State Industries SBD85 User's Manual
Contents
1. 194623 NA 64 1 1 2 galvanized pipe union 194127 194127 Technical Training Department Ashland City TN 2003 46 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 PARTS DESCRIPTION SBD65305NE A SBD85365NE A SBD100400NE A SBD85500NE d osos Flue 193595 193696 193995 193995 Main Burner Orifice 098044 7 098044 9 098044 9 n 098044 9 P 2 Main 192322 98047 192322 192322 RON Main Burner w Pilot Bracket 193873 193873 1 193873 193873 CARERE Pilot Burner 193314 4 193314 4 193314 4 193314 4 Pilot Burner 193314 3 193314 3 193314 3 193314 3 CLEANOUT ASSEMBLY 99038 99038 99038 990382. 181260 181260 181260 181260 181260 22 191790 193891 193891 193891 193891 22 Damper Drive Assembly 194484 194484 194484 194484 194484 22 Harness 194459 194459 194459 194459 194459 LABELS dais 76244 76244 76244 2 76244 2 76244 2 42 Instruction 195121 1 195121 1 195121 1 195121 1 195121 1 Arce Main Burner Orifice Natural 76243 32 76243 30 76243 35 76243 32 76243 32 V Main Burner Orifice 76243 48 76243 46 76243 51 76243 49 76243 49 45 EA 180618 42 43817 38 43817 38 43817 42 43817 38 AT aas 193444 193444 193444 193444 193444 48 Pilot Tubing 1417 60 1417 60 1417 60 1417 60 1417 60 49 let Tube tei tete nt 193729
3. 193889 193595 193595 193945 193595 MR Main Burner Orifice Bracket 98044 5 98044 5 98044 7 98044 5 98044 7 decer Main 98047 98047 98047 98047 192322 Essa Main Burner w Pilot Bracket 193873 1 193873 1 x2 193873 1 193873 1 193873 Pilot Burner 193314 4 193314 4 193314 4 193314 4 193314 4 NE Pilot Burner 193314 3 193314 3 193314 3 193314 3 193314 3 CLEANOUT ASSEMBLY 99038 99038 99038 99038 99038 12 Pressure Plate 99037 99037 99037 99037 99037 13 Screws Self 69852 69852 69852 69852 69852 dirus Control Ignition Module 193325 193325 193325 193325 193325 Control Dual 192828 192828 192828 192828 192828 Cover
4. 98044 3 98044 3 98044 5 98044 5 98044 5 d stet Main Burner 98047 98047 98047 98047 98047 Bate Main Burner w Pilot Bracket 193873 1 193873 1 193873 1 193873 1 193873 1 L oct Pilot Burner 193314 4 193314 4 193314 4 193314 4 193314 4 Pilot Burner 193314 3 193314 3 193314 3 193314 3 193314 3 CLEANOUT ASSEMBLY 11 Gasket n 99038 99038 99038 99038 99038 12 Pressure Plate 99037 99037 99037 99037 99037 13 Screws Self 69852 69852 69852 69852 69852 Visas Control Ignition Module 193325 193325 193325 193325 193325 6 Control Dual 192828 192828 192828 192828 192828 19 Cover 181260 181260 181260 181260 181260 22 193596 193596 1 193596 1 193596 1 193596 1 29b Damper Drive Assembly
5. 99037 99037 99037 99037 99037 13 Screws Self 69852 69852 69852 69852 69852 17 Control Ignition Module 193325 193325 193325 193325 193325 18 Control Dual WECO 192828 192828 192828 192828 192828 19 181260 181260 181260 181260 181260 22 19359 6 193596 1 191790 191790 191790 22b Damper Drive Assembly 194484 194484 194484 194484 194484 22c Harness 194459 194459 194459 194459 194459 LABELS icc emos 76244 76244 76244 2 76244 2 76244 2 42 Instruction 195121 195121 195121 195121 195121 43 Main Burner Orifice Natural 76243 32 76243 30 7
6. 193940 632112 1 1 2 galvanized pipe plug 194623 NA niri AT 194623 64 1 1 2 galvanized pipe union 194127 NA Zu siue 194127 Technical Training Department Ashland City TN 2003 50 SBD TANK TYPE HEATERS SERVICE HANDBOOK COMPONENT PART INFORMATION NAME SPECIFICATIONS STATE PART NUMBERS DUAL 120 180 RANGE 4 5 192828 CONTROLLER THERMOST DIFFERENTIAL AT LIQUID FILLED ANTI STACKING HIGH LIMIT OPENS 205 FIXED MANUAL ECO RESET BELOW 185 GAS VALVE NATURAL SBD 120 400 24VAC 60hz 192827 2 GAS 6A 7 to 3 5 W C STEP OPEN SBD 500 24VAC 60hz Dual 193366 0 Gas Valve STEP OPEN PROPANE SBD 120 400 192827 3 GAS 2 5 10 W C STEP OPEN SBD 500 24VAC 60hz Dual 193366 1 Gas Valve STEP OPEN INTERMITENT NATURAL 24 VAC 50 60 HZ 1A 193325 IGNITION GAS AND 7 MICROAMP SIGNAL DEVICE PROPANE CONTINUOUS RETRIAL CONTROL GAS DAMPER COMPLETE SEE PARTS LIST ASSEMBLY MOTOR 24 VAC 60 HZ 120 RPM 5 6521 WATT NOT 110 111 SERIES P C BOARD Service Switch 6522 W RELAY NOT 110 111 SERIES TRANSFORMER 120 V PRIMARY 24 VAC 193444 SECONDARY 40 VA 50 60 HZ CLASS 2 Technical Training Department Ashland City TN 2003 51 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD SERVICE CHECKLI
7. 191790 193891 193891 193891 22 Drive 194484 194484 194484 194484 194484 22 194459 194459 194459 194459 194459 LABELS Manifold es 76244 2 76244 2 76244 2 76244 3 76244 2 42 Instruction 195121 195121 195121 195121 195121 43 Main Burner Orifice Natural 76243 32 76243 32 76243 30 76243 33 76243 29 44 Main Burner Orifice LP 76243 49 76243 48 76243 45 76243 51 76243 44 45 43817 38 180618 42 180618 42 43817 38 180618 42 47 193444 193444 193444 193444 193444 4822 Pilot 193729 1417 60 1417 60 1417 60 1417 60 esie e 193729 193729 192626
8. 76243 37 76243 32 76243 31 76243 28 44 Main Burner Orifice LP 76243 48 76243 49 76243 48 76243 44 Anode 43817 38 180618 42 180618 42 180618 42 AT ison 193444 193444 193444 193444 48 Pilot 1417 60 1417 60 1417 60 1417 60 49 NA ead 192626 192626 192626 B snos Gas Valve 192827 2 192827 2 192827 2 193366 0 52 censum es 192827 3 sm eret 192827 3 193366 1 55 Switch Panel Mounting Plate 193448 193448 193448 193448 56 OFON Swilch 193243 193243 193243 193243 57 Enne 193404 193404 193404 193404 Jumper Wire es 1934
9. 193476 193476 193476 193476 59 Control Box 193447 193447 193447 193447 193447 60 98185 98185 98185 2 98185 2 98185 2 61 195100 195100 195098 195098 195098 62 1 1 2 galvanized pipe cap 193940 193940 193940 193940 193940 63 1 1 2 galvanized pipe plug 194623 194623 194623 194623 194623 64 1 1 2 galvanized pipe union 194127 194127 194427 194127 194127 Technical Training Department Ashland City TN 2003 45 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 ITEM PARTS SBD81190NE SBD100199NES A SBD100250NE A SBD65251NE A SBD100275NE fesi Flue Baffle 193795 1 193889 193595 193595 193945 Main Burner Orifice Bracket 98044 5 98044 5 098044 5 098044 7 098044 5 Mai
10. 192626 193729 192626 193729 Bios c Gas Valve 192827 192827 192827 192827 192827 SP ERE Gas Valve 192827 1 192827 1 192827 1 192827 1 192827 1 55 Switch Panel Mounting Plate 193448 193448 193448 193448 193448 56 Off On 193243 193243 193243 193243 193243 57 B shihg ertet 193404 193404 193404 193404 193404 58 Jumper e 193476 193476 193476 193476 193476 59 Control Box 193447 193447 193447 193447 193447 60 Cover 98185 2 98185 2 98185 2 98185 2 98185 2 195100 195198 195102 195098 195102 62 1 1 2 galvanized pipe cap 193940 193940 NAE od 193940 NA BS 1 1 2 galvanized pipe plug
