State Industries SBD71 User's Manual
Contents
1. ra gt 22b Damper Drive Assembly 226 Harness Adapter LABELS 41 Manifold 42 Instruction Manual 43 Main Burner Orifice Natural 44 Main Burner Orifice 45 Anode 47 Transformer cesses 48 Pilot 6 49 Inlet 5 55 bts Gas Valve Natural 52 Gas Valve LP 55 ud bus Switch Panel Mounting Plate 56i Off On Switch 537 sss 58 Jumper Wire eese 59 sce Control Box Panel 60 Cover Burner eT e 62 5252 1 1 2 galvanized pipe cap 03 5 1 1 2 galvanized pipe plug 64 nis 1 1 2 galvanized pipe union Technical Training Department Ashland City 92003 48 SBD TANK HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A2. Oise Gas Valve Natural 0 Gas Valve 1 1 55 ss Switch Panel Mounting Plate 56 Off On Switch sss BUSRING 58 Jumper Wire 59 Control Box 60 Cover Burner 61 62 1 1 2 galvanized pipe cap 63 1 1 2 galvanized pipe plug 3 64 4 1 1 2 galvanized pipe union Technical Training Department Ashland City TN 2003 47 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 ITEM PARTS DESCRIPTION Flue Main Burner Orifice Bracket Main Main Burner w Pilot Bracket Oise ined Pilot Burner Natural Pilot Burner LP CLEANOUT ASSEMBLY 11 5 elt 12 Pressure Plate 143 EN Screws Self Tapping pem Control Ignition Module 18 Control Dual WECO 19 Cover
3. SERVICE DATE SERIAL NUMBER LOCATION ADDRESS GAS TYPE CHECK ONE NATURAL PHONE PROPANE Check Clearances circle answer A Are exterior clearances adequate B Are interior clearances adequate Comments Check Makeup Air Requirements A Is the quantity of make up air adequate per the National Fuel Gas Code Comments B Is the quality of make up air adequate 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 Venting check A Properly sized per the National Fuel Gas Code B Does the installation have mechanically assisted venting If so is it operational Comments Technical Training Department Ashland City TN 92003 52 yes yes yes yes yes yes yes no no no no no no no V VI VII SBD 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
4. 02003 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 Replace the Damper Drive 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 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 62003 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 and the jumper wire Replace the thermostat between the high limit and the thermostat is in place The meter reads 24 VAC Goto step 8 Note If the high limit to thermostat jumper wire was disconnected earlier
5. Harness LABELS 41 42 Instruction 43 Main Burner Orifice 44 Main Burner Orifice AT sous TraiSfOFmer zero 48 Pilot 6 955 99 99 49 llet Tube 51 Gas Valve 52 Gas Valve 55 Ac Switch Panel Mounting Plate Off On 5 5 5 555 Bins BUSHING udis 58 us Jumper 59 5 iei Control Box 60 Cover 61 Hydro Cannon sese 62 552 1 1 2 galvanized pipe 63 1 1 2 galvanized pipe plug 64 1 1 2 galvanized pipe Technical Training Department Ashland City TN 92003 50 SBD TANK TYPE HEATERS SERVICE HANDBOOK COMPONENT PART INFORMATION NAME SPECIFICATIONS DUAL 120 180 RANG
6. SBD TANK HEATERS SERVICE HANDBOOK 11 WIRE HARNESS TEST Honeywell wets 55422 CONTINUOUS RE TRY G a 100 SHUTOFF IP AUTO KGMITION 90 SEC FOR IGNITION 210 y 8D Hz if module has been used with wert v it will wark 1 MAX von denti 97 41562 A STEP 11 WIRE HARNESS TEST Test for 24 between terminal 24V the IID module and 24V GND IF THEN 24 VAC is not present Check the wiring harness 24 VAC is present e Goto step 12 Note This test be easier to conduct removing the red wire from the IID terminal Test 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 62003 31 SBD TANK HEATERS SERVICE HANDBOOK 12 MODULE TEST SB8600M Al conTinuousRE tRY 100 SHUTOFF IP 90 SEC TRIAL FOR IGNITION js ANBI 221 20 Hz if module hes been usad with 24V 60 went damper B will work 1 MAX MAX foal tied AWARNING Explosion hazard Can cause injury or death This dayice can matturstion 9 5 wet Never try to use devica that has been wet replace il 97 4152 AE STEP 12 MODULE TEST Power to the Pilot Valve Using multimeter test
7. 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 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 This service checklist may be photo copied to assist with SBD service call Technical Training Department Ashland City TN 92003 53 yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes 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 92003 54 Prepared by the State W
