State Industries SBD85 500 manual

MODELS COVERED SBD71 120 Through SBD85 500 T h e Ex p e r t’ s C h o ic e® COMMERCIAL T h e Ex p e r t’ s C h o ic e® COMMERCIAL Self Cleaning Commercial Gas W ater Heaters with Flue Damper and Electronic Ignition Part Number STC-072 Printed in the U.S.A. - 0106 State Water Heaters 500 T ennessee W altz Parkway Ashland City , TN 37015 800-365[...]

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 W i r e H a r n e s s T e s t 3 1 Installation 3 IID Module 32 Clearances 4 Pilot Spark 33 Air Requirements 5-8 Pilot Valve 34-35 Conta[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 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. Tools Required: • Phil[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 3 INSTALLATION This portion of the handbook will review some oft en overlooked installation considerations, taking note of necessary installation requirements for the SBD 71120 through SBD 85500 model heaters. The installation manual cove rs most of these i[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 4 EXTERIOR CLEARANCE This illustrates the exterior roof clearances for SBD units with natural draft venting. The vent shall extend at least 3 feet above the hi ghest point where it passes through a roof of a building, and at least 2 feet higher than any por[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 5 AIR FOR COMBUSTION 10 CUBIC FEET OF AIR PER 1,000 BTU Stoichiometric or theoretical complete com 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 cu.ft. of "exces[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 6 MAKE-UP AIR DIRECT COMMUNICATION A fresh supply of make-up air for combusti on can be supplied to t he heater through make- up air ducts which directly communicate wit h the out of doors. Tw o openings are required - one within 12 inches of the top of the[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 7 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 enclosu re.[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 8 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 [...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 9 CONTAMINATED AIR Along with adequate make-up air, the quality of the air is important. Contaminants in combustion air can lead to premature heat er failure. Vapors from bleaches, soaps, waxes, salts, etc. are draw n into the combustion chamber with the ma[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 10 GAS PRESSURE REQUIREMENTS 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[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 11 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 filt er screen [...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 12 VENTING Atmospheric, Single, and Multiple Heaters All SBD water heaters are classified by ANSI as category I (non-condensing, negative pressure venting) appliances. They are approved for type B vent. For larger applications, SBD water heaters can be comm[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 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 cases it may be necessary to run a vent larger than the draft diverter outlet. 4. Take the maximum vertical rise po[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 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 be kept hot for pro[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 15 POWER VENT KITS FOR SIDEWALL VENTING Water Heater Models Part Number SBD-120-200 193933-0 SBD-250-500 193933-1 SBD water heaters can be used with power vent kits for sidewall venting. State offers power vent kits for use on installations with a maximum o[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 16 SBD SEQUENCE OF OPERATION 1. Thermostat calls for heat 2. Flue damper opens 3. Intermittent Ignition Control 5. Main gas valve opens 7. Thermostat satisfies 4. Pilot gas opens, Pilot sparks and flame proves 6. Main burner ignites 8. Main and pilot burner[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 17 SBD ELECTRICAL SEQUENCE 100 – 109 Series[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 18 SBD ELECTRICAL SEQUENCE OF OPERATION 115/60/12A IID Module (24V) Receives Voltage Module (PV) Terminal Sends 24V to Pilot Coil Module (Spark) Sends 10,000V Spark to Pilot Spark Stops Damper Motor Energized and Damper Closed Power to Damper #2 Interru p t[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 19 TROUBLESHOOTING SBD WATER HEATERS To troubleshoot a SBD water heater check that: • 120 VAC is supplied to the heater • 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 mu[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 20 STEP 2 HIGH LIMIT, LEFT TERMINAL TEST 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[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 21 STEP 3 TEST HIGH LIMIT RIGHT TERMINAL STEP 3. TO TEST HIGH LIMIT RIGHT TERMINAL . Ensure that the jumper wire between the high limit and thermostat is c onnected, and the damper motor power line is connected. Test for 24 VAC between the high limit right [...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 22 STEP 4 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: • Go to step 5. If the damper is closed: • Go to step 7. Note: If the[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 23 STEP 6 PC BOARD MOTOR TEST 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 (part # 194484) and go to step [...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 24 STEP 7 THERMOSTAT TEST STEP 7. THERMOSTAT TEST. Set the thermostat to call for heat. Using your multimeter, test for 24 VAC between right terminal and ground. IF THEN The meter does not read 24 VAC and the jumper wire between the high limit and the t her[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 25 EFFIKAL DAMPER The wiring colors from the damper PC Board ar e 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 not necessary on production[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 26 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 • Damper closed • High Limit closed[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 27 NORMAL OPERATION (continued) Condition: • 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 See Troubleshooting Step 9B. Condition: • The[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 28 TROUBLESHOOTING THE EFFIKAL DAMPER 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 [...