11. NA 194623 3 194623 3 64 1 1 2 galvanized pipe 194127 194127 Technical Training Department Ashland City TN 2003 49 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 CGA CGA CGA ITEM PARTS DESCRIPTION SBD85365NE A SBD100400NE A SBD85500NE A Flu e Baffle neinni atan 193945 193995 193995 Main Burner Orifice Bracket 098044 9 098044 9 098044 9 d sus Main Burner ecce 98047 ul 192322 Ron 98047 RUE PER Main Burner w Pilot 193873 1 193873 1 193873 1 innixi Pilot Burner 193314 4 193314 4 193314 4 Pilot Burner 193314 3 193314 3 193314 3 CLEANOUT ASSEMBLY 11 rr c 99038 99038 99038 12 545 Pressure Plate 99037 99037 99037 13 Screws Self
12. 192626 51 Valve 192827 192827 192827 192827 192827 52 1 192827 1 192827 1 192827 1 192827 1 192827 1 55 Switch Panel Mounting Plate 193448 193448 193448 193448 193448 56 Switch 193243 198248 55 4 193243 193243 193243 57 c BUSHING tie s e Um 193404 193404 193404 193404 193404 58 Wire 193476 193476 193476 193476 193476 59 Box 193447 193447 193447 193447 193447 60 98185 2 98185 2 98185 2 98185 3 98185 2 61 Hydro Cannon 195100 195100 195098 195102 195098 62 1 1 2 galvanized pipe cap 193940 193940 193940 193940 6 1 1 2 galvanized pipe 194623
13. Roof Surface NOTE d Within 40 No Height Above a ae Horizontally Parapet Required 3 Min when Distance from Walls or Parapet is More than 10 Wall or Parapet Chimney More Than 10Feet 10 or Less Height Above Any a gt p or Less Roof Surface Within10 N Chimney 10 Feet or Less Height Above Any Horizontally Copyright by the American Gas Association Used by permission of the copyright holder This illustrates the exterior roof clearances for SBD units with natural draft venting The vent shall 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 in diameter or less NFPA 54 ANSI Z 223 1 SEC 7 5 2a Sec 7 6 2a may allow reduction to 8 feet with a Listed vent cap Technical Training Department Ashland City TN 2003 4 SBD TANK TYPE HEATERS SERVICE HANDBOOK AIR FOR COMBUSTION 10 CUBIC FEET OF AIR PER 1 000 BTU 1 000 _ BTU 2 5 CU EXCESS AIR Stoichiometric or theoretical complete combustion requires 10 cubic feet of air per 1000 BTUH input of the gas input The National Fuel Gas Code also recommends an additional 2 5 cu ft of excess air This 12 5 cu ft minimum supply air per 1000 BTUH input applies to natural and propane gas models The National Fuel Gas Code also specifies min
14. 193448 193448 193448 193448 56 OFON Switch 193243 193243 193243 193243 193243 LT ON oe carne i set e 193404 193404 193404 193404 193404 58 Jumper Wire s 193476 193476 193476 193476 193476 59 Control Box 193447 193447 193447 193447 193447 60 Cover 98185 98185 98185 2 98185 2 98185 2 61 195100 195100 195098 195098 195098 527 oe 1 1 2 galvanized pipe 193940 193940 193940 193940 193940 1 1 2 galvanized pipe 194623 194623 194623 194623 194623 64 1 1 2 galvanized pipe 194127 194127 194127 194127 194127 Technical Training Department Ashland City TN 2003 48 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 PARTS DESCRIPTION SBD100199NES A SBD100250NE A SBD65251NE A SBD100275NE A SBD65305NI ENS Flue
15. 69852 niens 69852 ns 69852 Tassen Control Ignition Module 193325 193325 193325 18 Control Dual 192828 192828 192828 19 Cover 181260 181260 181260 22 Drafthood 193891 193891 193891 22b Damper Drive Assembly 194484 194484 194484 22C Harness 194459 194459 194459 LABELS 41 Manifold iesire ette eco tete 76244 4 76244 4 76244 4 42 5 Instruction 194027 194027 ne 194027 43 Main Burner Orifice Natural 76243 32 76243 31 76243 29 44 Main Burner Orifice 76243 49 76243 48 76243 44 45 Anode 180
16. Self Cleaning Commercial Gas Water Heaters with Flue Damper and Electronic Ignition 58071 120 Through 58085 500 Also includes Parts List Part Number STC 072 COMMERCIAL Printed in the U S A 0106 The Expert s Choice SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD HANDBOOK TABLE OF CONTENTS PAGE PAGE Troubleshooting continued Introduction 1 2 Troubleshooting the Efflkal 28 30 Wire Harness Test 31 Installation 3 Module 32 Clearances 4 Pilot Spark 33 Air Requirements 5 8 Pilot Valve 34 35 Contaminated Air 9 Main Burner Test 36 Flammable 9 Flame Rectification 37 Gas Pressure 10 Module 38 Gas Valve 11 Main Gas Valve 39 40 Venting 12 15 Sequence of Operation Mechanical 16 Service Charts and General Electrical 17 18 Questions and Answers 41 42 Troubleshooting Parts List 43 50 Transformer 19 High Limit 20 21 Component Part Information 51 Damper on Standby 22 PC Board 22 23 Service Check List 52 53 Thermostat 24 Effikal Damper 25 Comments 54 Effikal Harness Test 26 Normal Operation 26 27 SBD SERVICE HANDBOOK INTRODUCTION This service handbook is designed to aid in servicing and troubleshooting State SBD water heaters in the field No duplication or reproduction of this book may be made without the express written authorization of the State Water Heater Company The following text and illustrations will provide you with a step by step procedure to verify proper installation operation and troubl
17. 12 Pressure 99037 99037 99037 99037 13 Screws Self 69852 69852 oe 69852 69852 Control Ignition Module 193325 103398 193325 193325 18 5 Control Dual 192828 192828 192828 192828 19 Cover 181260 181260 181260 22 193891 193891 193891 193891 22 Damper Drive Assembly 194484 194484 194484 194484 22 Harness 194459 194459 194459 194459 LABELS dic Manifold ect ies 76244 3 76244 76244 4 76244 4 dd ose Instruction 195121 195121 195121 43 Main Burner Orifice
18. UA EL FILTER STEP 2 5 y REG 10 07 W REG BE 75 Wt T0 124 W C 8922 _ SBD 120 400 GAS VALVE STEP 18A MAIN GAS VALVE CHECK Disconnect wires from gas valve TH and TR terminals Using a multimeter test for 68 ohms plus or minus 5 between TH and TR on the main valve coil IF THEN The meter reads O or infinity e Replace the gas valve The meter reads 68 ohms plus or minus 5 The main burner will ignite Technical Training Department Ashland City TN 2003 39 SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 18B MAIN GAS VALVE COIL CHECK PILOT GAS MANIFOLD PRESSURE TAP The PV wire is connected to the blue wire The MV PV wire on the IID is connected to the white wire The MV wire is disconnected from the gas valve GAS MANIFOLD PRESSURE TAP STEP 18B MAIN GAS VALVE COIL CHECK SBD 500 ONLY Condition Pilot lights e Sparking stops burner ignition Test Procedure Power off Disconnect red main valve wire from module MV terminal Meter set to test for DC amperage 10A wire to red gas valve wire COM wire to MV terminal of ignition module Turn power on to heater After pilot lights and sparking stops IF THEN 25 to 35 DC Amps is not present e Replace the gas valve 25 to 35DCA is present e Main burner gas should ignite Be certain to correct yo
