combustibles Side Ceiling SBN 100 250NE A SBN 100 275NE A SBN 85 310NE A ISBN 85 366NE A 6 6 6 6 SBN 85 390NE A 1 24 4 4 A B and C clearances to non combustibles is O inches a 12 inch clearance to cover remains unchanged 2003 4 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK Exterior Clearance The illustration below shows the required clearances for venting units using natural draft venting Required Exterior Clearances More Than 10 Than 10 Pelght Above Any Root Surtace NOTE Within 10 Ho Height Above Herizonially Parapet Required when Distance tram Walls Parapet is Mare than 10 Chimney Chimney_ More Than 10Feet Height Above Any g or Less Rool Surface Within 10 Horizontally jJ Min Chimney 10 Feet or Less Copyright by the American Gas Association Used by permission of the copyright holder The vent must extend at least 3 feet above the highest point where it passes through a roof of a building and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet for vents of 12 inches in diameter or less References NFPA 54 ANSI Z 223 1 SEC 7 5 2a and Sec 7 6 2a may allow reduction to 8 feet with a listed vent
16. cap Technical Training Department 5 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK Air Supply Stoichiometric or theoretical complete combustion requires 10 cubic feet of air per 1 000 BTUH of gas supplied The National Fuel Gas code also recommends an additional 2 5 cubic feet of excess air For information on minimum make up air opening sizes for various building installations refer to the National Fuel Gas Code NFPA 54 ANSI Z223 1 Sec 5 3 Insufficient make up air is a major cause of combustion problems Insufficient Make Up Air Backdraft One common example is in a restaurant installation where exhaust vent equipment was not considered in sizing make up requirements This condition may result in air being backdrafted by the restaurant exhaust equipment through the heater causing the draft proving switch to open and or erratic heater shutdown 2003 6 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK A fresh supply of make up air for combustion can be supplied to the heater through make up air ducts which directly communicate with the outdoors Make Up Air Direct Communication Not Direct Vent Inch Per 4 000 BTUH Two openings are required one within 12 inches of the top of the enclosure and one within 12 inches of the bottom of the enclosure Each opening must have a free area o
17. d Input Heaters in Thousands of Btu hr Manifold and Common Vent Diameter Inches 55000 J Ss J WOT 9 9 B 8B 8 825000 12 12 12 101 9 9 4 1000000 1 14 14 14 12 12 10 9 isnt Connector Diameter Inches 1 Ft 9 8 818171 71 6 6 er Jsea alalz 7 7 6 SEE 7 7 7 6 6 Number of Combined Input Heaters in Thousands of Btu hr Manifold amp Common Vent Diameter 11011019 9 8 8 7 7 14 12 12 12 10 9 9 8 14 14 14 12 12 12 10 9 MODEL SBN 85 366NE SBN 85 390NE Input 366 000 399 000 Btu hr Total Vent Height Feet Vent Connector Size 6 inches 6 8 10 15 20 30 50 100 Input Btu hr Vent Connector Diameter Inches 9 9 9 8 8 8 8 8 it 1919 9 9 8 8 8 8 art 9 98 8 8 8 art 9 9 9 8 8 8 8 8 9 8 8 8 8 8 3 Ft 9 9 8 818 8 8 Number of Heaters in Thousands of Btu hr Manifold amp Common Vent Diameter Inches __ 732000 12 10 10 9 9 9 8 8 79800 12 12 10 10 9 9 8 8 14 14 14 12 12 10 9 9 14 14 14 12 12 10 10 9 16 16 14 14 14 12 12 10 16 16 16 14 14 12 12 jio Technical Training Department 17 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK SBN SEQUENCE OF OPERATION Sequence 1 Thermistors probes call for
18. e T amp P 192467 192467 192467 192467 53 Wire Harness Control Natural 194545 194545 194545 194545 Wire Harness Control Propane 194399 194399 194399 194399 54 Wire Harness Power 194398 194398 194398 194398 Items not illustrated Part numbers underlined are recommended stock items for emergency replacement Request from Parts Department by giving all information such as model and series number type of gas and specifications High Altitude Main Burner Orifice Table NEO Orifice Drill Size 2003 42 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK GENERAL QUESTIONS AND ANSWERS Q What is the effect of the draft inducer A The draft inducer has several effects minimizes the excess air through the heater this often reduces the required vent size reduces draft through the heater when it is off replaces the draft hood of comparable products does not pressurize the vent common B vent materials and the familiar fuel gas codes for venting Category I fan assisted products still apply Do not combine vent with products that do create a positive pressure vent Category III or IV SBN Induced Draft Model Q What is the significance of low NOx nitrogen oxide SBN Models A Currently only Southern California and Texas have adopted rules to reduce the NOx emissions under Rules 1121 and 1146 2 but more of Califor