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 29 TROUBLESHOOTING THE EFFIKAL DAMPER (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 •[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 30 TROUBLESHOOTING THE EFFIKAL DAMPER (continued) Condition: Thermostat closed, damper is open fully STEP 10A TEST FOR 24VAC BETWEEN BLACK AND YELLOW IF THEN 24VAC is present This is correct – continue to Step 11 24VAC is not present • See Step 9B. • [...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 31 STEP 11 WIRE HARNESS TEST STEP 11. WIRE HARNESS TEST. Test for 24 VAC between terminal 24V on the IID module, and 24V GND. IF THEN 24 VAC is not present: • Check the wiring harness. 24 VAC is present: • Go to step 12. Note: This test may be easier to[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 32 STEP 12 IID MODULE TEST 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. IF THEN The meter does not read 24 VAC and the IID mod[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 33 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: • A 7/64” spark gap • Spark cable[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 34 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* oh[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 35 STEP 14B PILOT VALVE TEST – SBD 500 ONLY 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 [...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK 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[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 37 STEP 16 FLAME RECTIFICATION STEP 16. FLAME RECTIFICATION Note: Flame rectification means that an alternating cu rrent (AC) signal is changed to a direct current (DC) signal. The pilot flame is the 'switch' which connects the pilot hood to the i[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 38 STEP 17 IID MODULE 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. [...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 39 STEP 18A MAIN GAS VALVE CHECK 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 [...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 40 STEP 18B MAIN GAS VALVE COIL CHECK 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 ?[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 41 GENERAL SERVICE CHART CONDITION CAUSE SOLUTION DAMPER OPENS NO POWER TO IID MODULE . DAMPER NOT FULLY OPEN . DEFECTIVE PROTECTOR SWITCH .EFFIKAL – REPLACE DAMPER CONTROL ASSEMBLY . REPLACE DAMPER . REPLACE PC BOARD PILOT LIGHTS, SPARKS CONTINUOUSLY PIL[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 42 GENERAL QUESTIONS AND ANSWERS Q. What is unique about the Canadian – SBC-CGA – models vs. U.S. SBD models? A. The Canadian models have different dimensions to meet Canadian code requirements. Q: How much electrical power is required for a SBD water h[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department 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[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 44 SBD MODELS 120 THRU 500A (continued) SERIES 110-111[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 45 SBD MODELS 120 THRU 500A (continued) SERIES 110-111 Series 110-111 1 ..........Flue Baffl e ................................. 193595 .............. 192199-3 ........... 193795-1 ......... 193696 .......... .... 193696 3 ..........Main Burner Orif ice Bra[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 46 SBD MODELS 120 THRU 500A (continued) SERIES 110-111 ITEM PARTS DESCRIPTION SBD81190NE S BD100199NES/A SBD100250NE/A S BD65251NE/A SBD100275NE/A 1 ..........Flue Baffl e ................................... 193795-1 ....... 193889 ................ 193595 .[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 47 SBD MODELS 120 THRU 500A (continued) SERIES 110-111 1 ........... Flue Baffle ........................................ 193595 ....................... 193696 ............................ 1 93995 ................ 193995 3 ........... Main Burner Orifice Br[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 48 SBD MODELS 120 THRU 500A (continued) SERIES 110-111 CGA CGA CGA CGA 1 ............. Flue Baffle ...................................... 193595........... 192199-3 ....... 193795-0 ......... 193696 193795-0 3 ............. Main Burner Orifice Bracket .....[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 49 SBD MODELS 120 THRU 500A (continued) SERIES 110-111 1 ............ Flue Baffle ..................................... 193889 ............ 193595 .............. 193595 .............. 193945 .. ....... 193595 3 ............ Main Bur ner Orifice Bra cket ...[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 50 SBD MODELS 120 THRU 500A (continued) SERIES 110-111 1 ............ Flue Baffl e ................................................... 193945 ........................ 193995 ................ ......... 193995 3 ............ Main Burner Orifice Bracket ......[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 51 COMPONENT PART INFORMATION NAME SPECIFICATIONS STATE PART NUMBERS DUAL CONTROLLER THERMOST AT 120-180 O RANGE, + 4 O , 5 O DIFFERENTIAL, LIQUID FILLED, ANTI- STACKING # 192828 HIGH LIMIT (ECO) OPENS - 205 O FIXED, MANUAL RESET BELOW 185 O GAS VALVE NATUR[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 52 SBD SERVICE CHECKLIST (This service checklist may be photo copied to assist with SBD service call.) This checklist is intended to aid the Servic e Agent in determini ng that the State SBD Water Heater has been properly installed and is operating correctl[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department 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 the installation have a recirculating system? yes no If so, is it operational? yes no VI. PROPER SEQUENCE OF OPERATION Du[...]

SBD TANK TYPE HEATERS SERVICE HANDBOOK Technical Training Department Ashland City, TN ©2003 54 COMMENTS Author: Terry Mulder[...]

MODELS COVERED SBD71 120 Through SBD85 500 T h e Ex p e r t’ s C h o ic e® COMMERCIAL T h e Ex p e r t’ s C h o ic e® COMMERCIAL Self Cleaning Commercial Gas W ater Heaters with Flue Damper and Electronic Ignition Part Number STC-072 Printed in the U.S.A. - 0106 State Water Heaters 500 T ennessee W altz Parkway Ashland City , TN 37015 800-365[...]