19. 194484 194484 194484 194484 194484 22 Harness 194459 194459 194459 194459 194459 LABELS docui Manifold ire c tsp mir 76244 0 76244 0 76244 2 76244 2 76244 2 42 Instruction 195121 1 195121 1 195121 1 195121 1 195121 1 dir oce Main Burner Orifice Natural 76243 32 76243 30 76243 35 76243 32 76243 32 44 Main Burner Orifice LP 76243 49 76243 46 76243 51 76243 49 76243 49 45 Anode 43817 38 43817 38 43817 38 43817 42 43817 38 Ty NS 193444 193444 193444 193444 193444 48 Pilot Tubing 1417 60 1417 60 1417 60 1417 60 1417 60 49 193729 192626 193729 192626 193729 Bip Gas Valve 192827 192827 192827 192827 192827 Gas Valve 192827 1 192827 1 192827 1 192827 1 192827 1 55 Switch Panel Mounting Plate 193448
20. The other wire emerging from the pilot solenoid connects to the pilot valve electrical output on the IID terminal PV The TR terminal connects directly to the main valve electrical output from the IID module terminal MV On the outlet view of the gas valve we see the pilot gas connection port manifold gas connection port a limited bleed vent port the manifold gas and pressure tap See step 18 for SBD 500 gas valve illustration Technical Training Department Ashland City TN 2003 INLET VIEW lop Knob Filter Screen Gas Inlet TOP VIEW Main Gas Regulator TR Pilot Gas Regulator Limited Bleed Port Manifold Pilot Gas Gas Connection Port Port SBD TANK TYPE HEATERS SERVICE HANDBOOK VENTING Atmospheric Single and Multiple Heaters All SBD water heaters are classified by ANSI as category non condensing negative pressure venting appliances They are approved for type B vent For larger applications SBD water heaters can be common vented together either in tapered manifold or constant size manifold Follow National Fuel Gas Code requirements for sizing and installation Combined Vents When vents are combined the area of the combined vent should be equal to area of the largest single vent plus 50 of area of all others joining 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 1
21. e See Steps 1 thru 4 Check the harness plugs connecting heater and damper for looseness or damage Technical Training Department Ashland City TN 2003 28 SBD TANK TYPE HEATERS SERVICE HANDBOOK TROUBLESHOOTING THE EFFIKAL DAMPER continued Condition Thermostat closed damper open Service Switch A1 IS CORRECT CHECK SERVICE SWITCH STEP 9B POSITION IF THEN Switch is incorrect position Replace damper board motor assembly Switch is not in correct position e Adjust switch e Cycle thermostat to verify that damper operation is correct Technical Training Department Ashland City TN 2003 29 SBD TANK TYPE HEATERS SERVICE HANDBOOK TROUBLESHOOTING THE EFFIKAL DAMPER continued Condition Thermostat closed damper is open fully STEP 10A TEST FOR 24VAC BETWEEN BLACK AND YELLOW IF THEN 24VAC is present This is correct continue to Step 11 24VAC is not present e See Step 9B e Check the harness plug connecting e Check that cam on shaft rotates with shaft e Replace the damper board e Ensure that cam is secure against end switch Condition Damper rotates continuously STEP 10B ADJUST END SWITCH TO CAM CONTACT IF THEN Damper stops in proper position 24 VAC should be open on a call for heat and close during standby Damper does not stop in proper position e Replace damper assembly Technical T
22. in place The meter reads 24 VAC e Goto step 8 Note If the high limit to thermostat jumper wire was disconnected earlier to simulate a satisfied thermostat reconnect the jumper to the terminals Note A yellow wire from this thermostat terminal connects to the damper PC board Technical Training Department Ashland City TN 2003 24 SBD TANK TYPE HEATERS SERVICE HANDBOOK EFFIKAL DAMPER The wiring colors from the damper PC Board are different colors than the wires on the heater wiring harness The male female plugs to connect the damper board to the heater harness join in only one way B Adapter E Plug Service EN p Switch p gt ai Terminal Effikal Control Cover Photo of kit mounting Effikal Style Adapter not necessary on production 110 111 Series The heater harness wires still serve the same function Black 24V Constant if high limit closed Damper 2 1 3 Yellow 24V To damper if the thermostat is closed Red 24V From damper to IID if damper closes end switch White Neutral common Orange Brown Yellow Black Erom Heater Male Plug Sr 9 2 c Female Plug Technical Training Department 25 Ashland City TN 2003 SBD TANK TYPE HEATERS SERVICE HANDBOOK HARNESS CHART Heater Harness Function Damper Harness Black 24V Hot 1 Brown Yellow 24V from Thermostat 2 Orange Red 24V from damper 3 Yellow White 24V c
23. replace switch e Check that the 120 VAC is supplied from transformer The meter reads 24 VAC e Goto step 2 Technical Training Department Ashland City TN 2003 19 SBD TANK TYPE HEATERS SERVICE HANDBOOK HIGH LIMIT LEFT TERMINAL TEST Ground T 24 VAC FM Transformer X fa amp gt STEP 2 HIGH LIMIT LEFT TERMINAL TEST Test for 24 VAC between the left high limit terminal and ground IF THEN The meter does not read 24 VAC e Check wiring between transformer and high limit The meter reads 24 VAC e Goto Step 3 Note The high limit Energy Cut Off opens if the tank water temperature exceeds 205 degrees The control is resettable manually when the tank water temperature drops below 185 degrees Technical Training Department Ashland City TN 2003 20 SBD TANK TYPE HEATERS SERVICE HANDBOOK P3 Temperature High Limit ECO Adi Dial Reset Button High Limit Thermostat Jumper Wire Black To Damper Motor STEP 3 TO TEST HIGH LIMIT RIGHT TERMINAL Ensure that the jumper wire between the high limit and thermostat is connected and the damper motor power line is connected Test for 24 VAC between the high limit right terminal and ground IF THEN The meter does not read 24 VAC e Push the reset button and redo the test storage water temperature below 185 degr
