SERVICE HANDBOOK SandBlaster ® Self-Cleaning Induced Draft Multi Flue Commercial Gas Water Heaters M O D E L S C O V E R E D SBN71 120 Through SBN85 390 (A) Series 108 Models and SBD30 150, SBD30 199 Booster Heaters SBN Meets Low NOx Requirements of SCAQMD Rules 1121 & 1146.2 Part Number 317927-000 Printed in the U.S.A.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK Table of Contents SBN 71-120 thru 85-390, SBD30-150/199 SERVICE HANDBOOK INTRODUCTION.........2 QUALIFICATIONS..................................................................................................................3 TOOLS REQUIRED...............................................................................................................3 COMMERCIAL TANK TYPE GAS MODEL NUMBER BREAK DOWN..................
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK WATER HEATER CONTROL BOARD TROUBLESHOOTING AND DIAGNOSTIC LED INTERPRETATION.............................................................................................................................33 WATER HEATER CONTROL BOARD TROUBLESHOOTING AND DIAGNOSTIC LED INTERPRETATION.............................................................................................................................
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER 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.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK INSTALLATION CONSIDERATIONS - CLEARANCES This portion of the handbook reviews some often overlooked installation considerations clearances, air supply, gas pressure requirements, and venting—taking note of necessary installation requirements for SBN and SBD30-150/199 . The installation manual covers most of these items in detail. A 24-inch clearance for all serviceable parts is recommended.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK MINIMUM CLEARANCE TO COMBUSTIBLES Model Number "A" Right Side "B" Left Side "C" Back "D" Ceiling SBN-120 thru 200A 2" 2" 2" 12" SBN-250/A thru 310/A 3" 3" 3" 12" SBN-366 6" 6" 6" 6" SBN-390 4" 4" 4" 4" 2” 2” 2” 12” SBD30-150/199 A, B, and C clearances to non-combustibles is “0” inches - a 12 inch clearance to cover remains unchanged.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK REQUIRED EXTERIOR CLEARANCES The illustration below shows the required clearances for venting units using natural draft venting. The vent must 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 inches in diameter or less). References: NFPA 54 2006; ANSI Z 223.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK REQUIRED EXTERIOR CLEARANCES Stoichiometric or theoretical complete combustion requires 10 cubic feet of air per 1,000 BTUH of gas supplied. The National Fuel Gas code also recommends an additional 2.5 cubic feet of “excess” air. For information on minimum make-up air opening sizes for various building installations, refer to the National Fuel Gas Code NFPA 54, ANSI Z223.1, Sec. 5.3 INSUFFICIENT MAKEUP AIR ........
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK MAKE-UP AIR – DIRECT COMMUNICATION WITH OUTDOORS 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 outdoors.(Not Direct Vent) 1 SQUARE INCH PER 4,000 Btu FOR EACH OPENING Two openings are required: one within 12 inches of the top of the enclosure and one within 12 inches of the bottom of the enclosure.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER 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 by-products.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK GAS VALVE The supply gas pressure is normally measured at the gas valve inlet gas pressure tap, if available, when the gas is flowing. The manifold gas pressure is measured at the manifold pressure tap of the gas valve when the gas is flowing. Gas valves used are 24 volt AC combination-step opening gas valves. They incorporate the main valve and gas pressure regulator into one body.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK GAS VALVE The outlet view of the Gas Valve, shown on the right, shows the Manifold Gas Outlet Connection, the two 24 volt Main Valve (MV) Solenoid connections, and the Manifold Pressure Tap. The two yellow wires from the 12-pin plug on the Ignition Board attach to the MV terminals.