19. ervice handbook is a supplement to the SBN nstallation and Operation Manual The handbook provides information on servicing and troubleshooting State Industries SBN water heaters in the field While this handbook is not intended to be all inclusive it contains e step by step procedures with illustrations to verify proper installation operation and troubleshooting e quick reference data to assist in servicing the product line e answers to common questions encountered in the operation of the product line The handbook is intended to be used by licensed plumbing professionals Reference should be made to the installation manual accompanying the product If you are experiencing a problem not covered in this handbook please contact the State Industries Technical Information Department at 1 800 527 1953 or your local State Industries representative for further assistance No duplication or reproduction of this book may be made without the expressed written authorization of the State Industries 2003 2 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK Qualifications Installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the field involved Plumbing air supply venting gas supply and electrical testing skills are required Tools Required
20. f not less than 1 square inch per 4 000 BTUH of the total input of all appliances within the enclosure The lower opening primarily provides combustion air The upper opening provides vent dilution air and acts as a relief opening for flue gases should the vent become obstructed or a downdraft condition occur Additionally when the heater is installed in a confined space and communicating with the outdoor air one permanent opening beginning within 12 inches 30 cm of the top of the enclosure must be permitted where the equipment has clearances of at least 1 inch 2 5 cm from the sides and back and 6 inches 16 cm from the front of the appliance The opening must directly communicate with the outdoors and must communicate through a vertical or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors and must have a minimum free area of a 1 square inch per 3 000 BTUH 7cm2 per kW of the total input of all equipment located in the enclosure and b not less than the sum of the areas of all vent connectors in the confined space Technical Training Department 7 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK Often it is more practical to install vertical make up ducts to the outdoors Make Up Air Vertical Ducts Again two openings are required one within 12 inches of the top of the enclosure and one within twelve inches of the bottom of the enc
21. haust 194424 194424 Burner Orifice Bracket Main 98044 98044 Burner Orifice Main N SBN 76243 33 76243 32 Burner Assembly Main N SBN 194648 194648 194648 Burner w Igniter Bracket Main BTN 194760 194760 194760 Gasket Cleanout 99038 99038 99038 99038 Control Ignition Assembly 194392 194392 194392 194392 Cover Control Box 194395 194395 194395 194395 Cover Inner 194388 4 194388 4 194388 194388 Cover Jacket 194389 194389 194389 194389 194389 Ignitor Flame Sensor 194405 194405 194405 194405 194405 Insulation Top 194439 194439 194439 194439 194439 Manual Instruction SBN 194403 194403 194403 194403 194403 Plate Mounting 193439 193439 193439 193439 193439 Probe ECO Upper Thermostat 194396 194396 194396 194396 194396 Probe Lower Thermostat 194397 194397 194397 194397 194397 Rod Anode 180618 42 180618 42 Switch Blower Prover 194411 3 194411 7 194411 4 194411 3 194411 Switch Low Gas Pressure 191149 5 191149 5 191149 5 191149 5 191149 5 Switch Off On 193243 193243 193243 193243 193243 Thermostat Digital 194393 194393 194393 194393 194393 Tube Inlet 192626 1 192626 1 192626 1 192626 1 192626 1 Tube Outlet 192627 1 192627 1 192627 1 192627 1 192627 1 Valve Gas Natural SBN 194536 1 194536 1 194536 194536 BTI Valve Gas Propane 194536 3 194536 3 194536 3 194536 3 Valve T amp P 192467 192467 192467 192467 Wire Harness Control Nat Gas 194545 194545 194545 194545 Wire Harness Power 194398 194398 194398 194398 Items not illus