24. 4 plus area of 8 inch vent 50 or 78 sq inches Referring to chart 78 sq inches require 10 diameter vent Area in Square mg Area in Square Vent Size Inches Vent Size 5 20 28 38 50 6 7 8 9 64 Nine Rules for Good Vents 1 The vent pipe should ALWAYS be the same size as the outlet of the draft diverter or factory supplied vent reducer e Model SBD 120 are supplied with a 6 to 5 reducer e Models SBD 250 251 and 275 are supplied with a 8 to 6 reducer Technical Training Department Ashland City TN 2003 12 SBD TANK TYPE HEATERS SERVICE HANDBOOK Nine Rules for Good Vents continued 2 The diameter of a vent pipe should NEVER be reduced no matter what the circumstances 3 In some cases it may be necessary to run a vent larger than the draft diverter outlet 4 Take the maximum vertical rise possible immediately above the draft diverter 5 90 AVOID WHERE POSSIBLE Technical Training Department 13 Ashland City TN 2003 SBD TANK TYPE HEATERS SERVICE HANDBOOK Nine Rules for Good Vents continued 6 Horizontal pipe should be sloped upward at a minimum of 1 per foot 7 Horizontal elements should be limited to 75 of the vertical rise of the vent above the connection MAXIMUM 75 VERTICAL RISE ABOVE CONNECTION 8 Flue gases must be kept hot for proper venting mung FIFE ENEE WALL
25. 618 42 180618 42 180618 42 Transformer 193444 193444 193444 Pilot Tubing eren 1417 60 unes 1417 60 1417 60 49 Inlet Tbe iit eene 192626 192626 192626 Gas Valve 192827 2 192827 2 193366 52S Gas Valve 192827 3 192827 3 193366 1 bb x sus Switch Panel Mounting Plate 193448 193448 193448 56 Off On 193243 193243 193243 DT xanux BUSHING anteire 193404 193404 193404 193476 nme 193470 Re 193476 59 Accesses Control Box 193447 193447 193447 60 Cover 98185 2 9818522 98185 2 61 195102 es 105098 195098 62 1 1 2 galvanized pipe 193940
26. 6243 35 76243 32 76243 32 44 Burner Orifice LP 76243 49 76243 46 76243 51 76243 49 76243 49 45 43817 38 43817 38 43817 38 43817 42 43817 42 47 193444 193444 193444 193444 193444 48 1417 60 1417 60 1417 60 1417 60 1417 60 cese cete 193729 192626 193729 192626 192626 51 Gas Valve 192827 192827 192827 192827 192827 52 Valve 1 192827 1 192827 1 192827 1 192827 1 192827 1 55 Switch Panel Mounting Plate 193448 193448 193448 193448 193448 56 Switch 193243 193243 193243 193243 193243 57 5 ce e 193404 193404 193404 193404 193404 58 Jumper Wire s 193476
27. 76 193476 193476 193476 59 Control Box 193447 193447 193447 193447 60 Cover 98185 3 98185 4 98185 4 194111 61 195102 195098 195098 195098 62 1 1 2 galvanized pipe 193940 193940 63 1 1 2 galvanized pipe 194623 3 194623 3 194623 3 64 1 1 2 galvanized pipe union 194127 194127 194127 Technical Training Department Ashland City TN 2003 47 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 CGA CGA CGA CGA CGA ITEM PARTS DESCRIPTION SBD71120NE SBD81154NE SBD76180NE 58085199 SBD76190l decus Flue 193595 192199 3 193795 0 193696 193795 0 Main Burner Orifice
28. 85 DCA is not present e Replace the gas valve 75 to 85 DCA is present e Pilot should work if gas not air is present to pilot Power off reattach blue gas valve wire to PV terminal of module Technical Training Department Ashland City TN 2003 35 SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 15 MAIN BURNER TEST STEP 15 MAIN BURNER TEST Visually check for main burner IF THEN The main burner ignites e Sequence is complete The main burner does not ignite e Goto step 16 Technical Training Department Ashland City TN 2003 36 SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 16 FLAME RECTIFICATION Ignitor Foe Sensor n 248 STEP 16 FLAME RECTIFICATION Note Flame rectification means that an alternating current AC signal is changed to a direct current DC signal The pilot flame is the switch which connects the pilot hood to the igniter and ground If the pilot hood and igniter sensor had the same surface area the flame switch would conduct an AC signal Because the pilot surface is greater than the igniter surface the signal becomes a DC current that the module can interpret The pilot hood must be properly grounded and the pilot flame must remain in contact with both surfaces for the flame proving signal to remain constant If the signal is broken for just 8 tenths of a second the heater will cycle off Sparking at the pilot will continue if an insufficien
29. 9 Obstructions can cause down drafts Technical Training Department Ashland City TN 2003 14 SBD TANK TYPE HEATERS SERVICE HANDBOOK POWER VENT KITS FOR SIDEWALL VENTING 4 E a Garage E ane i d Dincannezi haama re Sraa damiger T Puy Ferrada kee wore heroes Oto regla Connector on harpy Female plug to Damper oda id 2 L Larger Lo 40 Power Venter cable with L _ MOMME 1 connect Som FT d witch 000 Male plug to Cable _ mu 5 q i wei C k a E NOTE Facirg ring SEE WATER HEATER DIACRAJM FOR COMPLETE WATER HEATER WIE on AM m POLLIS in TALL POU P PRODUC TS MAKAL dips m mm mw Water Heater Models Part Number SBD 120 200 193933 0 SBD 250 500 193933 1 SBD water heaters can be used with power vent kits for sidewall venting State offers power vent kits for use on installations with a maximum of 100 equivalent feet of vent piping The power vent kits also use type B vent materials When power venting specific exterior clearances must be maintained as outlined in the National Fuel Gas Code NFPA 54 ANSI A223 1 sec 7 8 Technical Training Department Ashlan
30. D ASME A SERIES 110 111 EFFIKAL DAMPER DRIVE ASSEMBLY GAS VALVES HONEYWELL VALVE SBD 500A Technical Training Department Ashland City TN 2003 43 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 CLEANOUT ASSEMBLY Technical Training Department Ashland City TN 2003 44 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 ITEM PARTS SBD71120NE SBD81154NE SBD81180NE SBD100199NET SBD100199NE Flue Baffle 193595 192199 3 193795 1 193696 193696 Main Burner Orifice Bracket 98044 3 98044 3 98044 5 98044 5 98044 5 3 Main 98047 98047 98047 98047 98047 Bo Main Burner w Pilot Bracket 193873 1 19887351 193873 1 193873 1 193873 1 Pilot Burner Natural 193314 4 193314 4 193314 4 193314 4 193314 4 Pilot Burner LP 193314 3 193314 3 193314 3 193314 3 193314 3 CLEANOUT ASSEMBLY 99038 99038 99038 99038 99038 12 Pressure