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK VENTING All SBN and SBD water heaters are classified by ANSI as Category I (non-condensing, negative pressure venting) appliances. They are approved for type B vent. The draft inducer does not pressurize the exhaust.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK VENT TABLES FOR CATEGORY I - TYPE B GAS VENT Multiple Gas Fired Tank-Type Heaters When venting multiple Category I tank type heaters using Type B vent pipe, follow the installation tables below which give sizing and data based upon NFPA 54/ANSI Z223.1-2006. Model: SBN 71-120 Input:120,000 Btu/hr. Total Vent Height (feet) Vent Connector Size: 5” Input Btu/hr No.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK VENT TABLES FOR CATEGORY I - TYPE B GAS VENT Model: SBN80-180; SBN100-199; SBN100-200; SBD30-199 Input:180,000, 190,000 and 199,000 Btu/hr. Total Vent Height (feet) Vent Connector Size: 6” Input Btu/hr No.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK VENT TABLES FOR CATEGORY I - TYPE B GAS VENT Model: SBN100-250 Input:250,000 Btu/hr. Total Vent Height (feet) Vent Connector Size: 6” Input Btu/hr No.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK VENT TABLES FOR CATEGORY I - TYPE B GAS VENT Model: SBN 85-310 Input:310,000 Btu/hr. Total Vent Height (feet) Vent Connector Size: 6” Input Btu/hr No.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK VENT TABLES FOR CATEGORY I - TYPE B GAS VENT Model: SBN 85-366NE, SBN 85-390NE Input:366,000/399,000 Btu/hr. Total Vent Height (feet) Vent Connector Size: 6” Input Btu/hr 366,000 399,000 366,000 399,000 366,000 399,000 No.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK SBN /SBD30-150/199 SEQUENCE OF OPERATION Sequence 2 1. Thermistors (probes) call for heat. 2. Inducer fan starts and provides draft. 3. Hot surface igniter = 20 sec. warm-up. 1 4. Main gas valve opens 4 sec. trial for ignition. (Maximum 5 trials.) 5. Main burner ignites and proves. 6. Thermostat reaches the temperature 6 setting. 7. Main burners “OFF” - Auto restart after 60 min.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK COMBINED VENTING COMBINING VENTS (MANIFOLDING Vent Size 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.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK 9 RULES FOR GOOD VENTING VENT PIPE VENT CONNECTOR 1.The vent pipe should ALWAYS be the 2. The diameter of a vent pipe should same size as the outlet of the draft hood or NEVER be reduced, no matter what the circumstances. factory supplied vent reducer. Model SBN71-120 is supplied with a 6” to 5” reducer. 3. In some cases it may be necessary to 4.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK 9 RULES FOR GOOD VENTING 5.Use a 45° elbow in place of a 90° elbow where possible. Avoid the use of a 90° elbow immediately above the draft hood. Allow the maximum vertical rise before any elbow. VERTICAL RISE EQUAL TO 1/4” PER FOOT OF HOROZONTAL RUN HORIZONTAL RUN 6.Horizontal pipe should be sloped upward at a minimum of ¼” per foot.
SBN71-120 thru 85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK 9 RULES FOR GOOD VENTING VENT RUNS BEYOND EXTERIOR WALLS OR INTO UNHEATED AREAS SHOULD BE DOUBLE WALL. HORIZONTAL ELEMENTS LIMITED TO 75% OF TOTAL VERTICAL HEIGHT 7.Horizontal elements should be limited 8.Flue gases must be kept hot for proper to 75% of the vertical rise of the vent above the connection. venting. Single wall vent exposed to cold air may not vent properly. 9.Obstructions can cause down drafts.
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK DRAFT PROVING PRESSURE SWITCH - SETTINGS Draft Proving Pressure Switch Table SBN Models Pressure Setting To Close Switch (Inches W.C.) SBD Models 366 (-) 1.60 ± .10" 275 (-) 2.00" ± .10" 310 (-) 1,75" ± .10" 120/200 (-) 2.40" ± .10" 154/180 (-) 2.60" ± .10" 30-150/199 (-) 2.50" ± .10" NOTE: Pressure Switch Contacts are Normally Open “N.O.” and close on a fall in pressure.