8. Self Cleaning Commercial Gas Water Heaters with Flue Damper and Electronic Ignition SBD71 120 Through SBD85 500 stote Part Number 317926 000 COMMERCIAL Printed in the U S A 0810 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 troubleshooting procedures Additi
9. ST ouis Bushing 58 Jumper 59 ss Control Box Panel 60 Cover Burner a 62 1 1 2 galvanized pipe cap 63 1 1 1 2 galvanized pipe plug 64 1 1 2 galvanized pipe union Technical Training Department Ashland City TN 2003 49 SBD TANK HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 ITEM PARTS DESCRIPTION dci Main Burner Orifice 2 Main Burner 55550555 505 50505 Main Burner w Pilot Pilot Burner Pilot Burner LP eee CLEANOUT ASSEMBLY T1 Gasket ts lv 12 Pressure Plate 13 Screws Self 17 Control Ignition Module 18 Control Dual 19 25 Cover 22 Drafthiood niece nii ris 22b Damper Drive Assembly 226
10. continued ITEM PARTS DESCRIPTION Tat Flue Baffle ones iir o 2 Main Burner Orifice Bracket utu Main Burner Disi Main Burner w Pilot Bracket Pilot Burner Natural Ti Pilot Burner LP CLEANOUT ASSEMBLY 1205 1 1 1 4 12 Pressure Plate 13 Screws Self Tapping 17 Control Ignition Module 18 Control Dual w ECO 10 00 Cover 22 Drafthood 22 Damper Drive Assembly 226 Harness Adapter LABELS Manifold 42 Instruction 43 Main Burner Orifice Natural 44 Main Burner Orifice LP 45 Anode 47 Transformer 48 Pilot Tubing esses 49 s Inlet ben tet 575 Gas Valve Natural PAARE Gas Valve 55 issus Switch Panel Mounting Plate 56 Off On 5
11. when Distance from Walls or Parapet is More than 10 Horizontally Within10 AN Chimney 10 Feet Less Height Above Any Roof Surface 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 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 minimum make up air opening sizes for various building installations Ref NFPA 54 ANSI Z223 1 sec 5 3 Technical Training Department Ashland City 22003 5 SBD TANK TYPE HEATERS SERVICE HANDBOOK MAKE UP AIR DIREC
12. 2 Technical Training Department Ashland City 2003 19 SBD TANK TYPE HEATERS SERVICE HANDBOOK HIGH LIMIT LEFT TERMINAL TEST FM Transformer 7 wij hi 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 Check wiring between transformer and high limit The meter reads 24 VAC 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 2003 20 SBD TANK TYPE HEATERS SERVICE HANDBOOK PN Temperature High Limit ECO Adj 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 Push the reset button and redo the test storage water temperature below 185 degrees The meter reads 24 VAC e Goto step 4 After Push in Reset 24 VAC is now present Reasons For Resetting Condit
13. 2 galvanized pipe Technical Training Department Ashland City TN 92003 46 SBD TANK HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 ITEM PARTS DESCRIPTION Flue duis Main Burner Orifice Bracket Vw UNT 098044 9 Main Burner Main Burner w Pilot Bracket Pilot Burner 4 Pilot Burner 3 CLEANOUT ASSEMBLY TA A Gasket ed el ete 12 Pressure Plate 13 Screws Self Tapping Control Ignition Module 18 Control Dual 19 3 Cover 88 0 22 Drafthood 22b Damper Drive Assembly 226 Harness LABELS 41 Manifold erecta 42 us Instruction Manual 43 1 Main Burner Orifice NAT 28 44 Main Burner Orifice LP 44 45 Anode 8004 42 Transformer c tct 48 Pilot 49 Inlet
14. BREAKDOWN Model Breakdown SBD 85 500 P EA CGA D Canadian Product if applicable Sandblaster Damper 85 Gallon Up to 8 000 Feet None Standard T Tall 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 IL D D 8 ji 12 CHIMNEY 30 48 ar FRONT VIEW OF SBD Clearance to Combustibles Table MODEL A B C 120 200 1 2 54CM 1 2 54CM 1 2 54CM 250 305 2 5 08CM 2 5 08CM 2 5 08CM 365 400 3 7 75CM 3 7 75CM 3 7 75CM 500 5 12 7CM 5 12 7CM 5 12 7CM 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 2003 3 SBD TANK TYPE HEATERS SERVICE HANDBOOK EXTERIOR CLEARANCE More Than 10 More Than 10 Height Above Any Roof Surface NOTE Within 10 No Height Above Parapet Required
15. for 24 between terminal PV and 24V GND on the during the 90 second trial for ignition IF THEN The meter does not read 24 and the Replace the module module is not between ignition trials The meter does read 24 VAC Gotostep 13 Technical Training Department Ashland City TN 62003 32 SBD TANK HEATERS SERVICE HANDBOOK STEP 13 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 e 7 64 spark gap Spark cable continuity e Ground cable continuity Sparking is present e Goto step 14 Power To Module Be Interrupted To Reset Trial for Ignition 90 sec 5 min 90 sec 5 min 90 sec Continuous Call for Sparking No Sparking No Sparking Trial heat Sparking Sparking Sequence Technical Training Department Ashland City TN 2003 33 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 ohm
