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SBD TANK TYPE HEATERS

SERVICE HANDBOOK

Technical Training Department

Ashland City, TN ©2003

1

SBD

HANDBOOK

TABLE OF CONTENTS

PAGE

PAGE

Troubleshooting (continued)

Introduction

1-2

Troubleshooting

the

Efflkal

28-30

Wire Harness Test

31

Installation

3

IID

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

IID

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. 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.

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Содержание SandBlaster SBD71 120

Страница 1: ...20 Through SBD85 500 The Expert s Choice COMMERCIAL Self Cleaning Commercial Gas Water Heaters with Flue Damper and Electronic Ignition Part Number STC 072 Printed in the U S A 0106 SERVICE HANDBOOK SandBlaster Also includes Parts List ...

Страница 2: ...ook 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 Additional quick ref...

Страница 3: ... 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 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 BREAKDOWN Model Breakdown SBD 85 500 P E A CGA D Up to 8 ...

Страница 4: ...rs The installation manual covers most of these items in detail 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 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 cl...

Страница 5: ...all 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 Copyright by the American Gas Association Used by permission of the copyri...

Страница 6: ...0 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 2 5 CU FT EXCESS AIR 10 CU FT COMB AIR 1 1 1 0 0 ...

Страница 7: ... 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 fron...

Страница 8: ...e 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 en...

Страница 9: ... 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 out improper combustion inconsistent pilot operation and or erratic heater shut down ...

Страница 10: ... 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 f...

Страница 11: ...ly 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 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 Supply Gas Dirt Leg Manifold Gas Port Manifold Pressure Tap ...

Страница 12: ...as 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 solenoi...

Страница 13: ...ed the area of the combined vent should be equal to area of the largest single vent plus 50 of area of all others joining 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 Model SBD 120 are supplied with a 6 to 5 reducer Models SBD 250 251 and 275 are supplied with a 8 to 6 reducer EXAMPLE To combine two 6 ...

Страница 14: ...3 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 ...

Страница 15: ...ts continued 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 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 ...

Страница 16: ...an 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 Male plug to Cable Female plug to Damper 40 Power Ve...

Страница 17: ...xamination 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 ...

Страница 18: ...SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City TN 2003 17 SBD ELECTRICAL SEQUENCE 100 109 Series ...

Страница 19: ...gized and Damper Closed Power to Damper 2 Interrupted Themostat Opens Main Burner Heats Tank Module MV Terminal Sends 24V To Main Gas Coil 90 Second Trial 5 Minute Delay Between Trials Continuously Pilot Ignites and Proves Flame Cam On Damper Blade Closes Proving End Switch Thermostat Closed High Limit Closed Tank Temperature Calling for Heat Motor Closes Damper High Limit ECO Closed Tank Temperat...

Страница 20: ...ater the tank is full of water gas is supplied to the unit STEP 1 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 Go to ste...

Страница 21: ...C 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 Go to 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 Ground 24 VAC FM Transformer ...

Страница 22: ...AC Go to step 4 After Push in Reset 24 VAC is now present Reasons For Resetting Condition Cause Solution High limit open Never set on initial installation Push high limit button Excessive water temperature Faulty thermostat Replace dual control Heater shut down before reaching thermostat setting Faulty high limit Replace dual control Note The right terminal of the high limit has a jumper wire conn...

Страница 23: ...Go to 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 connections between PC Board and high...

Страница 24: ...484 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 ver...

Страница 25: ...ight terminal and ground IF THEN The meter does not read 24 VAC and the jumper wire between the high limit and the thermostat is in place Replace the thermostat The meter reads 24 VAC Go to 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 connect...

Страница 26: ...2 3 4 Black Red Yellow White Orange Brown Yellow Black Male Plug From Heater 2 1 3 4 Female Plug Damper 1 2 3 4 Black Red Yellow White Orange Brown Yellow Black Male Plug From Heater 2 1 3 4 Female Plug Damper 1 2 3 4 Black Red Yellow White Orange Brown Yellow Black Male Plug From Heater 2 1 3 4 Female Plug Effikal Control Cover Photo of kit mounting Effikal Style Black 24V Constant if high limit ...

Страница 27: ...Orange Red 24V from damper 3 Yellow White 24V common 4 Black NORMAL OPERATION Condition Heater on standby Damper closed High Limit closed STEP 8 TEST FOR 24VAC BETWEEN BLACK COMMON 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 Wires are from left to right Black i Yellow i Brown i Orange ...

