State Water Heaters SBN 100-199NE Service Handbook Download Page 23 | Manualshive

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Technical Training Department

Ashland City, Tennessee

SBN TANK TYPE COMMERCIAL GAS WATER HEATER

SERVICE HANDBOOK

©2003

LOWER FRONT VIEW OF SBN WATER HEATER

Part N umber

194405

Volts AC

N ominal 80 VAC

Ohms R esistance

11.0 - 20.0 @ 77° F (25° C )

H SI

.1 - .25”

Notice that rods cross
main burner flame

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Summary of Contents for SBN 100-199NE

Page 1: ... com to view or download Specification Sheets Part No STC 074 20 00 Printed in the U S A 0204 SBN 71120 through 85390 A SERIES 100 Models SBN Meets Low NOx Requirements of SCAQMD Rules 1121 1146 2 Service Handbook For Self Cleaning Induced Draft Multi Flue Commercial Gas Water Heaters ...

Page 2: ...on 15 Top View 15 Front View 16 White Rogers Control 17 HSI Board 18 Wiring Diagram 20 Electrical Sequence 21 Pre Service Checklist 22 Control Board Diagnostic LED Interpretation and Troubleshooting 120 VAC Check to Heater 23 Polarity Check 24 Continuity Check of High Limit 25 Upper Temperature Probe Check 26 Inducer Check 27 Blower Prover Low Gas Pressure Circuit Check 28 HSI Voltage and Continui...

Page 3: ...s step by step procedures with illustrations to verify proper installation operation and troubleshooting quick reference data to assist in servicing the product line answers to common questions encountered in the operation of the product line The handbook is intended to be used by licensed plumbing professionals Reference should be made to the installation manual accompanying the product If you ar...

Page 4: ... capable of measuring continuity AC voltage and DC voltage gas pressure gauge or manometer gauge pt no 8099 2 water pressure gauge pt no 4798 thermometer pt no 4870 range 0 220 degrees F 1 2 inch socket with extension for removal of the clean out cover 1 1 16 inch socket with extension for anode removal Custom Commercial Storage Tank Model Number Break Down U G V 6 6 0 1 5 0 0 V A 1 2 5 U Unjacket...

Page 5: ...il Clearances A 24 inch clearance for all serviceable parts is recommended Clearances may vary between models See instruction manual or the label on the heater for clearances applicable to your specific model Top and Front Views of Minimum Clearances To Combustibles A B and C clearances to non combustibles is 0 inches a 12 inch clearance to cover remains unchanged Model A Right Side B Left Side C ...

Page 6: ...r Clearances The vent must extend at least 3 feet above the highest point where it passes through a roof of a building and at least 2 feet higher than any portion of a building within a horizontal distance of 10 feet for vents of 12 inches in diameter or less References NFPA 54 ANSI Z 223 1 SEC 7 5 2a and Sec 7 6 2a may allow reduction to 8 feet with a listed vent cap Copyright by the American Gas...

Page 7: ...s for various building installations refer to the National Fuel Gas Code NFPA 54 ANSI Z223 1 Sec 5 3 Air Supply One common example is in a restaurant installation where exhaust vent equipment was not considered in sizing make up requirements This condition may result in air being backdrafted by the restaurant exhaust equipment through the heater causing the draft proving switch to open and or erra...

Page 8: ...n air and acts as a relief opening for flue gases should the vent become obstructed or a downdraft condition occur Additionally when the heater is installed in a confined space and communicating with the outdoor air one permanent opening beginning within 12 inches 30 cm of the top of the enclosure must be permitted where the equipment has clearances of at least 1 inch 2 5 cm from the sides and bac...

Page 9: ...have a free area of not less than 1 square inch per 4 000 BTUH of the total input of all appliances within the enclosure When the heater is installed in an interior room with no roof access for vertical ducts horizontal make up air ducts should be installed When using horizontal ducts two openings are required one within 12 inches of the top of the enclosure and one within 12 inches of the bottom ...

Page 10: ...drawn into the combustion chamber with the make up air and once fired mix with water vapor in the gases to form extremely corrosive hydrochloric or hydrofluoric acid and other corrosive by products Air for Combustion Flammable Items Flammable items pressurized containers or any other potentially hazardous articles must never be placed on or adjacent to the heater Open containers of flammable mater...

