SERVICE HANDBOOK
®
SandBlaster
Self Cleaning Commercial Gas Water Heaters
with Flue Damper and Electronic Ignition
M O D E L S C O V E R E D
SBD71 120 Through SBD85 500
Part Number 317926-000
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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
• a 3/8 and 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
S
B
D
85
P
E
A
CGA
D
500
Canadian
Product
(if applicable)
500,000
BTUH
Propane
Sandblaster/Damper
*Up to 8,000 Feet
3 Year
Warranty
85
Gallon
High
Altitude*
ASME
Constructed
None=Standard
T=Tall
S=Short
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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
Clearance to Combustibles Table
MODEL
120 - 200
250 - 305
365 - 400
500
A
B
C
1” (2.54CM)
2” (5.08CM)
3” (7.75CM)
5” (12.7CM)
1” (2.54CM)
2” (5.08CM)
3” (7.75CM)
5” (12.7CM)
1” (2.54CM)
2” (5.08CM)
3” (7.75CM)
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 clearances
applicable to your specific model.
*20” (50.8CM) for 500 models.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
EXTERIOR CLEARANCE
"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”).
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
AIR FOR COMBUSTION
10 CUBIC FEET OF AIR PER 1,000 BTU
10 CU.
FT.
COMB.
AIR
(Minimum)
1,000
BTU
2.5 CU.
FT.
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)
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
MAKE-UP AIR
DIRECT COMMUNICATION
1 Square
Inch Per
4,000
BTUH
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:
a. 1 sq. in. per 3000 BTU per hr (7 cm2 per kW) of the total input of all equipment
located in the enclosure, and
b. Not less than the sum of the areas of all vent connectors in the confined space.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
MAKE-UP AIR
VERTICAL DUCTS
1 Square
Inch Per
4,000
BTUH
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
1 Square
Inch Per
2,000 BTUH
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.
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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 out, improper
combustion, inconsistent pilot operation, and/or erratic heater shut down.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
CONTAMINATED AIR
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
Flammable items, pressurized containers or any 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.
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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.
5.0" W.C.
4.0 " W.C.
13.8" W.C.
11" W.C.
10" W.C.
Minimum Supply Pressure
Manifold Pressure
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.
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SBD TANK TYPE 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 IID (terminal PV). The TR
terminal connects directly to 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
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
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 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 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 chart, 78 sq. inches require 10”
diameter vent.
Area in Square
Area in Square
Vent Size
Inches
20
28
38
50
Vent Size
10"
Inches
79
113
154
201
5"
6"
7"
8"
9"
12"
14"
16"
18"
64
254
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.
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SBD TANK TYPE 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.
5.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
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 proper venting.
The vent pipe should be extended to meet local codes
9. Obstructions can cause down drafts.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
POWER VENT KITS FOR SIDEWALL VENTING
Female plug
to Damper
40’, Power Venter
cable with “Y”
connect
Male plug
to Cable
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)
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
SBD SEQUENCE OF OPERATION
9. Flue damper closes
2. Flue damper opens
1. Thermostat calls for heat
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
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.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
SBD ELECTRICAL SEQUENCE
100 – 109 Series
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
SBD ELECTRICAL SEQUENCE OF OPERATION
115/60/12A
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
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 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 step 2.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
STEP 2
HIGH LIMIT, LEFT TERMINAL TEST
Ground
24 VAC
FM Transformer
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:
• 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.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
TEST HIGH LIMIT RIGHT TERMINAL
STEP 3
Temperature
High Limit (ECO)
Reset Button
Adj. Dial
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 VAC: • Push the reset button and redo the test (storage
water temperature below 185 degrees).
The meter reads 24 VAC:
• Go to step 4.
After Push in Reset - 24 VAC is now present
Reasons For Resetting
Cause
Condition
Solution
High limit open
Never set on initial
installation
Faulty thermostat
Push high limit button
Replace dual control
Replace dual control
Excessive water temperature
Heater shut down before
Faulty high limit
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.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
STEP 4
INSPECT THE DAMPER
Damper Closed
Damper Open
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:
If the damper is closed:
• Go to step 5.
• 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 limit.
• Go to step 6.
24 VAC is present:
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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
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
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 • Replace the thermostat
between the high limit and the thermostat is in place:
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 connects to the damper PC board.