31. ERVICE HANDBOOK 120 VAC to Junction Box OFF Switch 24V Transformer Tank Temperature Calling for Heat Tank Temperature Satisfied High Limit Closed High Limit ECO Closed Thermostat Closed Motor Closes Damper Motor Opens Damper Cam On Damper Blade Closes Proving End Switch IID Module 24V Receives Voltage _ Module Sends 24V Terminal Pilot Ignites and Proves Flame Module Spark Sends to Pilot Coil 10 000V Spark to Pilot Spark Stops Module MV 90 Second Trial Terminal Sends 24V 5 Minute Delay Between To Main Gas Coil Trials Continuously Main Burner Heats Tank Themostat Opens Power to Damper 2 Interrupted Damper Motor Energized and Damper Closed Technical Training Department Ashland City TN 2003 18 SBD TANK TYPE HEATERS SERVICE HANDBOOK TROUBLESHOOTING SBD WATER HEATERS To troubleshoot a SBD water heater check that e 120 VAC is supplied to the heater e the tank is full of water gas is supplied to the unit TEST THE TRANSFORMER STEP 1 TO TEST THE TRANSFORMER Using a multimeter test for 24 VAC between the secondary transformer terminals IF THEN The meter does not read 24 VAC e Check that the 120 VAC is supplied from the On Off Switch if not
32. OMMERCIAL STORAGE TANK MODEL NUMBER BREAKDOWN Model Breakdown SBD 85 500 CGA D Canadian if applicable Constructed Altitude None Standard T Tall 500 000 Sandblaster Damper BTUH 3 Year Warranty to 8 000 Feet S Short Technical Training Department Ashland City TN 2003 2 SBD TANK TYPE HEATERS SERVICE HANDBOOK INSTALLATION This portion of the handbook will review some often overlooked installation considerations taking note of necessary installation requirements for the SBD 71120 through SBD 85500 model heaters The installation manual covers most of these items in detail CLEARANCES FROM COMBUSTIBLES LING 6 15 12 T6 CHIMNI 30 48 bo d TOP VIEW FRONT VIEW Clearance to Combustibles Table MODEL A B C 120 200 1 2 54CM 1 2 54CM 1 2 54CM 250 305 2 5 08 2 5 08 2 5 08 365 400 3 7 75CM 3 7 75CM 3 7 75CM 500 5 12 7CM 5 12 7CM 5 12 7CM A 24 inch clearance for all serviceable parts is recommended Clearances may vary between SBD models See instruction manual or the label on the heater for clearances applicable to your specific model 20 50 8CM for 500 models Technical Training Department Ashland City TN 2003 3 SBD TANK TYPE HEATERS SERVICE HANDBOOK EXTERIOR CLEARANCE More Than 10 More Than 10
33. PANSION TANK DEPLETED ANODES SCHEDULE ANODE CHECKS REPLACE AS NEEDED DAMPER WILL NOT OPEN BINDING SHAFT SUPPORT VENTING DAMPER MOTOR EFFIKAL REPLACE DAMPER CONTROL ASSEMBLY NO SPARK AT PILOT DAMPER ASSEMBLY SEE STEP 10A DAMPER FULLY OPEN Services Switch may bypass problem until replacement part is received EFFIKAL REPLACE DAMPER CONTROL ASSEMBLY MODULE REPLACE IID STEP 12 SPARK CABLE REPLACE CABLE STEP 13 Technical Training Department Ashland City TN 2003 41 SBD TANK TYPE HEATERS SERVICE HANDBOOK GENERAL QUESTIONS AND ANSWERS Q What is unique about the Canadian SBC CGA models vs U S SBD models A Canadian models have different dimensions to meet Canadian code requirements Q How much electrical power is required for a SBD water heater A The SBD models draw approximately 7 Amps at 120VAC Q The units require leg kits to meet National Sanitation Foundation standards Q When should SBDs be delimed NOTE The Hydrocannon should eliminate or greatly reduce the lime build up rate from the water heater Many variables affect the liming up process including water temperature The amount of lime precipitation during the same period of time will be nearly 2 times greater if water is stored at 140 degrees F than at 120 degrees F A 180 degree setting will precipitate lime about seven times as fast as a 140 degree F setting volume of water The more gallons
34. ST This service checklist may be photo copied to assist with SBD service call This checklist is intended to aid the Service Agent in determining that the State SBD Water Heater has been properly installed and is operating correctly Because the circumstances of each installation may vary greatly it is not intended to be an all inclusive list of the problems that the Service Agent may encounter Any item checked no on this list should be thoroughly investigated and corrective action taken if required SERVICE AGENT INSTALLATION DATE MODEL NUMBER SERVICE DATE SERIAL NUMBER LOCATION ADDRESS GAS TYPE CHECK ONE NATURAL PHONE PROPANE l Check Clearances circle answer A Are exterior clearances adequate yes B Are interior clearances adequate yes Comments Il Check Makeup Air Requirements Is the quantity of make up air adequate per the National Fuel Gas Code yes Comments B Is the quality of make up air adequate yes Comments Gas Pressure fill in blank A Supply gas pressure inches of W C B Manifold gas pressure main burner inches of W C Comments IV Venting check A Properly sized per the National Fuel Gas Code yes B Does the installation have mechanically assisted venting yes If so is it operational yes Comments Technical Training Department Ashland City TN 2003 52 no no no no no no no V VI VII SBD
35. TANK TYPE HEATERS SERVICE HANDBOOK WATER PIPING Is the system properly sized Is the system properly installed Are there any water leaks Does the installation have a recirculating system If so is it operational PROPER SEQUENCE OF OPERATION During standby does damper close on standby During standby is pilot flame off On a call for heat does thermostat close On a call for heat does damper open completely Does sparking begin at pilot Is pilot flame established If so does sparking stop Does main burner ignite Does the thermostat satisfy Does damper close Comments SAFETY A Gas Does pilot flame prove before main burner ignites Does damper blade fully open before ignition sequence occurs Is burner cover plate in place Is burner floor shield in place Does IID lockout occur after 30 sec trial for ignition Propane models only B Water Temperature Is the thermostat adjusted to the lowest acceptable temperature Does the installation have a mixing valve If so is it operational What is the outlet temperature of the mixing valve Is a properly rated temperature and pressure relief valve installed C Electrical Is the 120 VAC electrical power supply properly wired Are all the SBD control covers in place Is the 120 VAC electrical power supply properly fused D Flammables Are flammable materials located in the area of the water heater Are flammable vapors located in the area of the water heater Thi
36. ant installation where exhaust vent equipment was not considered in sizing make up air requirements This may result in air being backdrafted by the restaurant exhaust equipment through the heater causing flue gas spillage flame roll out improper combustion inconsistent pilot operation and or erratic heater shut down Technical Training Department Ashland City TN 2003 8 SBD TANK TYPE HEATERS SERVICE HANDBOOK CONTAMINATED AIR Along with adequate make up air the quality of the air is important 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 byproducts 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 Training Department Ashland City TN 2003 9 SBD TANK TYPE HEATERS SERVICE HANDBOOK GAS PRESSURE REQUIREMENTS Supply Gas Manifold Pressure Dirt Leg Manifold Gas Port Natural Gas Propane Gas Maximum Supply Pressure 10 5 W C 13 8 W C Minimum Supply Pressure 5 0 W C 11 W C Manifold P
