State Industries Water Heater SBD71 120 User Manual

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

Printed in the U.S.A. - 0_D8_o1_w0_{nload from Www.Somanuals.com. All Manuals Search And Download.}

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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

CGA

500

Canadian

Product

(if applicable)

500,000

BTUH

Propane

Sandblaster/Damper

*Up to 8,000 Feet

3 Year

Warranty

Gallon

High

Altitude*

ASME

Constructed

None=Standard

T=Tall

S=Short

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SBD TANK TYPE HEATERS

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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

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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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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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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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 cm²per 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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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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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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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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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 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

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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

Vent Size

Inches

Vent Size

10"

Inches

113

154

201

12"

14"

16"

18"

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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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.

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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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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

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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 ELECTRICAL SEQUENCE

100 – 109 Series

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SBD ELECTRICAL SEQUENCE OF OPERATION

115/60/12A

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SBD TANK TYPE HEATERS

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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.

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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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.

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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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.

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

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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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.

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.

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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STEP 6

PC BOARD MOTOR TEST

Service Switch

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.

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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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.

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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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)

Red

Orange Brown Yellow Black

From Heater

�



Male Plug

�

Female Plug

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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

THEN

24VAC is present

24VAC is not present

Continue to Step 8A.

See Troubleshooting Step 9A

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NORMAL OPERATION (continued)

Condition:

•

Thermostat closed, damper in process of opening

STEP 8A

TEST FOR 24VAC BETWEEN BLACK AND ORANGE

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

THEN

24VAC is present

24VAC is not present

Continue to Step 10A.

See Troubleshooting Step 9B.

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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

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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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

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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TROUBLESHOOTING THE EFFIKAL DAMPER (continued)

Condition:

Thermostat closed, damper is open fully

STEP 10A

TEST FOR 24VAC BETWEEN BLACK AND YELLOW

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

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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STEP 11

WIRE HARNESS TEST

STEP 11. WIRE HARNESS TEST. Test for 24 VAC between terminal 24V on the IID

module, and 24V GND.

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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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.

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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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.

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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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.

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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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

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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STEP 15

MAIN BURNER TEST

STEP 15. MAIN BURNER TEST. Visually check for main burner.

THEN

The main burner ignites:

The main burner does not ignite

• Sequence is complete

• Go to step 16

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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.

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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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).

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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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.

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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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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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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GENERAL QUESTIONS AND ANSWERS

What is unique about the Canadian – SBC-CGA – models vs. U.S. SBD models?

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.

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.)

Deliming should be done when a slight rumbling or popping sound is detected when the

main burners are on.

What effect will lime build-up have on the SBD water heater?

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.

Anode rods provide additional protection against corrosion. When should these be

replaced?

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 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 MODELS 120 THRU 500A (continued)

SERIES 110-111

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SBD MODELS 120 THRU 500A (continued)

SERIES 110-111

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SBD MODELS 120 THRU 500A (continued)

SERIES 110-111

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SBD MODELS 120 THRU 500A (continued)

SERIES 110-111

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SBD MODELS 120 THRU 500A (continued)

SERIES 110-111

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SBD MODELS 120 THRU 500A (continued)

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SBD MODELS 120 THRU 500A (continued)

SERIES 110-111

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COMPONENT PART INFORMATION

NAME

SPECIFICATIONS

DUAL

CONTROLLER

120-180^ORANGE, + 4^O, 5^O

DIFFERENTIAL,

THERMOST

LIQUID FILLED, ANTI-

STACKING

HIGH LIMIT OPENS - 205^OFIXED, MANUAL

(ECO)

NATURAL

GAS

RESET BELOW 185^O

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 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(

)

___ -

____

Check Clearances (circle answer)

A. Are exterior clearances adequate?

B. Are interior clearances adequate?

yes

Comments:

II.

Check Makeup Air Requirements

A. Is the quantity of make-up air adequate per the National Fuel Gas Code?

yes

Comments:

B. Is the quality of make-up air adequate?

Comments:

III.

IV.

Gas Pressure (fill in blank)

Supply gas pressure

Manifold gas pressure (main burner)

inches of W.C.

Comments:

Venting (check)

Properly sized per the National Fuel Gas Code?

Does the installation have mechanically assisted venting?

yes

If so, is it operational?

Comments:

yes

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WATER PIPING

Is the system properly sized?

yes

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

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

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

What is the outlet temperature of the mixing valve?

Is a properly rated temperature and pressure relief valve installed?

yes

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

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

(This service checklist may be photo copied to assist with SBD service call.)

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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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