Страница 28: ...r 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 See Troubleshooting Step 9B Condition Thermostat closed damper fully open STEP 8B TEST FOR 24VAC BETWEEN BLACK AND YELLOW IF THEN 24VAC is present Continue to Step 10A 24VAC is not present See Troubleshooting Step 9B ...

Страница 29: ...ER Condition Thermostat closed damper closed STEP 9A TEST BETWEEN BLACK COMMON AND BROWN ON THE DAMPER BOARD IF THEN 24VAC is present This is correct 24VAC is not present See Steps 1 thru 4 Check the harness plugs connecting heater and damper for looseness or damage Wires are from left to right Black i Yellow i Brown i Orange ...

Страница 30: ...PER continued Condition Thermostat closed damper open STEP 9B A1 IS CORRECT CHECK SERVICE SWITCH POSITION IF THEN Switch is incorrect position Replace damper board motor assembly Switch is not in correct position Adjust switch Cycle thermostat to verify that damper operation is correct Service Switch Damper Open Damper Auto ...

Страница 31: ...his is correct continue to Step 11 24VAC is not present See Step 9B Check the harness plug connecting Check that cam on shaft rotates with shaft Replace the damper board 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...

Страница 32: ...Test for 24 VAC between terminal 24V on the IID module and 24V GND IF THEN 24 VAC is not present Check the wiring harness 24 VAC is present Go to 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 ...

Страница 33: ...T 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 ignition IF THEN The meter does not read 24 VAC and the IID module is not between ignition trials Replace the module The meter does read 24 VAC Go to step 13 ...

Страница 34: ...te 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 Trial for Ignition 90 sec 5 min 90 sec 5 min 90 sec Call for heat Sparking No Sparking Sparking No Sparking Sparking Continuous Trial Sequence ...

Страница 35: ... 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 Replace gas valve The meter does read 20 ohms plus or minus 5 Gas valve should work Also check that pilot gas is present and pilot tube or orifice are not blocked ...

Страница 36: ...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 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 of gas valve I...

Страница 37: ...OOK Technical Training Department Ashland City TN 2003 36 STEP 15 MAIN BURNER TEST STEP 15 MAIN BURNER TEST Visually check for main burner IF THEN The main burner ignites Sequence is complete The main burner does not ignite Go to step 16 ...

Страница 38: ... 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 insufficient signal is received by the module Sp...

Страница 39: ...E TEST 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 Go to step 18 ...

Страница 40: ... 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 Replace the gas valve The meter reads 68 ohms plus or minus 5 The main burner will ignite TH TR ...

Страница 41: ...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 Replace the gas valve 25 to 35DCA is present Main burner gas should ignite Be certain to correct you meter wire connections and setting before performing further tests RED WHITE BLUE MANIFOLD PRESSURE TAP MANIFOLD PRESSURE TAP PILOT ...

Страница 42: ...URE RELIEF VALVE FAULTY VALVE REPLACE RELIEF VALVE EXCESSIVE WATER TEMPERATURE CHECK WIRING REPLACE DUAL CONTROLLER LARGE VOLUME WATER RELIEF FROM T P VALVE 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 HAMME...

Страница 43: ...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 soun...

Страница 44: ...partment Ashland City TN 2003 43 SBD MODELS 120 THRU 500A SERIES 110 111 GAS VALVES HONEYWELL VALVE SBD 500A EFFIKAL DAMPER DRIVE ASSEMBLY PARTIAL REPLACEMENT PARTS LIST MODELS SBD 120 THRU 500A STANDARD AND ASME A SERIES 110 111 WHITE RODGERS VALVE SBC 120 400A ...

Страница 45: ...SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City TN 2003 44 SBD MODELS 120 THRU 500A continued SERIES 110 111 ...

Страница 46: ...59 LABELS 41 Manifold 76244 76244 76244 2 76244 2 76244 2 42 Instruction Manual 195121 195121 195121 195121 195121 43 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 Rod 43817 38 43817 38 43817 38 43817 42 43817 42 47 Transformer 193444 193444 193444 193444 193444 48 Pilot Tubing 1417 60 1417 6...