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK THERMOSTAT AND IGNITION CONTROL BOARD VIEW State Water Heaters Ashland City, Tennessee © 2007 24 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK WHITE RODGERS INTEGRATED CONTROL - THERMOSTAT State Water Heaters Ashland City, Tennessee © 2007 25 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK WHITE RODGERS IGNITION CONTROL BOARD State Water Heaters Ashland City, Tennessee © 2007 26 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK GAS CONTROL VALVE / BURNER AREA VIEW SBN's HSI Part Number 194405 Volts AC Nominal 80 VAC Ohms Resistance 11.0 - 20.0 @ 77° F (25° C) NOTICE FLAME ROD CROSSES PATH OF FLAME .1 - .
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK WIRING DIAGRAM State Water Heaters Ashland City, Tennessee © 2007 28 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK ELECTRICAL SEQUENCE – SBN, SBD30-150/199 1. Switch Power on to unit. 2. Thermostat calls for heat. 3. Ignition Control Board performs diagnostic check on system components. 4. On completion of diagnostics check, the Ignition Control Board sends signal to Exhaust Inducer. 5. Exhaust Inducer begins drawing air through appliance closing the Prover Switch. 6.
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK OPERATING SEQUENCE – FLOW CHART State Water Heaters Ashland City, Tennessee © 2007 30 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK DIAGNOSTIC SEQUENCE OF OPERATION – FLOW CHART State Water Heaters Ashland City, Tennessee © 2007 31 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK PRE-SERVICE CHECK LIST Use the following checklist BEFORE you begin servicing the water heater. 1.
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK WATER HEATER CONTROL BOARD TROUBLESHOOTING AND DIAGNOSTIC LED INTERPRETATION TEST 1 – 120VAC POWER CHECK ● No Green display “Power” LED on. ● Plugs are in receptacles. ● Supply power breaker is not “open” ● On/Off heater switch is “On”. White Rodgers Integrated Control 120 V. AC check to water heater ON/OFF switch TEST 1 Check for 115-125 V. AC black wire to ground\ 115 V.
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK WATER HEATER CONTROL BOARD TROUBLESHOOTING AND DIAGNOSTIC LED INTERPRETATION Conditions: ● Power On ● Red, heater control “Call for Heat” LED – on ● Red, ignition control board diagnostic LED – Flashing ● Note LED Flash Code before resetting heater. LED Status Indication 1 Flash System is in lock out. 2 Flashes Draft proving (pressure) switch failed to open within 5 seconds at the end of the last cycle.
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 2 – POLARITY CHECK Conditions: ● ● ● ● ● No hot water Green “Power” LED is on. Tank is more than 5° F below temperature dial setting. Red ignition control board diagnostic LED is flashing 6 times between pauses. Red, diagnostic “Call for Heat” LEDOFF. TEST 2 Polarity Check Check from on/off switch center and white wire terminals to ground 115-125 VAC is not present see Test 1.
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 3 - CONTINUITY CHECK OF HIGH LIMIT (ECO) Conditions: ● ● ● ● ● ● 0.0 Power On – No Hot Water Red, heater control “Call for Heat” LED – on Red ignition control board diagnostic LED – 4 Flashing Note LED Flash Code before resetting water heater control. See Description of diagnostic LED Flashes.
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 4 - UPPER TEMPERATURE PROBE CONTINUITY CHECK Conditions: ● ● ● Power On - Water below temperature set point. Red, water heater control “Reset Status” LED-OFF Call For Heat” LED off. Ohms Resistance Table °F Ohms 70° 11,884 120° 3,759 140° 2,488 180° 1,169 TEST 4 Upper Temperature probe continuity check Red wire to red wire - Turn supply power "Off" for this test If… then.....
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 5 - CALLING FOR HEAT – NO INDUCER OPERATION Conditions: ● ● ● ● Water Heater Control - Thermostat Power on Plugs in Receptacles Red “ Call for Heat” LED-ON Inducer “Off” Note flash code on ignition control board diagnostic LED “call for heat” LED Indicator “diagnostic LED indicator” 120 I f… then........