16. of gas valve IF THEN 75 to 85 DCA is not present e Replace the gas valve 75 to 85 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 62003 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 62003 36 SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 16 FLAME RECTIFICATION _ ignitor Sensor STEP 16 FLAME RECTIFICATION AN 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 jus
17. 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 Damper Auto 1 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 10 TEST FOR 24VAC BETWEEN BLACK AND YELLOW IF THEN 24VAC is present This is correct continue to Step 11 24VAC is not present e 566 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 Training Department Ashland City TN 92003 30
18. 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 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 restaurant 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 ou
19. 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 62003 11 INLET VIEW Knob Filter Screen Gas Inlet TOP VIEW Pilot solenoid Main Gas Regulator TR Pilot Gas Regulator TH OUTLET VIEW Limited 1 Bleed Manifold Port Pressure Tap Manifold Gas Port Pilot Gas Connection 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 a 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 5096 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 14 plus area of 8 inch vent 50 or 78 sq inches Referring to chart 78 sq inches require 10
20. E 4 5 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 GAS 6A 7 to 3 5 W C STEP OPEN SBD 500 24VAC 60hz Dual Gas Valve STEP OPEN PROPANE SBD 120 400 GAS 2 5 10 STEP OPEN SBD 500 24VAC 60hz Dual Gas Valve STEP OPEN INTERMITENT NATURAL 24 VAC 50 60 HZ 1A IGNITION GAS AND 7 MICROAMP SIGNAL DEVICE PROPANE CONTINUOUS RETRIAL CONTROL GAS DAMPER COMPLETE ASSEMBLY MOTOR 24 VAC 60 HZ 120 RPM 5 WATT NOT 110 111 SERIES P C BOARD Service Switch W RELAY NOT 110 111 SERIES TRANSFORMER 120 V PRIMARY 24 VAC SECONDARY 40 VA 50 60 HZ CLASS 2 Technical Training Department Ashland City TN 22003 51 SBD TANK HEATERS SERVICE HANDBOOK SBD SERVICE CHECKLIST 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
21. NT KITS FOR SIDEWALL VENTING E B 12 AE kil GE Turc a 1 Dincannezi rhasvreraLa1 20 38 da mier Plug Ferrada barca rral X Pan 8 rm aS wie plug 4 Giepie ie ee Siram abrar to Damper 864868 40 Power Venter cable with Y lis connect 3 CARE i z IAM Uom Male plug mes n dcl to Cable ui a Coo g 1 PATCH NOTE beri uad AE BEE WATER HEATER DICEAM FOR COMPLETE WATER HEATER Oy rw FOLLOW inc TA LL 848 8245 POLAD PRODUC TR MAKAL 1 24 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 Ashland City TN 62003 15 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD SEQUENCE OF OPERATION 9 Flue damper c
22. S 41 4 8 014 42a Instruction Manual AS si Main Burner Orifice Natural 44 Main Burner Orifice LP 45 Anode 4 5 Transformer 48 101 1 60 49 Inlet T be iiic 51 Gas Valve Natural Gas Valve DI hais Switch Panel Mounting Plate 56 Off On Switch BUSRING sissien oniiir 5B Jumper Wire 59 Control Box Panel 60 Cover 61 5 Hydro Cannon 6252 1 1 2 galvanized pipe 63 2 1 1 2 galvanized pipe plug 64 1 1 2 galvanized pipe union Technical Training Department Ashland City TN 92003 45 SBD TANK HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 ITEM PARTS Flue Baffle ches Main Burner Orifice Bracket a us Main Burner Main Burner w Pilot Bracket Pilot Burner Natural dun Pilot Burner LP CLEANOUT ASSEMBLY 14 Q83Ssk6
23. S 110 111 PARTIAL REPLACEMENT PARTS LIST MODELS SBD 120 THRU 500A STANDARD AND ASME SERIES 110 111 EFFIKAL DAMPER DRIVE ASSEMBLY GAS VALVES HONEYWELL VALVE SBD 500A Technical Training Department Ashland City TN 62003 43 SBD TANK HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 CLEANOUT ASSEMBLY HONEYWELL CONTROL IGNITION MODULE few WARE samasa mre 8 17 e Technical Training Department Ashland City TN 22003 44 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A continued SERIES 110 111 ITEM PARTS dd Fl e Baffle nue Main Burner Orifice Bracket Main 5 Main Burner w Pilot Bracket kom Pilot Burner Natural Tus Pilot Burner LP CLEANOUT ASSEMBLY 11 Gasket eem 12 Pressure Plate 13 Screws Self Tapping Control Ignition Module 18 58 Control Dual w ECO 19 Cover 22 22 Drive Assembly 226 Harness Adapter LABEL
24. SSARY CHECK VALVES THERMAL EXPANSION ADD THERMAL EXPANSION 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 2003 41 SBD TANK HEATERS SERVICE HANDBOOK GENERAL QUESTIONS AND ANSWERS Q What is unique about the Canadian SBC CGA models vs U S 580 models A The 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 se