Страница 47: ...ess Adapter 194459 194459 194459 194459 194459 LABELS 41 Manifold 76244 2 76244 2 76244 2 76244 3 76244 2 42 Instruction Manual 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 Anode Rod 43817 38 180618 42 180618 42 43817 38 180618 42 47 Transformer 193444 193444 ...

Страница 48: ...4459 194459 LABELS 41 Manifold 76244 3 76244 4 76244 4 76244 4 42 Instruction Manual 195121 195121 195121 195121 43 Main Burner Orifice NAT 76243 37 76243 32 76243 31 76243 28 44 Main Burner Orifice LP 76243 48 76243 49 76243 48 76243 44 45 Anode Rod 43817 38 180618 42 180618 42 180618 42 47 Transformer 193444 193444 193444 193444 48 Pilot Tubing 1417 60 1417 60 1417 60 1417 60 49 Inlet Tube NA 19...

Страница 49: ...fold 76244 0 76244 0 76244 2 76244 2 76244 2 42 Instruction Manual 195121 1 195121 1 195121 1 195121 1 195121 1 43 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 Rod 43817 38 43817 38 43817 38 43817 42 43817 38 47 Transformer 193444 193444 193444 193444 193444 48 Pilot Tubing 1417 60 1417 60 1...

Страница 50: ...44 76244 76244 2 76244 2 76244 2 42 Instruction Manual 195121 1 195121 1 195121 1 195121 1 195121 1 43 Main Burner Orifice Natural 76243 32 76243 30 76243 35 76243 32 76243 32 44 Main Burner Orifice LP 76243 48 76243 46 76243 51 76243 49 76243 49 45 Anode Rod 180618 42 43817 38 43817 38 43817 42 43817 38 47 Transformer 193444 193444 193444 193444 193444 48 Pilot Tubing 1417 60 1417 60 1417 60 1417...

Страница 51: ...ess Adapter 194459 194459 194459 LABELS 41 Manifold 76244 4 76244 4 76244 4 42 Instruction Manual 194027 194027 194027 43 Main Burner Orifice Natural 76243 32 76243 31 76243 29 44 Main Burner Orifice LP 76243 49 76243 48 76243 44 45 Anode Rod 180618 42 180618 42 180618 42 47 Transformer 193444 193444 193444 48 Pilot Tubing 1417 60 1417 60 1417 60 49 Inlet Tube 192626 192626 192626 51 Gas Valve Nat...

Страница 52: ... 60hz 6A 7 to 3 5 W C STEP OPEN SBD 500 24VAC 60hz Dual Gas Valve STEP OPEN 192827 2 193366 0 PROPANE GAS SBD 120 400 2 5 10 W C STEP OPEN SBD 500 24VAC 60hz Dual Gas Valve STEP OPEN 192827 3 193366 1 INTERMITENT IGNITION DEVICE CONTROL NATURAL GAS AND PROPANE GAS 24 VAC 50 60 HZ 1A 7 MICROAMP SIGNAL CONTINUOUS RETRIAL 193325 DAMPER COMPLETE ASSEMBLY SEE PARTS LIST MOTOR 24 VAC 60 HZ 120 RPM 5 WAT...

Страница 53: ...orrective action taken if required SERVICE AGENT INSTALLATION DATE MODEL NUMBER SERVICE DATE SERIAL NUMBER LOCATION ADDRESS GAS TYPE CHECK ONE NATURAL PHONE ___ ____ PROPANE I Check Clearances circle answer A Are exterior clearances adequate yes no B Are interior clearances adequate yes no Comments II Check Makeup Air Requirements A Is the quantity of make up air adequate per the National Fuel Gas...

Страница 54: ...ove before main burner ignites yes no Does damper blade fully open before ignition sequence occurs yes no Is burner cover plate in place yes no Is burner floor shield in place yes no Does IID lockout occur after 30 sec trial for ignition Propane models only yes no B Water Temperature Is the thermostat adjusted to the lowest acceptable temperature yes no Does the installation have a mixing valve ye...

Страница 55: ...SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City TN 2003 54 COMMENTS Author Terry Mulder ...

Страница 56: ... Heaters 500 Tennessee Waltz Parkway Ashland City TN 37015 800 365 8170 www statewaterheaters com Prepared by the State Water Heaters Training Department For additional technical information call 800 365 0577 Copyright 2006 State Industries Inc ...

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