37. d City TN 2003 15 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD SEQUENCE OF OPERATION 9 Flue damper closes 1 Thermostat calls for heat 2 Flue damper opens 7 Thermostat satisfies 4 Pilot gas opens Pilot sparks and flame proves 3 Intermittent Ignition Control 6 Main burner ignites 5 Main gas valve opens e 8 Main and pilot burners OFF SEQUENCE OF OPERATION To understand SBD tank type water heaters an examination of their sequence of operation is necessary When the thermostat calls for heat the relay in the draft hood assembly activates the flue damper motor The damper opens and power flows to the IID Intermittent Ignition Device This activates the IID module to open the pilot valve and begin sparking at the pilot burner assembly Once the pilot flame is established and confirmed back to the IID the sparking is stopped and the main gas valve is opened allowing gas flow to the main burner When the thermostat satisfies main and pilot gas is shut off Damper is returned to closed position Technical Training Department Ashland City TN 2003 16 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD ELECTRICAL SEQUENCE 100 109 Series QUICK CONNECT ADAPTER QUICK CONNECT Lg GROUND Lo GROUND Ly GROUND HONEYWELL 586 0 IGNITION CONTROL Technical Training Department Ashland City TN 2003 17 SBD ELECTRICAL SEQUENCE OF OPERATION 115 60 12A SBD TANK TYPE HEATERS S
38. ees The meter reads 24 VAC e Goto step 4 After Push in Reset 24 VAC is now present Reasons For Resetting Condition Cause Solution High limit open Never set on initial Push high limit button installation Excessive water temperature Faulty thermostat Replace dual control Heater shut down before Faulty high limit Replace dual control reaching thermostat setting Note The right terminal of the high limit has a jumper wire connected to the left terminal of the thermostat There is also a black wire connecting to the damper motor assembly This black wire supplies power to the motor to close the damper during periods of standby Technical Training Department Ashland City TN 2003 21 SBD TANK TYPE HEATERS SERVICE HANDBOOK INSPECT THE DAMPER STEP 4 INSPECT THE DAMPER Lower the thermostat setting so the unit will not be calling for heat then inspect the damper IF THEN If the damper is open e Goto step 5 If the damper is closed e Goto step 7 Note If the water temperature in the tank is below 120 degrees F temporarily disconnect the jumper wire between the high limit and thermostat to simulate a satisfied thermostat STEP 5 CHECK THE PC BOARD STEP 5 CHECK THE PC BOARD Test for 24 VAC between the black PC board wire connection and ground IF THEN 24 VAC is not present Check the black wire c
39. eshooting procedures Additional quick reference data is included to assist you in servicing this product The information contained in this handbook is designed to answer common questions encountered in the operation of the SBD product line and is not meant to be all inclusive If you are experiencing a problem not covered in this handbook please contact the Technical Information Department at 1 800 365 0577 or your Local State Water Heater Sales Representative for further assistance This handbook is intended for use by licensed plumbing professionals and reference should be made to the installation manual accompanying the product This handbook contains supplemental information to the SBD installation and operation manual Technical Training Department Ashland City TN 2003 1 SBD TANK TYPE HEATERS 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 e Phillips head screwdriver e standard screwdrivers e a3 8 and 7 16 inch open end wrench e set of marked drill bits e anelectrical multimeter tester capable of measuring continuity e gas pressure gauge or manometer e water pressure gauge e thermometer e 1 2 inch socket with extension for removal of the clean out cover e 1 1 16 inch socket with extension for anode removal CUSTOM C
40. flowing through the SBD the more exposure to accumulation hardness The harder the water the higher the possibility of lime build up 1 to 3 5 grains per gallon is soft 3 5 to 7 grains per gallon is moderate 7 to 10 5 grains per gallon is hard and 10 5 grains per gallon is very hard An aspirin is about 5 grains One grain is equal to 17 1 parts per million A Deliming should be done when a slight rumbling or popping sound is detected when the main burners are on Q What effect will lime build up have on the SBD water heater A One eighth inch of scale build up may reduce efficiency as much as 2296 a 1 4 inch build up as much as 38 A Less efficient heat transfer means more bottom head expansion contraction stress and premature leakage A Heavy build up on the bottom head and bottom portion of the flue pipes leads to more heat transfer at the top of the flues This can lead to stacking or erratic thermostat operation A Hydrocannon greatly reduces the possibility of lime build up Q Anode rods provide additional protection against corrosion When should these be replaced A When large gouges or pits appear in the anodes replace them It is recommended that these be inspected every 6 months Technical Training Department Ashland City TN 2003 42 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A SERIES 110 111 PARTIAL REPLACEMENT PARTS LIST MODELS SBD 120 THRU 500A STANDARD AN
41. imum make up air opening sizes for various building installations Ref NFPA 54 ANSI 7223 1 sec 5 3 Technical Training Department Ashland City TN 2003 5 SBD TANK TYPE HEATERS SERVICE HANDBOOK MAKE UP AIR DIRECT COMMUNICATION 1 Square Inch Per 4 000 BTUH 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 out of doors Two openings are required one within 12 inches of the top of the enclosure and one within twelve inches of the bottom of the enclosure Each opening shall have a free area of not less than 1 square inch per 4000 BTUH of the total input of all appliances within the enclosure The lower opening is primarily providing combustion air The upper opening is providing 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 commencing within 12 in 80 cm of the top of the enclosure shall be permitted where the equipment has clearances of at least 1 in 2 5 cm from the sides and back and 6 in 16 cm from the front of the appliance The opening shall directly communicate with the outdoors and shall communicate through a vertical or horizontal duct to the outdoors or spaces crawl or attic that freely communicate with the outdoors and
