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  
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COMMERCIAL  
The Expert’s Choice®  
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  
COMMERCIAL  
The Expert’s Choice®Download from Www.Somanuals.com. All Manuals Search And Download.  
©Copyright 2007 State Industries, Inc.  

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