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SBD TANK TYPE 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
Plug
Service
Switch
Motor
Lead
Service
Switch
Motor
Lead
Terminal
Heater
Harness
Motor
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
Red – 24V From damper to IID if damper closes end switch
White – Neutral (common)
2
d
1
3
4
Orange Brown Yellow Black
From Heater
�
�
Male Plug
�
Female Plug
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
HARNESS CHART
Heater Harness
Black
Yellow
Red
Function
24V Hot
24V from Thermostat
24V from damper
24V common
Damper Harness
1-Brown
2-Orange
3-Yellow
4-Black
White
NORMAL OPERATION
Condition:
•
•
•
Heater on standby
Damper closed
High Limit closed
Wires are from left to right:
•
•
•
Black
Yellow
Brown
Orange
TEST FOR 24VAC BETWEEN BLACK (COMMON)
AND BROWN
STEP 8
STEP 8. TEST FOR 24VAC BETWEEN BLACK (COMMON) AND BROWN
IF
THEN
24VAC is present
24VAC is not present
Continue to Step 8A.
See Troubleshooting Step 9A
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
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
24VAC is not present
Continue to Step 8B.
See Troubleshooting Step 9B.
Condition:
•
Thermostat closed, damper fully open
STEP 8B
TEST FOR 24VAC BETWEEN BLACK AND YELLOW
IF
THEN
24VAC is present
24VAC is not present
Continue to Step 10A.
See Troubleshooting Step 9B.
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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
ON THE DAMPER BOARD
STEP 9A
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.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
TROUBLESHOOTING THE EFFIKAL DAMPER (continued)
Condition:
Thermostat closed, damper open.
Damper
Open
Service
Switch
Damper
Auto
A1 IS CORRECT, CHECK SERVICE SWITCH
POSITION
STEP 9B
IF
Switch is incorrect position
THEN
Replace damper board/motor assembly.
Switch is not in correct position
•
•
Adjust switch
Cycle thermostat to verify that damper
operation is correct.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
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.
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/
Damper does not stop in proper position
•
Replace damper assembly.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
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:
24 VAC is present:
• Check the wiring harness.
• 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.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
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 the IID during the 90 second trial for
ignition.
IF
THEN
The meter does not read 24 VAC and the • Replace the module.
IID module is not between ignition trials:
The meter does read 24 VAC:
• Go to step 13
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SBD TANK TYPE 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:
• A 7/64” spark gap
• Spark cable continuity
• Ground cable continuity
• Go to step 14.
Sparking is present:
Power To Module May Be Interrupted To Reset .
Trial for Ignition
90 sec.
5 min.
90 sec.
5 min.
90 sec.
Continuous
Sparking Trial
Sequence
Call for
heat
Sparking No
Sparking
Sparking No
Sparking
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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 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
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
STEP 14B
PILOT VALVE TEST – SBD 500 ONLY
PILOT GAS
MANIFOLD
PRESSURE
TAP
BLUE
WHITE
RED
The MV/PV wire on the IID is connected to the white wire
The MV wire on the IID 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:
•
Turn off power to heater
•
Meter set to test for DC amperage (on meters, the 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
IF
THEN
.75 to .85 DCA is not present:
.75 to .85 DCA is present
• Replace the gas valve
• Pilot should work if gas (not air) is present to pilot
Power off, reattach blue gas valve wire to PV terminal of module.
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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:
The main burner does not ignite
• Sequence is complete
• Go to step 16
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
STEP 16
FLAME RECTIFICATION
STEP 16. FLAME RECTIFICATION
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 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.
Sparking at the pilot will stop almost immediately after the ignition module senses the pilot flame.
IF
THEN
Sparking continues after pilot is
established:
• Check wire connections
• Check flame contact between hood and
lighter
• Clean pilot burner surfaces
• Replace pilot assembly
• Go to step 17.
Sparking stops:
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
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. Conduct Step
18 before applying power to
replacement module.
• Go to step 18.
24 VAC is present:
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
STEP 18A
MAIN GAS VALVE CHECK
TH
TR
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
• Replace the gas valve
The meter reads 68* ohms plus or minus 5 • The main burner will ignite
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
STEP 18B
MAIN GAS VALVE COIL CHECK
PILOT GAS
MANIFOLD
PRESSURE
TAP
BLUE
WHITE
The PV wire is connected to the blue wire
RED
The MV/PV wire on the IID is connected to the white wire.
