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State Industries SBD85 500 manual

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Table of contents for the manual

  • Page 1

    COMMERCIAL Part Number 317926-000 Printed in the U.S.A. - 0810 SERVICE HANDBOOK SandBlaster ® Self Cleaning Commercial Gas W ater Heaters with Flue Damper and Electronic Ignition SBD71 120 Through SBD85 500 MODELS COVERED Th e E xp er t ’ s Ch o ic e®[...]

  • Page 2

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 1 SBD HANDBOOK TABLE OF CONTENT S PAG E PAG E Tr oubl es hooting (c ontinu e d) Int r odu c tio n 1-2 Troubleshooting the Efflkal 28-30 Wir e Ha r ne ss Te st 31 Installatio n 3 IID Module 32 Clearances 4 Pilot Spark 33 Air Requirements 5[...]

  • Page 3

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 2 Qualifications : Installation or service of this wa ter 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. Tool[...]

  • Page 4

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 3 INSTALLATIO N This portion of the handbook will review some of t en overlooked installation considerations, taking note of necessary installation requirements for the SBD 71120 through SBD 85500 model heaters. The installation manual co[...]

  • Page 5

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 4 EX T ER IOR CL EARANC E T his illus t ra t es t he ex t erior roo f clearances f or SBD uni ts wi t h na t ural dra ft ven t ing . T he vent shall extend at least 3 feet above the hi ghes t poin t where it passes t hrough a roo f o f a [...]

  • Page 6

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 5 AIR FOR COMBUSTION 10 CUBIC FEET OF AIR PER 1,000 BT U Stoichiometric or theoretical complete co m bustion 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 [...]

  • Page 7

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 6 MAKE-UP AIR DIRECT COMMUNICATION A f re s h s uppl y o f make-up air f or c ombu st i on can be supplied to t he heater through make - up air ducts which directly communicate wi t h the out of doors. Two openings are required - one with[...]

  • Page 8

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 7 MAKE-UP AIR VERTICAL DUCTS Often it is more practical to install vertical make-up air duc ts to t he ou t doors . Again , t wo openings are required - one within 12 inches of the top of the enclosure and one within twelve inches of the [...]

  • Page 9

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 8 INSUFFICIENT MAKE-UP AIR BACKDRAF T 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 c on s ide r ed in si z ing make-up air requir[...]

  • Page 10

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 9 CONTAMINATED AI R Along with adequate make-up air, the quality of t he air is impor t an t. Con t aminan ts in combustion air can lead to premature hea te r f ailu re . V apo rs fr om blea c he s, s oap s, wa xe s, s al ts, e tc. are dr[...]

  • Page 11

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 10 GAS PRESSURE REQUIREMENTS Natural Gas Propane Gas Max imum S uppl y Pr e ss ure 10 . 5" W. C. 13 .8" W. C. M ini mu m S uppl y Pr e ss ur e 5.0 " W. C. 11 " W. C . M ani f old Pr e ss ure 4.0 " W. C . 10 "[...]

  • Page 12

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 11 SBD G AS VA L VE 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 feat[...]

  • Page 13

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 12 VENTIN G Atm os ph er i c , S ingl e , a nd M ul t ipl e Heaters All SBD water heaters are classified by ANS I as ca t egory I (non-condensing , nega t ive pressure ven t ing) appliances . T hey are approved f or t ype B ven t. For lar[...]

  • Page 14

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 13 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 cas es i t may be ne ce ss a ry to r un a v en t la r ge r than the draft diverter outlet. 4. Ta[...]

  • Page 15

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 14 Nine Rules for Good Vents (continued) 6. Horizontal pipe should be sloped upward at a minimum of ¼” per foot. 7. Horizontal elements should be limited to 75% of the vertical rise of the vent above the connection. 8. Flue gases must [...]

  • Page 16

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 15 POWER VENT KITS FOR SIDEWALL VENTING SBD water heaters can be used with power vent ki ts f or s idewall v en t ing . Stat e o ff er s power ven t ki ts f or use on ins t alla t ions wi th a maximum of 100 equivalent feet of vent piping[...]

  • Page 17

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 16 SBD SEQUENCE OF OPERATIO N 1. Thermostat calls for heat 2. Flue damper opens 3. In termittent Ignition Control 5. Main gas valve opens 7. Thermostat satisfies 4. Pilot gas opens, Pilot sparks and flame proves 6. Main burner ignites 8. [...]

  • Page 18

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 17 SBD ELECTRICAL SEQUENCE 100 – 109 S er i es[...]

  • Page 19

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 18 SBD ELECTRICAL SEQUENCE OF OPERATION 115/60/12 A[...]

  • Page 20

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 19 TROUBLESHOOTING SBD WATER HEATERS To t roubleshoo t a SBD wa t er hea t er check t ha t: • 120 VAC is supplied to the heater • t he t an k is f ull of wa t er • gas is supplied to the unit STEP 1 TEST TH E T RAN SFO R ME R STEP 1[...]