42. ition IF THEN The meter does not read 24 VAC and the Replace the module IID module is not between ignition trials The meter does read 24 VAC e Goto step 13 Technical Training Department Ashland City TN 2003 32 STEP 13 SBD TANK TYPE HEATERS SERVICE HANDBOOK PILOT SPARK TEST STEP 13 PILOT SPARK TEST Visually check for spark at the pilot assembly Note The pilot burner mounts on the left side of the main burner IF THEN The igniter is not sparking Check for A 7 64 spark gap Spark cable continuity Ground cable continuity Sparking is present Go to step 14 Power To Module May Be Interrupted To Reset 90 sec Call for Sparking heat 5 min No Sparking Trial for Ignition Technical Training Department Ashland City TN 2003 90 sec 90 sec 5 min Sparking No Sparking 33 Sparking Continuous Trial Sequence SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 14A PILOT VALVE OHM TEST SBD 120 400 GAS VALVE STEP 14A PILOT VALVE OHM TEST If pilot assembly is sparking but no pilot flame is established disconnect the pilot valve solenoid leads Using a multimeter set to read ohms test for 20 ohms resistance 5 through the solenoid coil IF THEN The meter dose not read 20 ohms plus or minus 5 e Replace gas valve The meter doe
43. n 98047 98047 98047 98047 98047 5 Main Burner w Pilot Bracket 193873 1 193873 1 193873 1 193873 1 193873 1 Pilot Burner 193314 4 193314 4 193314 4 193314 4 193314 4 ores Pilot Burner 193314 3 193314 3 193314 3 193314 3 193314 3 CLEANOUT ASSEMBLY 14 Gasket m tento nn 99038 99038 99038 99038 99038 12 Pressure 99037 99037 99037 99037 99037 13 Screws Self 69852 69852 69852 69852 69852 17 Control Ignition Module 193325 193325 193325 193325 193325 18 Control Dual WECO 192828 192828 192828 192828 192828 19 181260 181260 181260 181260 181260 22 191790
44. ommon 4 Black NORMAL OPERATION Condition e Heater on standby e Damper closed e High Limit closed Wires are from left to right Black Yellow Brown Orange TEST FOR 24VAC BETWEEN BLACK COMMON STEP 8 AND BROWN STEP 8 TEST FOR 24VAC BETWEEN BLACK COMMON AND BROWN IF THEN 24VAC is present Continue to Step 8A 24VAC is not present See Troubleshooting Step 9A Technical Training Department Ashland City TN 2003 26 Condition SBD TANK TYPE HEATERS SERVICE HANDBOOK NORMAL OPERATION continued e Thermostat closed damper in process of opening STEP 8A TEST FOR 24VAC BETWEEN BLACK AND ORANGE IF THEN 24VAC is present Continue to Step 8B 24VAC is not present Condition e Thermostat closed damper fully open STEP 8B TEST FOR 24VAC BETWEEN BLACK AND YELLOW See Troubleshooting Step 9B IF THEN 24VAC is present Continue to Step 10A 24VAC is not present Technical Training Department Ashland City TN 2003 27 See Troubleshooting Step 9B SBD TANK TYPE HEATERS SERVICE HANDBOOK TROUBLESHOOTING THE EFFIKAL DAMPER Condition Thermostat closed damper closed Wires are from left to right Black Yellow Brown Orange TEST BETWEEN BLACK COMMON AND BROWN 21134788 ON THE DAMPER BOARD IF THEN 24VAC is present This is correct 24VAC is not present
45. onnections between PC Board and high limit 24 VAC is present Go to step 6 Technical Training Department Ashland City TN 2003 22 SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 6 PC BOARD MOTOR TEST Service Switch Motor Lead Motor Lead STEP 6 PC BOARD MOTOR TEST Check for 24 VAC between the two motor lead terminals of the PC board Disconnect the wires for this test IF THEN 24 VAC is not present e Replace the Damper Drive part 194484 and go to step 7 The board and relay are one piece Regardless of which part is defective both parts should be changed Voltage is present e This verifies that the motor is receiving power but not closing the damper Replace the Damper Drive and go to step 7 Note The service switch may be used to bypass the damper while waiting for a replacement part WARNING In the event of damper motor failure verify that the damper is in the open position before utilizing the service switch Technical Training Department Ashland City TN 2003 23 SBD TANK TYPE HEATERS SERVICE HANDBOOK THERMOSTAT TEST STEP 7 THERMOSTAT TEST Set the thermostat to call for heat Using your multimeter test for 24 VAC between right terminal and ground IF THEN The meter does not read 24 VAC and the jumper wire Replace the thermostat between the high limit and the thermostat is
46. raining Department Ashland City TN 2003 30 SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 11 WIRE HARNESS TEST Honeywell 5 55422 58500 CONTINUOUS RE TRY 100 SHUTOFF IP 980 SEC lie FOR IGNITION it gats wert ict device that has been wet STEP 11 WIRE HARNESS TEST Test for 24 VAC between terminal 24V on the IID module and 24V GND IF THEN 24 VAC is not present e Check the wiring harness 24 VAC is present e Goto step 12 Note This test may be easier to conduct by removing the red wire from the IID terminal Test for 24 VAC between the red wire and ground Reconnect the red wire to the 24V terminal after the test Technical Training Department Ashland City TN 2003 31 SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 12 MODULE TEST AWARNING Explogion hazard Can cause UOUS CONTINUOUS 100 SHUTOFF IP m 90 SEC TRIAL FOR IGNITION js ANBI 221 20 24V 80 Hz module has ban usad with m vert damper 8 will only work PA Ma ih damper oo injury or death Thie device can maffunction geb wet Never iry to usa device that has been wet replace 97 4152 STEP 12 IID MODULE TEST Power to the Pilot Valve Using a multimeter test for 24 VAC between terminal PV and 24V GND on the IID during the 90 second trial for ign