Page 11: ...lves They incorporate the main valve and gas pressure regulator into one body The Low Gas Pressure Switch the Supply Gas Inlet and the Supply Gas Pressure Tap are shown in the Inlet View to the right The top view of the gas valve shown on the right shows the Main Gas Regulator Manifold Pressure Tap Top Knob and the Limited Bleed Vent Port The main gas regulator is found under the silver cap screw ...

Page 12: ...EATER SERVICE HANDBOOK The outlet view of the Gas Valve shown on the right shows the Manifold Gas Outlet Connection the two 24 volt Main Valve MV Solenoid connections and the Manifold Pressure Tap The two yellow wires from the 12 pin plug on the Ignition Board attach to the MV terminals Outlet View ...

Page 13: ...pe B vent The draft inducer does not pressurize the exhaust Venting For larger applications SBN water heaters can be common vented together either in a tapered manifold or constant size manifold Follow the National Fuel Gas Codes requirements for sizing and installation of fan assisted products SBN Models may be common vented only with other Category I appliances See the Venting Section in the Nat...

Page 14: ...e area of the com bined vent should be equal to area of the largewst 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 14 plus area of 8 inch vent 50 or 78 sq inches Referring to char 78 sq inches require 10 diameter vent Vent Size Areain SquareInches Vent Size Areain SquareInch...

Page 15: ...me 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 6 Horizontal pipe should be sloped upward at a minimum of per foot 7 Horizontal elements should be limited to 75 of the vertical rise of the vent above the connection ...

Page 16: ...ment 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK 8 Flue gases must be kept hot for proper venting 9 Obstructions can cause down drafts The vent pipe should be extended to meet local codes ...

Page 17: ...hes 2 308 000 7 7 6 6 6 6 6 6 3 462 000 8 8 7 7 7 6 6 6 4 616 000 9 9 9 8 8 7 7 6 MODEL SBN 81 180NE SBN 100 199NE Input 180 000 190 000 and 199 000 Btu hr Total Vent Height Feet Vent Connector Size 6 inches 6 8 10 15 20 30 50 100 Input Btuh hr Rise Vent Connector Diameter Inches 180 000 1 Ft 7 7 6 6 6 6 6 6 190 000 1 Ft 7 7 7 6 6 6 6 6 199 000 1 Ft 7 7 7 6 6 6 6 6 180 000 2 Ft 6 6 6 6 6 6 6 6 190...

Page 18: ...0 9 9 8 8 8 7 7 3 825 000 12 12 12 10 9 9 8 8 4 1 100 000 14 14 14 12 12 10 9 9 MODEL SBN 85 310 Input 310 000 Btu hr Total Vent Height Feet Vent Connector Size 6 inches 6 8 10 15 20 30 50 100 Input Btu hr Rise Vent Connector Diameter Inches 310 000 1 Ft 9 8 8 8 7 7 6 6 310 000 2 Ft 8 8 8 7 7 7 6 6 310 000 3 Ft 8 8 8 7 7 7 6 6 Number of Combined Input Heaters in Thousands of Btu hr Manifold Common...

Page 19: ...mup 4 Main gas valve opens 4 sec trial for ignition Maximum 5 trials 5 Main burner ignites and proves 6 Thermistors reach the temperature setting 7 Main burners OFF Auto restart after 60 min 20 sec blower interpurge between trials Top View SBN Models Part No Pressure Setting To Close Switch Inches W C 366 194411 0 1 60 10 275 194411 1 2 00 10 310 194411 2 1 75 10 120 199 250 400 194411 3 2 40 10 1...

Page 20: ...19 Technical Training Department 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK FRONTVIEW OFWATER HEATER ...

Page 21: ...20 Technical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK 2003 WHITE ROGERS INTEGRATEDWATER HEATER CONTROL PART NO 194393 0 ALSO CALLED THERMOSAT ...

Page 22: ...21 Technical Training Department 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK HSI INTEGRATED IGNITION CONTROL BOARD PART NO 194392 E4 E1 ...

Page 23: ...ity Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK 2003 LOWER FRONT VIEW OF SBN WATER HEATER Part Number 194405 Volts AC Nominal 80 VAC Ohms Resistance 11 0 20 0 77 F 25 C HSI 1 25 Notice that rods cross main burner flame ...

Page 24: ...chnical Training Department 2003 Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK WIRING DIAGRAM Propane series models do not have a low gas presure switch R B R B Upper ECO ...

