Table of Contents
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Service Handbook
COMMERCIAL GAS HIGH EFFICIENCY WATER HEATERS
MODELS: SUF 60 thru 120
SUF 100 thru 250
SUF 130 thru 500
SERIES 100, 101 and 104.
500 Tennessee Waltz Parkway
Ashland City, TN 37015
SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN
PRINTED IN THE U.S.A. 1012
198152-004
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Table of Contents
Related Manuals for State Water Heaters SUF60
Summary of Contents for State Water Heaters SUF60
- Page 1 Service Handbook COMMERCIAL GAS HIGH EFFICIENCY WATER HEATERS MODELS: SUF 60 thru 120 SUF 100 thru 250 SUF 130 thru 500 SERIES 100, 101 and 104. 500 Tennessee Waltz Parkway Ashland City, TN 37015 SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN PRINTED IN THE U.S.A.
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Page 3: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ..............2 QUALIFICATIONS . -
Page 4: Introduction
INTRODUCTION The service handbook is designed to aid in servicing and troubleshooting State Water Heaters Ultra Force SUF commercial water heaters in the field. No duplication or reproduction of this book may be made without the express written authorization of the State Water Heaters. -
Page 5: Tools Required
TOOLS REQUIRED • ELECTRICAL MULTIMETER CAPABLE OF MEASURING CONTINUITY/ OHMS, AC & DC VOLTS, AMPERES, MICROAMPERES, MILLIVOLTS, and FREQUENCY (Hz) • UEi Model DL289 or equivalent • DIGITAL MANOMETER + 60" W. C. in .01" increments Note: A digital manometer is required for testing pressure switches and can replace a gas pressure gauge, draft gauge or slack tube manometer for checking gas pressure. -
Page 6: General Information
GENERAL INFORMATION INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:... - Page 7 GAS SUPPLY SYSTEMS Low pressure building gas supply systems are defined as those systems that cannot under any circumstances exceed 14” W.C. (1/2 PSI Gauge). These systems do not require pressure regulation. Measurements should be taken to insure that gas pressures are stable and fall within the requirements stated on the water heater rating plate.
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Page 8: Installation Quick Tips - Suf 120 And 150: Gas Pressure
INSTALLATION QUICK TIPS – SUF 120 AND 150: GAS PRESSURE ADJUSTMENT PROCEDURE: MANIFOLD GAS PRESSURE SUF 120 AND 150 MODELS Main line gas pressure to the water heater for natural gas should be between a maximum of 10.5" w.c. (2.62 kPa) for natural gas, 14.0"... -
Page 9: Installation Quick Tips - Suf 199 And 250 Gas Pressure
2. “Clock” the meter as in step (2) above. 3. Repeat steps (1) and (2) until the specified input rate is achieved. 4. Turn the manual gas control valve to “OFF”. Replace the pressure regulator cover screw. Remove the pressure gauge or manometer from the manifold pressure tap and replace the set screw in the manifold pressure tap. -
Page 10: Installation Quick Tips - Suf 300, 400, 500 Gas Pressure
INSTALLATION QUICK TIPS – SUF 300, 400, 500 GAS PRESSURE ADJUSTMENT PROCEDURE: MANIFOLD GAS PRESSURE SUF 300, 400, 500 A minimum dynamic gas supply pressure of 5.2" w.c. (1.30 kPa) for Natural Gas and 11" w.c. (2.74 kPa) for Propane (LP) Gas is required before making any adjustment to the gas control pressure regulator. -
Page 11: Installation Quick Tips - Suf 300, 400, 500
INSTALLATION QUICK TIPS – SUF 300, 400, 500 SEE MANUAL FOR COMPLETE INSTALLATION INSTRUCTIONS & DETAILS Servicing should only be performed by a Qualified Service Technician... -
Page 12: Installation - Venting Category And Materials
INSTALLATION – VENTING CATEGORY AND MATERIALS ULTRA FORCE VENTING Category IV • Positive pressure in vent, above atmospheric. • These models will produce excessive condensate in vent. • Vent system must not be combined with any other appliances. • Condensing water heater, thermal efficiency of this product will produce condensate in the vent system, the heater is equipped with provision for draining condensate from vent system. -