25. T COMMUNICATION 1 Square Inch Per 4 000 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 30 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 shall have a minimum free area of 1 sq in per 3000 BTU per hr 7 per kW of the total input of all equipment located in the enclosure and b Notless than the sum of the areas of all vent connectors in the confined
26. 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 62003 10 SBD TANK 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 TR 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 The other wire emerging from the pilot solenoid connects to the pilot valve electrical output on the terminal PV The TR terminal connects directly to
27. and City TN 2003 38 SBD TANK TYPE HEATERS SERVICE HANDBOOK 18 MAIN GAS VALVE CHECK MOREL 36 74 TYPE 416 D ay 60 Ha T cd P FIER CAP 2 AIR STEP 25 W p REG 10 07 W E W T0124 W C 8922 E17 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 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 MV PV wire on the 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 Sparking stops No main 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 presen
28. ater Heaters Training Department For additional technical information call 800 365 0577 State Water Heaters 500 Tennessee Waltz Parkway St te Ashland City TN 37015 COMMERCIAL 800 365 8170 The Exper t s Choice Copyright 2007 State Industries Inc www statewaterheaters com
29. diameter vent Vent Size 5 6 7 8 9 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 62003 12 SBD TANK 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 80 AVOID WHERE POSSIBLE Technical Training Department Ashland City TN 62003 13 SBD TANK HEATERS SERVICE HANDBOOK Nine Rules for Good Vents continued 6 Horizontal pipe should be sloped upward at a minimum of 74 per foot 7 Horizontal elements should be limited to 7596 of the vertical rise of the vent above the connection MAXIMUM 75 OF VERTICAL RISE ABOVE CONNECTION 8 Flue gases must be kept hot for proper venting boue ENEE WALL 9 Obstructions can cause down drafts Technical Training Department Ashland City TN 2003 14 SBD TANK HEATERS SERVICE HANDBOOK POWER VE
30. 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 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 SS ON THE DAMPER BOARD IF THEN 24VAC is present This is correct 24VAC is not present e See Steps 1 thru 4 Check the harness plugs connecting heater and damper for looseness
31. ion 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 62003 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 Goto step 5 If the damper is closed 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 e Check the black wire connections between PC Board and high limit 24 VAC is present e step 6 Technical Training Department Ashland City
32. loses 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 m 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 62003 16 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD ELECTRICAL SEQUENCE 100 109 Series QUICK CONNECT ADAPTER Quick CONNECT Lg GROUND Lo GROUND MOLEX L GROUND CONNECTOR JUNCTION BOX HONEYWELL 58600 IGNITION CONTROL GAS VALVE WHITE RODGERS Technical Training Department Ashland City TN 2003 17 SBD TANK TYPE HEATERS SERVICE HANDBOOK SBD ELECTRICAL SEQUENCE OF OPERATION 115 60 12 120 VAC to Ju
33. nction Box OFF Switch ON 24V Transformer Tank Temperature Calling for Heat High Limit Closed Tank Temperature Satisfied 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 PV Terminal Module Spark Sends Sends 24V to Pilot Coil 10 000V Spark to Pilot Pilot Ignites and Proves Flame 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 is supplied to the heater e the tank is full of water gasis 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 Check that the 120 VAC is supplied from the On Off Switch if not replace Switch Check that the 120 VAC is supplied from transformer The meter reads 24 VAC Goto step
34. onal 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 62003 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 Phillips head screwdriver standard screwdrivers e a39 8 7 16 inch open end wrench set of marked drill bits an electrical multimeter tester capable of measuring continuity gas pressure gauge or manometer water pressure gauge thermometer e 1 2 inch socket with extension for removal of the clean out cover 11 16 inch socket with extension for anode removal CUSTOM COMMERCIAL STORAGE TANK MODEL NUMBER