The MV wire is disconnected from the gas valve.
MANIFOLD
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
.25 to .35DCA is present
• Replace the gas valve
• Main burner gas should ignite.
Be certain to correct you meter wire connections and setting before performing further
tests.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
GENERAL SERVICE CHART
CONDITION
DAMPER OPENS NO POWER
TO IID MODULE
CAUSE
SOLUTION
.EFFIKAL – REPLACE DAMPER CONTROL
ASSEMBLY
. DAMPER NOT FULLY OPEN
. REPLACE DAMPER
. DEFECTIVE PROTECTOR
SWITCH
. REPLACE PC BOARD
PILOT LIGHTS, SPARKS
CONTINUOUSLY
PILOT FLAME NOT PROVING
SEE FLAME RECTIFICATION - STEP 16
INTERRUPT 120 VAC POWER
NOT PROVING PILOT
FLAME EXISTANCE
. CHECK GROUND WIRE
ATTACHMENT
HEATER WILL NOT IGNITE
. CLEAN OR REPLACE PILOT
ASSEMBLY
PILOT GAS NOT COMPLETELY
INTERRUPTED AT END OF
HEATING CYCLE
. CHECK SUPPLY GAS PRESSURE
. REPLACE GAS VALVE
WEEPING TEMPERATURE
AND
PRESSURE RELIEF VALVE
. THERMAL EXPANSION
. FAULTY VALVE
ADD THERMAL EXPANSION TANK
REPLACE RELIEF VALVE
LARGE VOLUME WATER
RELIEF FROM T&P VALVE
. EXCESSIVE WATER
TEMPERATURE
. FAULTY RELIEF VALVE
. CHECK WIRING
. REPLACE DUAL CONTROLLER
REPLACE RELIEF VALVE
PREMATURE TANK
LEAKAGE
CONDENSATION
. INCREASE STORED WATER
TEMPERATURE AND CONFIRM
PROPERLY SIZED APPLICATION
CONTAMINATED AIR
WATER HAMMER
. REMOVE CONTAMINANTS.
. SUPPLY CLEAN COMBUSTION
AIR.
. ADD WATER HAMMER
ARRESTOR.
. REDUCE WATER PRESSURE.
. REMOVE UNNECESSARY CHECK
VALVES.
THERMAL EXPANSION
DEPLETED ANODES
ADD THERMAL EXPANSION TANK.
SCHEDULE ANODE CHECKS -
REPLACE AS NEEDED.
DAMPER WILL NOT OPEN
BINDING SHAFT
DAMPER MOTOR
SUPPORT VENTING
EFFIKAL-REPLACE DAMPER CONTROL
ASSEMBLY
NO SPARK AT PILOT -
DAMPER FULLY OPEN
DAMPER ASSEMBLY
SEE STEP 10A
Services Switch may bypass problem until
replacement part is received. (EFFIKAL –
REPLACE DAMPER CONTROL ASSEMBLY
REPLACE IID STEP 12
IID MODULE
SPARK CABLE
REPLACE CABLE STEP 13
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
GENERAL QUESTIONS AND ANSWERS
Q.
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.
How much electrical power is required for a SBD water heater?
A: The SBD models draw approximately .7 Amps at 120VAC.
Q:
Q:
The units require "leg kits" to meet National Sanitation Foundation standards.
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 seven 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:
A:
A:
A:
One eighth inch of scale build-up may reduce efficiency as much as 22%; a 1/4 inch build-
up, as much as 38%.
Less efficient heat transfer means more bottom head expansion/contraction stress and
premature leakage.
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.