Page 13: Venting Tables - Suf 120 - 250
VENTING TABLES – SUF 120 ‑ 250 Maximum equivalent feet of intake and vent pipe using 3" PVC is 50 feet (15.2 m). Equivalent feet must include any 90° elbows (two 45° elbows equal one 90° elbow). Three inch diameter 90° elbows are equivalent to 5' (1.5 m) of pipe. -
Page 14: Concentric Venting
CONCENTRIC VENTING Concentric venting allows for a single wall penetration. For multiple water heater installation using this vent practice, any additional vents of this type may be located 12" (30.5 cm) on centerline to either side of the first vent or 12" (30.5 cm) on centerline vertically above the first vent. Concentric kits may be extended to a maximum allowable length of 5 feet (152 cm). -
Page 15: Vent Condensation
VENT CONDENSATION 6” PIPE FIELD SUPPLIED 6” x 4” REDUCER FIELD SUPPLIED 4” PIPE FIELD SUPPLIED EXHAUST ELBOW VENT CONNECTION FACTORY INSTALLED VENT (EXHAUST) CONNECTION Failure to properly install the drain line on the condensate elbow will result in a water heater shut down and a “blocked exhaust”... -
Page 16: Venting - All Models - Single Pipe Direct Vent - Using Outside Air Termination Clearances Sidewall Power Vent
VENTING – ALL MODELS – SINGLE PIPE DIRECT VENT – USING OUTSIDE AIR TERMINATION CLEARANCES SIDEWALL POWER VENT POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION F IX E D C LO S E D O P E R A B LE F IX E D C LO S E D... -
Page 17: Venting - All Models - Two Pipe Direct Vent - Using Outside Air Termination Clearances Sidewall Direct Vent
VENTING – ALL MODELS – TWO PIPE DIRECT VENT – USING OUTSIDE AIR TERMINATION CLEARANCES SIDEWALL DIRECT VENT DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION F IX E D C LO S E D O P E R A B LE F IX E D C LO S E D... -
Page 18: Vent Termination - Direct Vent - All Models
VENT TERMINATION – DIRECT VENT – ALL MODELS WHEN LOCATING THE TERMINALS ON A SIDEWALL, THE FOLLOWING SPECIFICATIONS PERTAINING TO TERMINAL LOCATION MUST BE FOLLOWED. 1. The intake vent terminal and the exhaust vent terminal must terminate on the same exterior wall and must be located at a minimum of 24"... -
Page 19: Direct Venting - All Models
DIRECT VENTING – ALL MODELS The air intake provided on the unit contains an air intake screen to prevent large particles from entering the unit. WHEN THE UNIT IS TO BE SET UP AS A DIRECT VENT, THE BALANCE PLATE AND AIR INTAKE SCREEN MUST BE REMOVED BEFORE GLUING PIPE TO THE CONNECTOR. -
Page 20: Control Overview
CONTROL OVERVIEW Interaction with the water heater controller is through an LCD display called the User Interface Module (UIM). This screen is also referred to as the “desktop” or “desktop menu”. Up and down buttons and three operation buttons allow navigation through the control menus and to make adjustments to the water heater. - Page 21 The table of status icons describes graphically operational details of the water heater. Below is a legend of all the status icons: Status Icon Description The temperature of the water in the tank has fallen and the water heater will now initialize a new heating cycle. The temperature of the water in the tank has reached the Operating Set Point.
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Page 22: Adjusting Tank Temperature - Operating Set Point - Differential
ADJUSTING TANK TEMPERATURE – OPERATING SET POINT – DIFFERENTIAL The Operating Set Point of this water heater determines the regulated temperature for the water in the tank. This parameter is adjusted in the desktop Temperature menu. Items in this menu allow you to monitor different temperature readings in the tank along with adjusting the Operating Set Point and Differential. - Page 23 ACTION: Press Change then use the UP and DOWN buttons to change the Operating Set Point. DISPLAY: Note: This procedure can also be used to change the Differential. The Tank Upper and Lower Temperatures are not user changeable. They are determined by the temperature probes on the heater. ACTION: Press Update to accept the change or Cancel to reset it.