  • Page 21

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 20 STEP 2 HIGH LIMIT, LEFT TERMINAL TES T STEP 2. HIGH LIMIT, LEFT TERMINAL TEST . Test for 24 VAC between the left high limit terminal and ground. N E H T F I The meter does not read 24 VAC: • Check wiring between transformer and high [...]

  • Page 22

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 21 STEP 3 TEST HIGH LIMIT RIGHT TERMINA L STEP 3. TO TEST HIGH LIMIT RIGHT TERMINA L . Ensure t ha t t he jumper wire between the high limit and thermostat is c onnected, and the damper motor power line is connected. Test for 24 VAC betwe[...]

  • Page 23

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 22 STEP 4 IN SPE CT T HE DA MPE R ST EP 4. I NSPEC T T HE DAMPER . Lower the thermostat setting so the unit will not be calling for heat, then inspect the damper. N E H T F I If the damper is open: • Go to step 5. If the damper is close[...]

  • Page 24

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 23 STEP 6 PC BOARD MOTOR TES T STEP 6. PC BOARD/MOTOR TEST . Check for 24 VAC between the two motor lead te rm inal s of t he PC boa rd. Di sc onne ct t he wi re s for t hi s te st. N E H T F I 24 VAC is not present: • Replace the Dampe[...]

  • Page 25

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 24 STEP 7 THERMOSTAT TES T ST EP 7. T HERM OST AT T ES T. Se t t he t hermo st a t to c all f or hea t. Us ing y our mul t ime t er , te st f or 24 V AC be t ween righ t t erminal and ground . N E H T F I The meter does not read 24 VAC an[...]

  • Page 26

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 25 EFFIKAL DAMPE R The wiring colors from the damper PC Board ar e di ff eren t colors than the wires on the heater wiring harness. The male/female plug s to connect the dampe r board to the heater harness join in only one way. Adapter no[...]

  • Page 27

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 26 HARNESS CHART Heater Harness Function Damper Harness Black 24V Hot 1-Brown Yellow 24V f rom T hermos tat 2- O range Red 24V from damper 3-Yellow White 24V common 4-Black NORMAL OPERATION Condition : • Hea t er on st andb y • Damper[...]

  • Page 28

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 27 NO RMA L OPE RA TIO N (c on t inu e d) Condition : • T hermos ta t c losed , damper in pro ce ss of opening STEP 8A TEST FOR 24VAC BETWEEN BLACK AND ORANG E N E H T F I . B 8 p e t S o t e u n i t n o C t n e s e r p s i C A V 4 2 . [...]

  • Page 29

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 28 TRO UB L ESH OOTING T HE EFFI KA L DAMPER Condition : Thermostat closed, damper c lo se d STEP 9A TEST BETWEEN BLACK (COMMON) AND BROWN ON THE DAMPER BOAR D N E H T F I t c e r r o c s i s i h T t n e s e r p s i C A V 4 2 24VAC is not[...]

  • Page 30

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 29 TROUBLESHOOTING THE EFFIKAL DAMPER (continued) Condition : T he rm o st a t c lo s ed , da m pe r open . STEP 9B A1 IS CORRECT, CHECK SERVICE SWITCH POSITIO N N E H T F I Swi t ch is incorrec t posi t ion Replace damper board / mo t or[...]

  • Page 31

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 30 TROUBLESHOOTING THE EFFIKAL DAMPER (continued) Condition : T hermos ta t closed , damper is open f ully STEP 10 A TEST FOR 24VAC BETWEEN BLACK AND YELLO W N E H T F I 1 1 p e t S o t e u n i t n o c – t c e r r o c s i s i h T t n e [...]

  • Page 32

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 31 STEP 11 WIRE HARNESS TES T STEP 11. WIRE HARNESS TEST . Test for 24 VAC between terminal 24V on the IID module, and 24V GND. N E H T F I 24 VAC is not present: • Check the wiring harness. 24 VAC is present: • Go to step 12. Note: T[...]

  • Page 33

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 32 STEP 12 IID MODULE TES 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 t he IID during the 90 second trial for ignition . N E H T F I The meter does not r[...]

  • Page 34

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 33 ST EP 13 PILOT SP ARK TES T STEP 13 . PILOT SP ARK TEST . Vis uall y c he ck fo r s pa rk at t he pilo t a ss e m bl y. No te: T he pilo t bu r ne r m oun ts on t he le ft s ide of t he m ain bu r ne r. N E H T F I T he igni t er is no[...]

  • Page 35

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 34 STEP 14 A PILOT VALVE - OHM TES T SBD 120 – 400 GAS VALVE STEP 14A. PILOT VALVE - OHM TEST . If pilo t a ss embl y i s s parking bu t no pilo t f lame is established, disconnect the pilot valve solenoid leads. Using a multimeter, (se[...]

  • Page 36

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 35 STEP 14 B PILOT VALVE TEST – SBD 500 ONL Y S TE P 14B . P ILOT VA LVE TE ST – S BD 500 ON LY. Testing the two coils of the Hone y well V R8404P 5004 gas val ve us ed on t he model SBD 500 only. Because of built in diodes , it is di[...]

