State Industries SBD71 120, SBD85 500 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

Also includes Parts List

Part Number STC-072

Printed in the U.S.A. - 0106

COMMERCIAL

The Expert’s Choice®

SBD TANK TYPE HEATERS

SERVICE HANDBOOK

SBD

HANDBOOK

TABLE OF CONTENTS

PAGE PAGE Troubleshooting (continued) Introduction 1-2 Troubleshooting the Efflkal 28-30 Wire Harness Test 31 Installation 3 IID Module 32 Clearances 4 Pilot Spark 33 Air Requirements 5-8 Pilot Valve 34-35 Contaminated Air 9 Main Burner Test 36 Flammable 9 Flame Rectification 37 Gas Pressure 10 IID Module 38 Gas Valve 11 Main Gas Valve 39-40 Venting 12-15

Sequence of Operation Mechanical 16 Service Charts and General Electrical 17-18 Questions and Answers 41-42

Troubleshooting Parts List 43-50 Transformer 19 High Limit 20-21 Component Part Information 51 Damper (on Standby) 22 PC Board 22-23 Service Check List 52-53 Thermostat 24 Effikal Damper 25 Comments 54

Effikal Harness Test 26 Normal Operation 26-27

SBD SERVICE HANDBOOK INTRODUCTION

This service handbook is designed to aid in servicing and troubleshooting State SBD water heaters in the field. No duplication or reproduction of this book may be made without the express written authorization of the State Water Heater Company.

The following text and illustrations will provide you with a step by step procedure to verify proper installation, operation, and troubleshooting procedures. Additional quick reference data is included to assist you in servicing this product.

The information contained in this handbook is designed to answer common questions encountered in the operation of the SBD product line and is not meant to be all inclusive. If you are experiencing a problem not covered in this handbook, please contact the Technical Information Department at 1-800-365-0577 or your Local State Water Heater Sales Representative for further assistance. This handbook is intended for use by licensed plumbing professionals and reference should be made to the installation manual accompanying the product. This handbook contains supplemental information to the SBD installation and operation manual.

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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 D 85

Sandblaster/Damper

85

Gallon

500,000

BTUH

*Up to 8,000 Feet

500

P

Propane

Warranty

E

3 Year

None=Standard

CGA

T=Tall

S=Short

A DB

Canadian

Product

(if applicable)

ASME

Constructed

High

Altitude*

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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.

MODEL A B C

120 - 200 1” (2.54CM) 1” (2.54CM) 1” (2.54CM) 250 - 305 2” (5.08CM) 2” (5.08CM) 2” (5.08CM) 365 - 400 3” (7.75CM) 3” (7.75CM) 3” (7.75CM)

500 5” (12.7CM) 5” (12.7CM) 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.

CLEARANCES FROM COMBUSTIBLES

Clearance to Combustibles Table

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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

1

,

0

1

,

0

1

B

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)

0

,

0

T

0

U

0

2.5 CU. FT.

EXCESS

AIR

10 CU.

FT.

COMB.

(Minimum)

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SBD TANK TYPE HEATERS

SERVICE HANDBOOK

MAKE-UP AIR

DIRECT COMMUNICATION

A fresh supply of make-up air for combustion can be supplied to the heater through makeup 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 cm

located in the enclosure, and

b. Not less than the sum of the areas of all vent connectors in the confined space.

1 Square Inch Per 4,000 BTUH

2

per kW) of the total input of all equipment

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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

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.

1 Square Inch Per 2,000 BTUH

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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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Supply Gas

SBD TANK TYPE HEATERS

SERVICE HANDBOOK

GAS PRESSURE REQUIREMENTS

Manifold Pressure Tap

Dirt Leg

Manifold Gas Port

Maximum Supply Pressure 10.5" W.C. 13.8" W.C. Minimum Supply Pressure 5.0" W.C. 11" W.C.

Manifold Pressure 4.0 " W.C. 10" W.C.

The supply gas pressure is normally measured at 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.

Natural Gas Propane Gas

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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 S q u are

Vent Size

5" 20 10" 79 6" 28 12" 113 7" 38 14" 154 8" 50 16" 201 9" 64 18" 254

Inches Vent Size

Area in Square

Inches

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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POWER VENT KITS FOR SIDEWALL VENTING

Female plug to Damper

40’, Power Venter cable with “Y” connect

Male plug to Cable

SBD TANK TYPE HEATERS

SERVICE HANDBOOK

Water Heater Models Part Number

SBD-120-200 193933-0 SBD-250-500 193933-1

SBD water heaters can be used with power vent kits for sidewall venting. State offers power vent kits for use on installations with a maximum 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

1. Thermostat calls for heat

7. Thermostat satisfies

3. Intermittent Ignition Control

2. Flue damper opens

4. Pilot gas opens, Pilot sparks and flame proves

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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