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Page 24: Changing The Display Units
CHANGING THE DISPLAY UNITS The desktop menu Display Settings has the option of selecting between degrees Fahrenheit and degrees Celsius for temperature displays. This can be found in the “Display Settings” menu. Also in this menu, you may adjust how the back-light operates and the contrast of the LCD screen. ACTION: From the Main Menu, press the DOWN button to highlight “Display Settings”... - Page 25 ACTION: Press Update to accept the change or Cancel to reject it. DISPLAY: Servicing should only be performed by a Qualified Service Technician...
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Page 26: Fault And Warning Conditions - Advanced Diagnostic Information
FAULT AND WARNING CONDITIONS – ADVANCED DIAGNOSTIC INFORMATION This water heater control has the ability to monitor almost all aspects of the water heater’s operation. In the event of an undesirable or unsafe condition that occurs, the water heater control will detect this condition and determine the appropriate action. -
Page 27: Access To The Current Fault Or Warning
ACCESS TO THE CURRENT FAULT OR WARNING When a fault or warning has been detected by the control it will automatically be displayed on the screen and the back light will blink. If you choose to leave the current fault or warning by pressing the Back key, you can always return to the fault through the display menu. -
Page 28: Fault Codes
FAULT CODES All faults, warnings, and errors are given in plain English text. Some have a Code alpha/numeric value assigned. Please read the full English text and not the alpha/numeric value when calling for assistance. Following is a complete list of all faults, warnings, and errors for this commercial gas control. 0x0D: AC Reversed 0x45: Upper Probe Short 0x46: Lower Probe Short... -
Page 29: Viewing The Fault History - Viewing Information About The Heater
VIEWING THE FAULT HISTORY – VIEWING INFORMATION ABOUT THE HEATER The controller for this water heater will store a history of the most recent ten Fault and Warning conditions that occurred and store them in the Fault History. The information about the fault or warning will include diagnostic information as well as an estimate of how long ago the fault occurred. -
Page 30: Control Sequence (Typical All Models)
CONTROL SEQUENCE (TYPICAL ALL MODELS) TYPICAL SEQUENCE 1. When the control is powered it should display “waiting for connection” and “UIM v2.06”*. The manufacturer and unit model will be next. The next display will include water temperature, temperature setting and heater status. * This number may change as software revisions are made. -
Page 31: Control Sequence Flow Chart
CONTROL SEQUENCE FLOW CHART Servicing should only be performed by a Qualified Service Technician... -
Page 32: Controls - Central Control Board - Ccb
CONTROLS – CENTRAL CONTROL BOARD – CCB The Central Control Board or CCB is contained in the housing shown below. Access to the board and the wiring harness plugs can be accomplished by removing two Phillips screws holding the cover. Remove these screws to release cover... - Page 33 This is the back of the UIM. Servicing should only be performed by a Qualified Service Technician...
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Page 34: Controls - Gas Control Valve Suf 120
CONTROLS – GAS CONTROL VALVE SUF 120 The gas control valve on the SUF 120 has a built-in adjustable pressure regulator. The adjustment screw is accessed by removing the cap screw marked "regulator" in the illustration. Inlet gas pressure may be read at the inlet pressure tap only if the manual shut off valve is in the “ON” position. -
Page 35: Controls - Gas Control Valve Suf 199 And 250
CONTROLS – GAS CONTROL VALVE SUF 199 AND 250 Pressure readings may be taken on the gas control valve by connecting to the pressure ports on the valve. The manifold pressure on this valve is 0" WC (0 kPa) when the water heater is running. Refer to the "Gas Pressure Specifications"... -
Page 36: Controls - Gas Control Valve, Orifice Chart - Suf 300/400 - 100/101