35. s plus or minus 5 Replace gas valve The meter does 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 2003 34 SBD TANK HEATERS SERVICE HANDBOOK STEP 14 PILOT VALVE TEST SBD 500 ONLY PILOT GAS MANIFOLD PRESSURE i The MV PV wire the IID is connected to the white wire The MV wire on the is connected to the red wire MANIFOLD GAS MANIFOLD PRESSURE TAP STEP 14B 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 Tank calls for heat PV terminal of module has 24 Vac No Pilot flame Test Procedure off power to heater Meter set to test for DC amperage on meters the black wire is the port the red wire is in the 10A port the dial is set to 20M 10A in the DC AMP test area Blue PV wire is disconnected from the ignition PV terminal 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
36. t desees 12 Pressure Plate 13 Screws Self Tapping 17 Control Ignition Module 18 Control Dual w ECO 419 05 Cover 22 22b Damper Drive Assembly 226 Harness Adapter LABELS 41 42 Instruction Manual 43 Main Burner Orifice Natural 44 Main Burner Orifice LP 45 Anode uou Transformer 48 Pilot 49 Inlet blu Gas Valve Natural 52 Gas Valve DD rs Switch Panel Mounting Plate 56 Off On Switch OT BUSRING 58 Jumper Wire 592 Control Box Panel 60 Cover Hydro Cannon 62 1 1 2 galvanized pipe cap 63 1 1 2 galvanized pipe plug 6 1 1
37. t Main burner gas should ignite Be certain to correct you meter wire connections and setting before performing further tests Technical Training Department Ashland City 2003 40 SBD TANK 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 CHECK SUPPLY GAS PRESSURE INTERRUPTED AT END OF HEATING CYCLE REPLACE GAS VALVE WEEPING TEMPERATURE AND THERMAL EXPANSION ADD THERMAL EXPANSION TANK PRESSURE RELIEF VALVE 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 UNNECE
38. t improper combustion inconsistent pilot operation and or erratic heater shut down Technical Training Department Ashland City TN 62003 8 SBD TANK HEATERS SERVICE HANDBOOK CONTAMINATED AIR Rust Chips 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 e 4 b ig 2 2 Flammable items pressurized containers or 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 62003 9 SBD TANK TYPE HEATERS SERVICE HANDBOOK GAS PRESSURE REQUIREMENTS Supply Gas Manifold Pressure Tap 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 Pressure 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
39. t 8 tenths of a second the heater will cycle off Sparking at the pilot will continue if an insufficient 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 Check wire connections established e Check flame contact between hood lighter Clean pilot burner surfaces Replace pilot assembly Sparking stops Go to step 17 Technical Training Department Ashland City TN 2003 37 SBD TANK TYPE HEATERS SERVICE HANDBOOK STEP 17 MODULE TEST ANWARNING Explosion hazard Can cause injury or death This device can malfunction if gets wet Never try use Device that has been wet replace it 58600 CONTINUOUS RE TRY G 100 SHUTOFFIP AUTO ONTON 90 TRIAL FOR IGNITION 24V 60 Hz if module has been used with 1 MAX 1 vent damper it will only work with damper connected 87 4152 REV A Pilot is lit Sparking has stopped 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 Replace the IID module Conduct Step 18 before applying power to replacement module 24 VAC is present e Goto step 18 Technical Training Department Ashl
40. 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 62003 24 SBD TANK 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 Adapter f xs Plug vt Service Switch Motor Lead 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 Yellow 24V To damper if the thermostat is closed 2 1 Red 24V From damper to IID if damper closes end switch White Neutral common Orange Brown Yellow Black Erom Heater Male Plug Female Plug Technical Training Department Ashland City TN 62003 25 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 common 4 Black NORMAL OPERATION Condition Heater on standby e Damper closed
41. ven times as fast as a 140 degree F setting volume of water The more gallons 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 22 1 4 inch build up as much as 3896 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 The 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 92003 42 SBD TANK HEATERS SERVICE HANDBOOK SBD MODELS 120 THRU 500A SERIE
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