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 6 - INDUCER ON.............NO IGNITION Conditions: ● ● ● ● Power on Plugs in receptacles Inducer operating No power to Hot Surface IGNITOR (HSI) Note LED flash code INDUCER EXHAUST/ VENT CONNECTION DRAFT PROVING PRESSURE SWITCH LOW GAS PRESSURE SWITCH INDUCER MOTOR TEST 6 24 VAC Check of Blower Prover/Low Gas Pressure Circuit If… then........
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 7 – INDUCER ON, PROVER SWITCH AND LOW GAS PRESSURE SWITCH CLOSED ....................NO IGNITOR OPERATION Conditions: ● ● ● ● Power on Plugs in receptacles Inducer on 24V at ignition board E1, Pin 10 CHECK E1PIN 10 TO GROUND – 24 V.
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 8 – IGNITOR HEATS .............. NO MAIN BURNER 24 V. E1 PLUG TO PIN 9 E1 PLUG TO PIN 12 TEST 8 IGNITOR HEATS......NO MAIN BURNER If....... then........ short heat up time of IGNITOR Check control box grounding. Normal (Approximate 20 seconds) warm up - no ignition Check for 24V from E1, Pin 12 to ground during 4 second trial. ........Yes - Continue................
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 9 – IGNITOR HEATS .......NO MAIN BURNER Conditions: ● Test 8 completed then: ● Turn off power ● Disconnect wires from gas valve TEST 9 IGNITOR HEATS – NO MAIN BURNER If… then..... Meter reads 0 or 1 Check meter scale setting to read between 550 and 650 Ohms Replace Gas Valve Meter indicates pilot and main coil have continuity Valve should be okay....
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 10 - MAIN BURNER IGNITION FOR LESS THAN 5 SECONDS Conditions: ● Power On – plug connected ● Main Burner ignites for approximately 5 seconds then goes out. ● Tests 8 and 9 completed ● Note flash code on ignition board LED. Hot Surface IGNITOR (Illustration of low NOx burner) E1, Pin 2 - From Flame Proving Rod TEST 10 MAIN BURNER IGNITION FOR LESS THAN 5 SECONDS If....... then.........
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK TEST 11 - WATER HEATER SHUTTING OFF BELOW SETTING Conditions: ● Main burner ignited ● Stored water is below temperature setting more than 5° F (Tank Average). ● Power off ● Plug disconnected from heater control board receptacle E3 and E4 TEST 11 WATER TEMPERATURE CIRCUIT CHECK - CONTINUITY If… then.....
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK DISPLAY LIGHTS ON INTEGRATED WATER HEATER CONTROL State Water Heaters Ashland City, Tennessee © 2007 45 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK PARTS SBN71-120 thru 85-390 series 100 State Water Heaters Ashland City, Tennessee © 2007 46 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK PARTS SBN71-120 thru 85-390 series 100 State Water Heaters Ashland City, Tennessee © 2007 47 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK PARTS SBN71-120 thru 85-390 series 100 State Water Heaters Ashland City, Tennessee © 2007 48 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK PARTS SBN71-120 thru 85-390 series 108 State Water Heaters Ashland City, Tennessee © 2007 49 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK PARTS SBN71-120 thru 85-390 series 108 State Water Heaters Ashland City, Tennessee © 2007 50 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK PARTS SBN71-120 thru 85-390 series 108 State Water Heaters Ashland City, Tennessee © 2007 51 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK PARTS SBD30-150/199NE State Water Heaters Ashland City, Tennessee © 2007 52 Technical Training Department
SBN71-120 thru SBN85-390, SBD30-150/199 TANK TYPE COMMERCIAL GAS WATER HEATER SERVICE HANDBOOK PARTS SBD30-150/199NE State Water Heaters Ashland City, Tennessee © 2007 53 Technical Training Department
Prepared by the State Water Heaters Training Department. For additional technical information call 800-365-0577. State Water Heaters COMMERCIAL ©Copyright 2007 State Industries, Inc. 500 Tennessee Waltz Parkway Ashland City, TN 37015 800-365-8170 www.statewaterheaters.