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
SBD MODELS 120 THRU 500A
SERIES 110-111
PARTIAL REPLACEMENT
PARTS LIST
MODELS SBD 120 THRU 500A:
STANDARD AND ASME (A)
SERIES 110/111
EFFIKAL DAMPER DRIVE ASSEMBLY
GAS VALVES
HONEYWELL VALVE SBD 500A
WHITE RODGERS VALVE SBC 120 – 400A
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
SBD MODELS 120 THRU 500A (continued)
SERIES 110-111
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
SBD MODELS 120 THRU 500A (continued)
SERIES 110-111
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
SBD MODELS 120 THRU 500A (continued)
SERIES 110-111
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
SBD MODELS 120 THRU 500A (continued)
SERIES 110-111
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
SBD MODELS 120 THRU 500A (continued)
SERIES 110-111
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
SBD MODELS 120 THRU 500A (continued)
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
SBD MODELS 120 THRU 500A (continued)
SERIES 110-111
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
COMPONENT PART INFORMATION
NAME
SPECIFICATIONS
DUAL
CONTROLLER
120-180O RANGE, + 4O, 5O
DIFFERENTIAL,
THERMOST
AT
LIQUID FILLED, ANTI-
STACKING
HIGH LIMIT OPENS - 205O FIXED, MANUAL
(ECO)
NATURAL
GAS
RESET BELOW 185O
SBD 120-400;24VAC, 60hz,
.6A,.7” to 3.5” W.C.,
GAS VALVE
STEP OPEN
SBD 500; 24VAC, 60hz, Dual
Gas Valve,
STEP OPEN
PROPANE
GAS
SBD 120-400;
2.5 – 10” W.C.
STEP OPEN
SBD 500; 24VAC, 60hz, Dual
Gas Valve,
STEP OPEN
INTERMITENT
IGNITION
DEVICE
NATURAL
GAS AND
PROPANE
GAS
COMPLETE
ASSEMBLY
MOTOR
24 VAC, 50-60 HZ, .1A;
.7 MICROAMP SIGNAL
CONTINUOUS RETRIAL
CONTROL
DAMPER
24 VAC, 60 HZ, 120 RPM, 5
WATT
(NOT 110, 111 SERIES)
Service Switch
(NOT 110, 111 SERIES)
120 V PRIMARY, 24 VAC
SECONDARY,
P.C. BOARD
W/RELAY
TRANSFORMER
40 VA, 50-60 HZ, CLASS 2 "B"
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SBD TANK TYPE 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
MODEL NUMBER
SERIAL NUMBER
INSTALLATION DATE
SERVICE DATE
LOCATION ADDRESS
GAS TYPE - CHECK ONE
NATURAL
PROPANE
PHONE(
)
___ -
____
I.
Check Clearances (circle answer)
A. Are exterior clearances adequate?
B. Are interior clearances adequate?
yes
yes
no
no
Comments:
II.
Check Makeup Air Requirements
A. Is the quantity of make-up air adequate per the National Fuel Gas Code?
yes
yes
no
no
Comments:
B. Is the quality of make-up air adequate?
Comments:
III.
IV.
Gas Pressure (fill in blank)
A.
B.
Supply gas pressure
Manifold gas pressure (main burner)
inches of W.C.
inches of W.C.
Comments:
Venting (check)
A.
B.
Properly sized per the National Fuel Gas Code?
Does the installation have mechanically assisted venting?
yes
yes
no
no
If so, is it operational?
Comments:
yes
no
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
V.
WATER PIPING
Is the system properly sized?
yes
yes
yes
yes
yes
no
no
no
no
no
Is the system properly installed?
Are there any water leaks?
Does the installation have a recirculating system?
If so, is it operational?
VI.
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?
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
no
no
no
no
no
no
no
no
Is pilot flame established?
If so, does sparking stop?
Does main burner ignite?
Does the thermostat satisfy?
Does damper close?
Comments:
VII.
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 IID lockout occur after 30 sec. trial for ignition? (Propane models only)
yes
yes
yes
yes
yes
no
no
no
no
no
B. Water Temperature
Is the thermostat adjusted to the lowest acceptable temperature?
Does the installation have a mixing valve?
If so, is it operational?
yes
yes
yes
no
no
no
What is the outlet temperature of the mixing valve?
Is a properly rated temperature and pressure relief valve installed?
yes
no
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?
yes
yes
yes
no
no
no
D. Flammables
Are flammable materials located in the area of the water heater?
Are flammable vapors located in the area of the water heater?
yes
yes
no
no
(This service checklist may be photo copied to assist with SBD service call.)
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SBD TANK TYPE HEATERS
SERVICE HANDBOOK
COMMENTS
Author: Terry Mulder
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Prepared by the State Water Heaters Training Department.
For additional technical information call 800-365-0577.
State Water Heaters
500 Tennessee Waltz Parkway
Ashland City, TN 37015
800-365-8170
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