47. ressure 4 0 W C 10 W C The supply gas pressure is normally measured at the dirt leg or at the gas pressure tapping on the gas supply shutoff valve This reading must be measured with flowing gas The manifold gas pressure is measured at the manifold pressure tap of the gas valve when the gas is flowing Technical Training Department Ashland City TN 2003 10 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD GAS VALVE The gas valves used on all SBD water heaters are 24 volt AC combination step opening gas valves They incorporate the pilot valve main valve and gas pressure regulators into one body The inlet view of the valve features a filter screen and the top knob The top knob is a manual on off gas control for both the pilot and main gas valves When the top knob is placed on the black mark gas is supplied only to the pilot valve On the top view we see the pilot solenoid and pilot and main gas regulators The top view also displays the TH and terminals The pilot gas regulator is found under its cover screw It is factory preset at 3 5 W C but can be adjusted from 2 5 to 5 inches water column The main gas regulator is found under its cover screw It is factory preset to 3 5 inches W C and adjusts gas pressure output from 2 5 to 5 inches water column The two electrical terminals are marked TH and TR The TH terminal is the common between the pilot valve solenoid coil and the main valve solenoid coil
48. s read 20 ohms plus or minus 5 e Gas valve should work Also check that pilot gas is present and pilot tube or orifice are not blocked Technical Training Department Ashland City TN 2003 34 SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 14B PILOT VALVE TEST SBD 500 ONLY PILOT GAS MANIFOLD PRESSURE MV PV wire the IID is connected to the white wire The MV wire on the IID is connected to the red wire MANIFOLD GAS MANIFOLD PRESSURE TAP STEP 148 PILOT VALVE TEST SBD 500 ONLY Testing the two coils of the Honeywell VR8404P 5004 gas valve used on the model SBD 500 only Because of built in diodes it is difficult to test for ohms resistance through these coils The following is a DC amperage check of the main and pilot coils Condition e Tank calls for heat e PV terminal of module has 24 Vac No Pilot flame Test Procedure e Turn off power to heater e Meter set to test for DC amperage on meters the black wire is in the com port the red wire is in the 10A port the dial is set to 20M 10A in the DC AMP test area e Blue wire is disconnected from the ignition PV terminal e Install meter in series between gas valve and ignition module 10A wire to blue gas valve lead common wire to PV module terminal Turn power on to heater after module receives 24V Test DC Amperage through Pilot coil of gas valve IF THEN 75 to
49. s service checklist may be photo copied to assist with SBD service call Technical Training Department Ashland City TN 2003 53 no no no no no no no no no no no no no no no no no no no no no no no no no no no no no SBD TANK TYPE HEATERS SERVICE HANDBOOK COMMENTS Author Terry Mulder Technical Training Department Ashland City TN 2003 54 Prepared by the State Water Heaters Training Department For additional technical information call 800 365 0577 State Water Heaters 500 Tennessee Waltz Parkway stote Ashland City TN 37015 COMMERCIAL 800 365 8170 The Expert s Choice Copyright 2006 State Industries Inc www statewaterheaters com
50. shall have a minimum free area of 1 sq in 3000 BTU per hr 7 cm kW of the total input of all equipment located in the enclosure and Not less than the sum of the areas of all vent connectors in the confined space Technical Training Department Ashland City TN 2003 6 SBD TANK TYPE HEATERS SERVICE HANDBOOK MAKE UP AIR VERTICAL DUCTS Often it is more practical to install vertical make up air ducts to the out doors 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 enclosure Each opening shall have a free area of not less than 1 square inch per 4000 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 twelve inches of the bottom of the enclosure Each opening shall have a free area of not less than 1 square inch per 2000 BTUH of the total input of all appliances within the enclosure Technical Training Department Ashland City TN 2003 7 SBD TANK TYPE HEATERS SERVICE HANDBOOK INSUFFICIENT MAKE UP AIR BACKDRAFT Insufficient make up air is a major cause of combustion problems One common example is in a restaur
51. t signal is received by the module Sparking at the pilot will stop almost immediately after the ignition module senses the pilot flame IF THEN Sparking continues after pilot is e Check wire connections established e Check flame contact between hood and lighter Clean pilot burner surfaces Replace pilot assembly Sparking stops e Goto step 17 Technical Training Department Ashland City TN 2003 37 SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 17 MODULE TEST AWARNING Explosion hazard Can cause serious injury or death This deica can malfunction if gets wet Mawar try t0 use vice that has been wet replace it 97 4152 REV Pilot is lit Sparking has stopped S8600M CONTINUOUS RE TRY G 9 100 SHUTOFFIP ort dea 90 SEC TRIAL FOR IGNITION Ja nem 22120 24V 60 Hz W module has been used with 1 MAX 1 vent damper it will only work with damper connactad STEP 17 IID MODULE TEST Power to the Main Valve Using a multimeter test for 24 VAC between terminal MV on the IID and 24V GND IF THEN 24 VAC is not present e Replace the IID module Conduct Step 18 before applying power to replacement module 24 VAC is present e Goto step 18 Technical Training Department Ashland City TN 2003 38 SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 18A MAIN GAS VALVE CHECK saps TYPE 4 5
52. u meter wire connections and setting before performing further tests Technical Training Department Ashland City TN 2003 40 SBD TANK TYPE HEATERS SERVICE HANDBOOK GENERAL SERVICE CHART CONDITION CAUSE SOLUTION DAMPER OPENS NO POWER EFFIKAL REPLACE DAMPER CONTROL TO IID MODULE DAMPER NOT FULLY OPEN ASSEMBLY DEFECTIVE PROTECTOR SWITCH REPLACE DAMPER REPLACE PC BOARD PILOT LIGHTS SPARKS CONTINUOUSLY PILOT FLAME NOT PROVING SEE FLAME RECTIFICATION STEP 16 HEATER WILL NOT IGNITE NOT PROVING PILOT FLAME EXISTANCE INTERRUPT 120 VAC POWER CHECK GROUND WIRE ATTACHMENT CLEAN OR REPLACE PILOT ASSEMBLY PILOT GAS NOT COMPLETELY INTERRUPTED AT END OF HEATING CYCLE CHECK SUPPLY GAS PRESSURE REPLACE GAS VALVE WEEPING TEMPERATURE AND PRESSURE RELIEF VALVE THERMAL EXPANSION ADD THERMAL EXPANSION TANK FAULTY VALVE REPLACE RELIEF VALVE LARGE VOLUME WATER EXCESSIVE WATER CHECK WIRING RELIEF FROM T amp P VALVE TEMPERATURE REPLACE DUAL CONTROLLER FAULTY RELIEF VALVE REPLACE RELIEF VALVE PREMATURE TANK LEAKAGE CONDENSATION INCREASE STORED WATER TEMPERATURE AND CONFIRM PROPERLY SIZED APPLICATION CONTAMINATED AIR REMOVE CONTAMINANTS SUPPLY CLEAN COMBUSTION AIR WATER HAMMER ADD WATER HAMMER ARRESTOR REDUCE WATER PRESSURE REMOVE UNNECESSARY CHECK VALVES THERMAL EXPANSION ADD THERMAL EX
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