  • Page 37

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 36 STEP 15 MAIN BURNER TES T STEP 15 . M AIN BURN ER TEST . Vi s uall y c he ck for m ain bu r ne r. N E H T F I The main burner ignites: • Sequence is complete The main burner does not ignite • Go t o st ep 16[...]

  • Page 38

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 37 STEP 16 FLAME RECTIFICATIO N STEP 16. FLAME RECTIFICATIO N No te: F la m e re ct ific at ion m ean s t ha t an al ter na t ing cu rrent (AC) signal is changed to a direct current (DC) signal. The pilot flame is the 'switch' w[...]

  • Page 39

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 38 STEP 17 IID MODULE TES T Pilot is lit - Sparking has stopped. STE P 17 . II D MO DU LE TE ST ( Pow er to t he Ma in Va l ve) . Using a multimeter, test for 24 VAC between terminal MV on the IID and 24V (GND). N E H T F I 24 VAC is not [...]

  • Page 40

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 39 STEP 18 A MAIN GAS VALVE CHEC K SBD 120 – 400 GAS VALVE S TE P 18A . MA IN G AS VA LV E CHECK . Disconnect wires from gas valve TH and TR t erminals . Using a mul t ime t er , t es t f or 68 ohms plus or minus 5 be t ween TH and TR o[...]

  • Page 41

    S BD T ANK TYPE HE A TE RS SER VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 40 STEP 18 B MAIN GAS VALVE COIL CHEC K STEP 18B . M AIN GAS VA LVE C OIL CH E CK – S BD 500 ON LY Condi t ion : • Pilot lights • Sparking stops • No main burner ignition T es t Procedure : • Power off • Disconnec t red , main[...]

  • Page 42

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 41 GENE RA L SE RV ICE CHAR T N O I T U L O S E S U A C N O I T I D N O C DAMPER OPENS NO POWER TO II D MO DUL E . DAMPER NOT FULLY OPEN . DE F EC TI VE PR OT EC TO R S WIT CH .EFFIKAL – REPLACE DAMPER CONTROL ASSEMBL Y . REPLACE DAMPER . R[...]

  • Page 43

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 42 GENERAL QUESTIONS AND ANSWER S Q. What is unique about the Canadian – S BC-C GA – m od el s vs . U .S. S BD m od e ls? A. The Canadian models have different dimen s ions to meet Canadian code requirements. Q: How much electrical power [...]

  • Page 44

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 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 / 11 1 WHITE RODGERS VALVE SBC 120 – 400 [...]

  • Page 45

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 44 SBD MODELS 120 THRU 500A (continued) SERIES 110-111[...]

  • Page 46

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 45 SBD MODELS 120 THRU 500A (continued) SERIES 110-111[...]

  • Page 47

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 46 SBD MODELS 120 THRU 500A (continued) SERIES 110-111[...]

  • Page 48

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 47 SBD MODELS 120 THRU 500A (continued) SERIES 110-111[...]

  • Page 49

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 48 SBD MODELS 120 THRU 500A (continued) SERIES 110-111[...]

  • Page 50

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 49 SBD MODELS 120 THRU 500A (continued)[...]

  • Page 51

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 50 SBD MODELS 120 THRU 500A (continued) SERIES 110-111[...]

  • Page 52

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K Technical Training De partment As hl a nd C i ty , T N © 200 3 51 COMPONENT PART INFORMATION NAME SPECIFICATIONS DUA L CO NTRO LL ER THERMOS T AT 120-18 0 O RANGE, + 4 O , 5 O DIFFERENTIAL , L IQ UI D FI LL ED , AN TI - STA C KI N G HIGH LIMIT (ECO ) OPENS - 20 5 O FIXED, MANUAL RESET BELOW 18 5 O GAS VA[...]

  • Page 53

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K t n e m t r a p e D g n i n i a r T l a c i n h c e T Ashland City, TN ©2003 52 S BD SERVICE CHECK LIST ( Thi s service check li st may be pho to c opi ed to assist wi th SBD service ca ll. ) This checklist is intended to aid the Service Agent in determining that the State SBD Water Heater has been prope[...]

  • Page 54

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K t n e m t r a p e D g n i n i a r T l a c i n h c e T Ashland City, TN ©2003 53 V. WATER PIPING Is the system properly sized? yes no Is the system properly installed? yes no Are there any water leaks? yes no Does t he ins t alla ti on have a recircula t ing sys t em? yes no If so, is it operational? yes [...]

  • Page 55

    SBD TANK TYPE HEATERS SE R VI CE HANDB OO K t n e m t r a p e D g n i n i a r T l a c i n h c e T Ashland City, TN ©2003 54 CO MMEN TS Author: Terry Mulder[...]

  • Page 56

    State Water Heaters 500 T ennessee W altz Parkway Ashland City , TN 37015 800-365-8170 www .statewa terheaters.com Prepared by the State Water Heaters T raining Department. For additional technical information call 800-365-0577. ©Copyright 2007 State Industries, Inc. COMMERCIAL Th e E x p e rt ’ s Ch oi ce ®[...]