22. heck that flame prover will be in main flame replace HSI assembly still no extended main burner ignition replace ignition control board Technical Training Department 35 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 11 WATER HEATER SHUTTING OFF BELOW SETTING Conditions Main burner ignited Stored water is below temperature setting more than 5 F Tank Average Power off Plug disconnected from heater control board receptacle and E4 Water Temperature Circuit Check Continuity TEST 11 continuity check pin to pin of lower see Test 4 temperature probe shows 1 0 E4 check wiring and plug connections to heater control board receptacle E4 replace lower temperature probe continuity check red wire pin to red wire pin see Test 4 on upper temperature sensor shows 1 check wiring and plug connections to heater E3 control board receptacle replace upper temperature probe all above checks are oka replace the water heater control 2003 36 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK DISPLAY LIGHTS ON INTEGRATED HEATER CONTROL Power Energy Cut OH Etatu LED Status Indication Action to be Taken for heat Normal status none The ECO Energy Cut eCheck for Off has opened excessively hot water 203 F or higher Correct the problem
23. hnical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK 8 Flue gases must be kept hot for DOUDLE WALL proper venting EKTERIOE DFSCK HALL 9 Obstructions can cause down drafts The vent pipe should be extended to meet local codes Technical Training Department 15 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TYPE GAS VENT p Nu m Multiple Gas Fired Tank Type Heaters Lus When venting multiple tank type heaters using Type oirr B vent pipe follow the installation diagram figure 4 and tables below which give sizing and data based upon NFPA 54 ANSI Z223 1992 MODEL SBN 71 120NE Input 120 000 Btu hr Total Vent Height Feet Vent Connector Size 5 inches 6 8 10 15 20 30 50 100 Input Vent Connector Diameter Inches 1200 X 1tFt 6 6 5 5 5 5 5 5 Heaters in Thousands of Btu hr Manifold and Common Vent Diameter Inches 2 J 22000 17 71 6 Jejejeje je 3 JJA 360 00 d 81817 77 7 6 6 6 4 4800 J 9 to 9 8 8 7 7 6 MODEL SBN 81 154NE 5 O Input 154 000 Btu hr Total Vent Height Feet Vent Connector Size 6 inches 6 8 10 15 20 30 50 100 t Btu hr ise Vent Connector Diameter Inches imt J eleje 6 6 6 6 6 154
24. losure Each opening must have a free area of not less than 1 square inch per 4 000 BTUH of the total input of all appliances within the enclosure Make Up Air Horizontal Ducts When the heater is installed in an interior room with no roof access for vertical ducts horizontal make up air ducts should be installed When using horizontal ducts two openings are required one within 12 inches of the top of the enclosure and one within 12 inches of the bottom of the enclosure Each opening must have a free area of not less than 1 square inch per 2 000 BTUH of the total input of all appliances within the enclosure 2003 8 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK Along with adequate make up air the quality of the air is important Contaminated Air Contaminants in combustion air can lead to premature heater failure Vapors from bleaches soaps waxes salts etc are drawn into the combustion chamber with the make up air and once fired mix with water vapor in the gases to form extremely corrosive hydrochloric or hydrofluoric acid and other corrosive by products Air for Combustion Flammable Items Flammable items pressurized containers or any other potentially hazardous articles must never be placed on or adjacent to the heater Open containers of flammable material should not be stored or used in the same room with the heater Technical
25. nia and Texas are expected to implement this requirement in 2001 Ground level ozone from man made pollution is a major ingredient in smog NOx is a contributor to this ground level ozone formation The boilers and water heaters affected by Rule 1121 and 1146 2 release about 14 tons of NOx emissions into the air each day By comparison approximately the same quantity of NOx is emitted by 288 000 typical passenger vehicles daily It is estimated that a full implementation of this emissions rule will reduce NOx by about 11 tons daily These emission requirements are expected to be implemented by other cities and states soon The rules apply to natural gas water heaters and boilers Technical Training Department 43 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK Q When should anode rods which provide additional protection against corrosion be replaced A Anode rods should be replaced when large gouges or pits appear in the anodes It is recommended that anodes be inspected every six months Q Does the inducer motor require oiling A No Q What size breaker should be used A The heater should draw less then 5 amps and there is a 3 amp car type fuse on the control board This fuse protects the boards 2003 44 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK Electrical Information PartName Number Voltage I