CONTROLS – GAS CONTROL VALVE, ORIFICE CHART ‑ SUF 300/400 ‑ 100/101 The gas control valve has a built-in field adjustable pressure regulator. The gas control valve for the SUF Natural gas model is shown below. This is a 24V. solenoid operated gas control valve. Low Gas Pressure Switch... -
Page 37: Controls - Gas Control Valve, Orifice Chart - Suf 400/500
CONTROLS – GAS CONTROL VALVE, ORIFICE CHART – SUF 400/500 The gas control valve has a built-in field adjustable pressure regulator. The regulator may be adjusted by removing the cap screw. The adjustment screw is underneath. The gas control valve for the SUF 500 Natural gas model is shown below. -
Page 38: Controls - Pressure Switches - All Models
CONTROLS – PRESSURE SWITCHES – ALL MODELS All SUF models are provided with four pressure switches. These switches are essential to the safe and proper operation of the unit. The switches are wired to the central control board (CCB) individually and each is monitored individually. -
Page 39: Controls - Pressure Switches - Suf 120 Through 250
CONTROLS – PRESSURE SWITCHES – SUF 120 THROUGH 250 Note: Check the website www.statewaterheaters.com for Technical Bulletin S023-06 “Air Pressure Switches” under “Literature/Service Handbooks” Servicing should only be performed by a Qualified Service Technician... -
Page 40: Controls - Pressure Switches - Suf 300, 400, 500
CONTROLS – PRESSURE SWITCHES – SUF 300, 400, 500 Note: Check the website www.statewaterheaters.com for Technical Bulletin S023-06 “Air Pressure Switches” under “Literature/Service Handbooks” Servicing should only be performed by a Qualified Service Technician... -
Page 41: Controls - Connections, Igniter, Flame Sensor, Sight Glass, Powered Anodes
CONTROLS – CONNECTIONS, IGNITER, FLAME SENSOR, SIGHT GLASS, POWERED ANODES The connections for the hot surface igniter and the flame sensor are shown below. Also shown is the burner sight glass. These features are typical for all models. Flame Sensor Hot Surface Igniter Mounting Bolts... -
Page 42: Hot Surface Igniter / Flame Sensor / Control Timing
HOT SURFACE IGNITER / FLAME SENSOR / CONTROL TIMING HOT SURFACE IGNITER This water heater is equipped with an electric hot surface igniter. The igniter material is silicone carbide and should not be handled with bare hands because of possible damage to the igniter. The normal ohm reading at 77 °F (25 °F) is listed between 40 and 70 ohms. -
Page 43: Blower Speed Control Suf 199 And 250
BLOWER SPEED CONTROL SUF 199 AND 250 The input of the SUF 199 and SUF 250 is determined by blower. The input of the water heater may be determined by clocking the meter as shown on Page 5 or by making sure the blower is receiving the proper signal. -
Page 44: Variable Frequency Drive - Suf 400 And 500
VARIABLE FREQUENCY DRIVE – SUF 400 AND 500 The Ultra Force SUF 400 and 500 models have a variable frequency drive (VFD) that controls the rpm of the blower motor. The VFD receives a signal from the central control board that instructs the VFD to transmit the proper frequency to the blower to produce the proper blower speed and proper input. -
Page 45: Variable Frequency Drive - Blower Speed And Pressure Readings
VARIABLE FREQUENCY DRIVE – BLOWER SPEED AND PRESSURE READINGS The instructions for the VFD are sent from the CCB in the form of a DC current. The chart below lists the current readings, the frequency signal displayed by the VFD, and the pressure switch settings needed for the CCB to let the burner operate. -
Page 46: Wiring Diagram - Suf 120 - 300
WIRING DIAGRAM – SUF 120 ‑ 300 LOW GAS 24 VAC BLOCKED BLOCKED BLOWER PRESSURE SWITCH GAS VALVE AIR INTAKE PROVER EXHAUST ENABLE/DISABLE CIRCUIT JUMPER WIRE BETWEEN PINS 8 AND 11 ON J6 PLUG HOT SURFACE IGNITER 1 BLACK 2 WHITE FLAME SENSOR 1 RED (ECO) 2 BLACK... -
Page 47: Wiring Diagram - Suf 400, 500
WIRING DIAGRAM – SUF 400, 500 LOW GAS 24 VAC BLOCKED BLOWER BLOCKED PRESSURE SWITCH GAS VALVE INTAKE AIR PROVER EXHAUST ENABLE/DISABLE CIRCUIT JUMPER WIRE BETWEEN PINS 8 AND 11 ON J6 PLUG HOT SURFACE IGNITER 1 BLACK 2 WHITE FLAME SENSOR 1 RED (ECO) 2 BLACK... - Page 48 COMMERCIAL GAS HIGH EFFICIENCY WATER HEATERS 500 Tennessee Waltz Parkway Ashland City, TN 37015 Technical Support: 800-365-8170 • Parts: 800-821-2017 www.statewaterheaters.com Copyright © 2012 State Industries, Inc., All rights reserved.