Page 25: ...6 to 2 60 10 W C depending on heater model Ignition Control Board 120 VAC HSI Warm Up 20 seconds Variable Voltage 80 120 VAC Gas Valve Open 3 Second Trial HSI Off 3 Seconds to Prove Flame After HSI Off Flame Proves No Yes Tank Heated to Set Temperature 20 Second Blower Purge Gas Valve Off Call for Heat LED Off 60 Second Blower Post Purge Blower Prover Opens Standby LED On 2 More Trials To Prove Fl...

Page 26: ...water and gas shut off valves open ____________________________________________________ Are there room exhaust or air intake fans ____________________________________________________ 3 Did you note the condition of the water heater ____________________________________________________ Is the ON OFF switch On ____________________________________________________ What is the temperature of the stored ...

Page 27: ... E13 check power from E14 to heater control E2 receptacle voltage is not present from heater control receptacle E2 black to ground check wiring from ignition control board E14 to heater control receptacle E2 replace ignition control board power is present at E2 green LED should be on CONTROL BOARD DIAGNOSTIC LED INTERPRETATION AND TROUBLESHOOTING TEST 1 120 VAC CHECK TO WATER HEATER Conditions No ...

Page 28: ...d to open within 5 seconds at the end of the last cycle 3 Flashes Draft proving pressure switch failed to close 2 1 inches of water column pressure within 5 seconds after the inducer was started The low gas pressure switch closes at 5 2 04 w c may have remained open 4 Flashes Open on high temperature limit switch ECO 6 Flashes 115 volt supply power connection is indicating reversed polarity 7 Flas...

Page 29: ...rse supply wire connections polarity is reversed TEST 3 CONTINUITY CHECK OF HIGH LIMIT ECO Conditions Power On No Hot Water Red heater control Call for Heat LED on Red ignition control board diagnostic LED 4 Flashing Note LED Flash Code before resetting heater See Description of diagnostic LED Flashes Turn Power Off TEST 2 POLARITY CHECK continued Continued on next page TEST 2 Polarity Check Check...

Page 30: ...nuity is indicated probe should be okay also verify Ohms resistance for water temperature Reading will be approximate TEST 3 Continuity check of ECO energy cut off high limit Black to Black wires of upper probe Power is off If then continuity is indicated opens at 203 F closes at 193 F If water is below 193 F continuity is correct continuity is not present replace ECO sensor if water temperature i...

Page 31: ... ignition control board diagnostic LED TEST 5 115 120 V Check to Inducer Test on Ignition Board 4 Pin Receptacle E4 If then pin 1 to ground check has no voltage reset control by interrupting power note possible reasons for this from flashing LED code replace igntion board pin 1 to ground has voltage proceed pin 3 to ground has no voltage check wiring harness and plugs replace inducer Water Heater ...

Page 32: ...rom inducer voltage check of each blower switch terminal to ground shows voltage to only 1 terminal switch is open check for proper draft should also see LED 3 flash code check for blocked exhaust check that blower outlet exhaust damper is open replace blower draft proving switch 24V is present from each switch terminal to ground check wiring from blower switch to low gas pressure switch voltage c...

Page 33: ...d connection from E4 plug to HSI receiving plug replace HSI Assembly continuity is present resistance should be between 11 and 20 Ohms at a temperature of 77 F voltage is not present between E4 Pin 2 to ground replace ignition board voltage is present continue voltage is not present between E4 Pin 4 to ground check wiring and plug connections to HSI replace HSI voltage is present note igntion boar...

Page 34: ... check control box grounding normal Approximate 20 seconds warm up no ignition check for 24V from E1 Pin 12 to ground during 4 second trial Yes Continue No Replace Igntion Board no voltage present E4 Pin 12 to ground replace ignition board 24 Volt was present from E1 Pin 12 to ground but no main burner check that air has been purged from gas circuit check that wiring and connections to gas valve a...

Page 35: ...ditions Test 8 completed then Turn off power Disconnect wires from gas valves TEST 9 Continuity Check Of Gas Valve Coil If then meter reads 0 or 1 check meter scale setting to read between 550 and 650 Ohms replace Gas Valve meter indicates pilot and main coil have continuity valve should be okay still no gas to main burner then coil may be stuck Replace Valve ...

Page 36: ... Note flash code on ignition board LED TEST 10 Flame Prover Circuit Check If then no extended main burner igntion check wiring and plug connections of HSI assembly plug and ignition board receptacles E1 Pin 2 check that HSI assembly is not cracked or dirty check that flame prover will be in main flame replace HSI assembly still no extended main burner ignition replace ignition control board Main B...