26. ntegrated Water 194393 0 Heater Control Field Output 24 V 11 5 Temperature Control Board 1 5 nducer Blower 194408 0 120 VAC ECO Part of Upper 24 V Opens at 203 Temperature Sensor 194396 5 4 F Closes 193 F 0 3 vaes 2 Inducer Blower 194408 120 VAC 2 2 FLA 3 5 LRA gniter 194405 120 VAC OPT Power Venter 120 VAC 14 5 FLA 26 0 LRA Draft Proving Pressure Switch Table Pressure Setting To Close Switch Inches SBN Models W C 36 PO 194415 02 50 40 Technical Training Department 45 2003 Ashland City Tennessee For Additional Information Contact State Water Heater Technical Information At 1 800 365 0577 Prepared By The Training Department In Ashland City Tennessee stote WATER HEATERS Website www statewaterheaters com
27. o Yes No Yes No Yes No Yes No 2003 SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK CONTROL BOARD DIAGNOSTIC LED INTERPRETATION AND TROUBLESHOOTING TEST 1 120 VAC CHECK TO WATER HEATER Conditions Green display Power LED on Plugs are in receptacles Supply power breaker is not open On Off heater switch is On Water Heater Control Display LED s J Li Ignition Control B dy 2 Board Ground 120 Vac Check To Water Heater On Switch TEST 1 Check for 115 125 VAC black wire to ground 115 V check to E13 terminal and 2B receptical Wie o center black wire to ground check wiring from switch to break box terminal E13 check wiring from on off Left outside terminal voltage is not present at E13 to ground to E13 replace on off switch power is present at E13 check power from E14 to heater control E2 receptacle check wiring from ignition control board E14 to voltage is not present from heater control heater control receptacle E2 receptacle E2 black to ground M replace ignition control board power is present at E2 green LED should be on 2003 26 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK FLASH CODES OF DIAGNOSTIC INDICATOR Conditions Power On Red heater control Call for Heat LED on Red ignition c
28. ontrol board diagnostic LED Flashing Note LED Flash Code before resetting heater LED Status 0 O 1 Flash System is in lock out 2 Flashes Draft proving pressure switch failed to open within 5 seconds at the end of the last cycle Draft proving pressure switch failed to close 2 1 inches of water column pressure within 5 seconds after the inducer was started The low gas pressure switch closes at 5 2 04 w c may have remained open Continuous Flash Continuous flame sensed for more than 5 seconds without gas valve being energized Continuous ON Internal control board failure Control system self adjusts to use a minimum voltage for ignition Lower voltage results in lower igniter temperature which results in longer igniter life Igniter voltage may vary from Nominal 80 VAC TEST 2 POLARITY CHECK Conditions No hot water Display Green Power LED is on Tank is more than 5 below temperature dial setting Red ignition control board diagnostic LED is flashing 6 times between pauses Diagnostic If Red diagnostic Call for y Heat LED OFF Continued on next page Technical Training Department 27 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 2 POLARITY CHECK continued LOW GAS PRESSURE n mm RETURN WO VAC CIRCUIT FACTORY INSTALLED BY INSTALLER Ground Polarity Check
29. r 1 Hour Then Retry Standby LED On 2003 24 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK PRE SERVICE CHECKLIST Use the following checklist BEFORE you begin servicing the water heater 1 Have you removed the cover from the controls Did you take notice of the status lights on the upper water heater control Did you take notice of the red LED in the upper left corner of the lower ignition control 2 Did you note conditions of the room Where does the supply air come from Is the room clean What is stored with the heater How is the heater vented Are all water and gas shut off valves open Are there room exhaust or air intake fans 3 Did you note the condition of the water heater Is the ON OFF switch What is the temperature of the stored water Test at T amp P valve or nearby faucet Is the thermal expansion tank installed 4 Did you write down the complete model and serial numbers of the water heater If so what are they 5 Does the water heater have a good ground wire connection If not the inducer will typically come on for a short time 3 5 seconds then go off and the red LED will flash 8 times Technical Training Department 25 Ashland City Tennessee Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes N
30. resent from E1 Pin check that air has been purged from gas circuit 12 to ground but no main burner check that wiring and connections to gas valve and E1 Pin 9 are correct check for 24 VAC at E1 Pin 9 to ground during 4 second trial Technical Training Department 33 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 9 IGNITER HEATS NO MAIN BURNER Conditions Test 8 completed then Turn off power Disconnect wires from gas valves Manifold i Pressure Tap Lh Manifold Gas Outlet Continuity Check Of Gas Valve Coil check meter scale setting to read between 550 meter reads O or 1 and 650 Ohms replace Gas Valve m valve should be meter indicates pilot and main coil have f y P still no gas to main burner then coil may be continuity stuck Replace Valve 2003 34 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 10 MAIN BURNER IGNITION FOR LESS THAN 5 SECONDS Conditions Power On plug connected Main Burner ignites for approximately 5 seconds then goes out Tests 8 and 9 completed Note flash code on ignition board LED Hot Surface Igniter fio extended Man OTHO check wiring and plug connections of HSI assembly plug and ignition board receptacles E1 Pin 2 check that HSI assembly is not cracked or dirty c
31. ssure Switch 24 VAC Check of Blower Prover Low Gas Pressure Circuit EN ee igntion board receptacles E1 Pin 7 to ground shows n replace Ignition board no voltage E1 Pin 7 has 24 Volt to ground check wire connection to and from inducer voltage check of each blower switch terminal to eswitch is open check for proper draft should ground shows voltage to only 1 terminal also see LED 3 flash code echeck for blocked exhaust echeck that blower outlet exhaust damper is open replace blower draft proving switch 24V is present from each switch terminal to ground cheek Wg pressure switch Eu AA voltage check to each terminal of low gas pressure switch is open test for a minimum of 5 2 switch and ground shows only voltage on 1 W C Natural Gas or 10 5 Propane flowing terminal supply gas pressure should also see 3 Flash LED code replace low gas pressure switch voltage is present to each pressure switch terminal check wiring from low gas pressure switch to and ground ignition board recetacles E1 Pin 10 Technical Training Department 31 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 7 INDUCER ON PROVER SWITCH AND LOW GAS SWITCH CLOSED NO IGNITER OPERATION Conditions Power Check E4 pin 4 to Ground Plugs in receptacles Inducer on un a 24V at ignition board Pis E1
32. trated Part numbers underlined are recommended stock items for emergency replacement consider gas used in your area only Request from Parts Department by giving all information such as model and series number type of gas and specifications Technical Training Department 41 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK 250 A 275 310 366 A 400 Blower Assembly Blower 194408 194408 Outlet Assembly Exhaust 194424 194424 Burner Orifice Bracket Main 98044 98044 Burner Orifice Main N SBN 76243 30 76243 29 Burner Assembly SBN 194648 194648 Burner w Igniter Bracket SBN 194383 194383 194383 Gasket Cleanout 99038 99038 Control Ignition Assembly 194392 194392 Cover Control Box 194395 194395 194395 194395 Cover Inner SBN 194388 4 194388 4 194388 194388 Cover Jacket 194389 194389 Igniter Flame Sensor 194405 194405 Insulation Top 194439 194439 Manual Instruction SBN 194403 194403 Plate Mounting 193243 193243 Probe ECO Upper Thermostat 194396 194396 Probe Lower Thermostat 194397 194397 Rod Anode 180618 42 180618 42 180618 42 Switch Blower Prover SBN 194411 3 194411 8 194411 19441 3 Switch Low Gas Pressure 191149 5 191149 5 191149 5 191149 5 Switch Off On 193243 193243 193243 193243 Thermostat Digital 194393 194393 194393 Tube Inlet 192626 1 192626 1 192626 1 Valve Gas Natural SBN 194536 1 194536 1 194536 194536 Valv
33. ture probe continuity check Red wire to red wire Turn supply power Off for this test test indicates no continuit replace probe probe should be okay also verify Ohms continuity is indicated resistance for water temperature Reading will be approximate Technical Training Department 29 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 5 CALLING FOR HEAT NO Heater Control INDUCER OPERATION 22 Display Conditions LED s Power on Plugs in Receptacles Red Call for Heat LED ON Inducer Off Note flash code on ignition control board diagnostic LED m 2 is Diagnostic i LED Ignition Control Board 115 120 V Check to Inducer TEST 5 Test on r Board 4 Pin 4 Mme control n interrupting power note pn ood tek has no vonage sb reasons for this from flashing LED code replace igntion board 1 to ground has voltage proceed iri pin 3 to ground has no voltage Toa ATOSS ana PADS ereplace inducer 2003 30 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 6 INDUCER ON NO IGNITION Conditions Power on Plugs in receptacles Inducer operating No power to Hot Surface Igniter HSI Note fest code of LED Draft Exhaust Optional Hor Inducer Water Outlet Low Gas Pre

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