Page 37: ...le E3 and E4 TEST 11 Water Temperature Circuit Check Continuity If then continuity check pin to pin of lower temperature probe shows 1 or 0 E4 see Test 4 check wiring and plug connections to heater control board receptacle E4 replace lower temperature probe continuity check red wire pin to red wire pin on upper temperature sensor shows 1 or 0 E3 see Test 4 check wiring and plug connections to heat...

Page 38: ... for excessively hot water 203 F or higher Correct the problem The ECO Energy Cut Off has opened Normal status none Calling for heat Action to be Taken Indication LED Status Push the manual reset button Troubleshoot for why the ECO opened Tank has cooled below 120 F Preceded by ECO Open indication Tank is at a set temperature of 2 F Check the breaker No power Check for excessively hot water 203 F ...

Page 39: ... 5 seconds after the inducer was started Open on high temperature limit switch ECO 115 volt supply power connection is indicating reversed polarity Interrupt power to reset Heater had not sensed the flame check gas supply and igniter condition Test for defective switch or a pressurized room condition that may be forcing air through the inducer Check the draft The low gas pressure switch closes at ...

Page 40: ...al control board failure Verify that the main burner flame is in contact with the flame Check wiring and connection to HSI assembly Clean the flame sensor rod of soot or metal flakes Check igniter for lack of voltage cracks or lose connection 11 20 Ohms at 77 F 25 C is good Check ground connection Check that the gas valve is not failing to close at the end of a heating cycle Replace ignition contr...

Page 41: ...ical Training Department Ashland City Tennessee SBN TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK 2003 PART LOCATIONS ON SBN SERIES 120 000 390 000 BTU H INPUT MODELS 120 THROUGH 400 A www stateind com ...

Page 42: ... 194403 40 Plate Mounting 193439 193439 193439 193439 193439 41 Probe ECO Upper Thermostat 194396 194396 194396 194396 194396 42 Probe Lower Thermostat 194397 194397 194397 194397 194397 43 Rod Anode 180618 42 180618 42 180618 42 180618 42 180618 42 44 Switch Blower Prover 194411 3 194411 7 194411 4 194411 3 194411 45 Switch Low Gas Pressure 191149 5 191149 5 191149 5 191149 5 191149 5 46 Switch O...

Page 43: ... 40 Plate Mounting 193243 193243 193243 193243 193243 41 Probe ECO Upper Thermostat 194396 194396 194396 194396 194396 42 Probe Lower Thermostat 194397 194397 194397 194397 194397 43 Rod Anode 180618 42 180618 42 180618 42 180618 42 180618 42 44 Switch Blower Prover SBN 194411 3 194411 8 194411 2 194411 19441 3 45 Switch Low Gas Pressure 191149 5 191149 5 191149 5 191149 5 191149 5 46 Switch Off O...

Page 44: ...ly only Southern California and Texas have adopted rules to reduce the NOx emissions under Rules 1121 and 1146 2 but more of California and Texas are expected to implement this requirement in 2001 Ground level ozone from man made pollution is a major ingredient in smog NOx is a contributor to this ground level ozone formation The boilers and water heaters affected by Rule 1121 and 1146 2 release a...

Page 45: ...on against corrosion be replaced A Anode rods should be replaced when large gouges or pits appear in the anodes It is recommended that anodes be inspected every six months Q Does the inducer motor require oiling A No Q What size breaker should be used A The heater should draw less then 5 amps and there is a 3 amp car type fuse on the control board This fuse protects the boards ...

Page 46: ...203 5 4 F Closes 193 F 0 3 Main Gas Valve 24 VAC 1 5 2 2 FLA 3 5 LRA Igniter 194405 120 VAC 2 OPT Power Venter 120 VAC 14 5 FLA 26 0 LRA 120 VAC Electrical Information Integrated Water Heater Control Temperature Control Board 194393 0 Inducer Blower 194408 SBN Models Part No Pressure Setting To Close Switch Inches W C 366 194411 0 1 60 10 275 194411 1 2 00 10 310 194411 2 1 75 10 120 200 250 390 1...

Page 47: ...For Additional Information Contact State Water Heater Technical Information At 1 800 365 0577 Prepared By The Training Department In Ashland City Tennessee Website www statewaterheaters com ...

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