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Table of Contents
Related Manuals for State Water Heaters Utra-Force STC-077
Summary of Contents for State Water Heaters Utra-Force STC-077
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Page 2: Table Of Contents
SUF Service Handbook TABLE OF CONTENTS Introduction ....2 Installation Clearances ..... 3 Gas Requirements . -
Page 3: Introduction
S U F This service handbook is designed to aid in servicing and troubleshooting State SUF 150, 199 and 240 water heaters. No duplication or reproduction of this book may be made without the express written authorization of the State Water Heaters Company. -
Page 4: Installation
S U F This portion of the handbook will review often overlooked installation require- ments. The installation manual covers these items in detail. SUF water heaters are approved for installation on com- bustible flooring. The minimum clear- ance to combustibles or non- combustibles is 0 inches from the sides and rear, 0 inches from vent piping, and 1.5 inches from the top cover. -
Page 5: Venting
S U F Equivalent Feet of Pipe Intake or Exhaust NUMBER OF 90° ELBOWS ONE (1) TWO (2) THREE (3) FOUR (4) FIVE (5) SIX (6) 4-inch PVC may be used for a MAXIMUM intake of ONE HUNDRED TWENTY (120) EQUIVALENT FEET and a MAXIMUM exhaust of ONE HUNDRED TWENTY (120) EQUIVALENT FEET. - Page 6 S U F SEALED DIRECT SEALED DIRECT VENT SIDEWALL VENT VERTICAL SEALED DIRECT VENT SEALED DIRECT VENT HORIZONTAL INTAKE VERTICAL INTAKE VERTICAL EXHAUST HORIZONTAL EXHAUST This unit can be vented using only PVC (Class 160, ASTM D-2241; Schedule 40, ASTM D-1785; or Cellular Core Schedule 40 DWV, ASTM F-891), Schedule 40 CPVC (ATSM F-411), or ABS (ASTM D-2661) pipe.
- Page 7 S U F S E R V I C E H A N D B O O K I N S T A L L A T I O N CONCENTRIC VENT TERMINATION The concentric vent termination kit, Part No. 9003910005 can be used on SUF 150 – 240 Ultra Force water heaters.
- Page 8 S U F S E R V I C E H A N D B O O K I N S T A L L A T I O N VENTING CLEARANCES This illustrates the exterior clearances for these SUF units when installed as direct vent heaters. N O T E : 24 inches between inlet and outlet is a MINIMUM.
- Page 9 S U F EXTERIOR SIDEWALL CLEARANCES Horizontal Vent (Using Room Air for Combustion) Horizontal Direct Vent (Using Outdoor Air for Combustion) When multiple units are directly vented through a wall, all intake vent terminals must be no lower than the highest exhaust vent terminal. CAUTION DO NOT TERMINATE THE VENTING WHERE NOISE FROM THE EX- HAUST OR INTAKE WILL BE OBJECTIONABLE.
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Page 10: Air Requirements
S U F S E R V I C E H A N D B O O K I N S T A L L A T I O N AIR REQUIREMENTS MINIMUM AIR FOR COMBUSTION 10 Cubic Feet of Air Per 1000 BTUH Stoichiometric or theoretical complete combustion requires 10 cubic feet of air per 1000 BTUH of gas input. - Page 11 S U F A fresh supply of make-up air for combustion can be supplied to the heater through make-up air openings, 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 12 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.
- Page 12 S U F S E R V I C E H A N D B O O K I N S T A L L A T I O N MAKE-UP AIR Horizontal Ducts When the heater is installed in an interior room with no roof access for vertical ducts, horizontal make-up ducts should be installed.
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Page 13: Contaminated Air
S U F S E R V I C E H A N D B O O K I N S T A L L A T I O N CONTAMINATED AIR RUST CHIPS Along with adequate make-up air, the quality of the air is important. Contaminants in combustion air can lead to premature heater failure. -
Page 14: Multiple Unit Piping
S U F MULTIPLE UNIT — WATER PIPING NOTES APPLY TO ALL SYSTEMS: *ADD GATE VALVES TO INLET AND OUTLET OF EACH UNIT FOR ISOLATION FLEXIBILITY. LOCATE AT THE SAME POINT FROM TEE. ** ADD THERMAL EXPANSION TANK TO COLD WATER SUPPLY IF NECESSARY. -
Page 15: Condensation
S U F S E R V I C E H A N D B O O K I N S T A L L A T I O N CONDENSATION The average dewpoint of natural gas flue products is 127° F. Propane flue products is 119° F. With 70°... -
Page 16: Operation
S U F S E R V I C E H A N D B O O K O P E R A T I O N OPERATION SEQUENCE OF OPERATION State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 STC-077... -
Page 17: Controls
S U F NORMAL INDICATIONS / READINGS / SETTINGS • On/Off switch in the “on” position • Water Temperature F° — current average tank water temperature displayed • 120 VAC LED light on • 24 VAC LED light on • High Limit/Vent Switch LED light on •... -
Page 18: Circuit Boards
S U F S E R V I C E H A N D B O O K O P E R A T I O N CIRCUT BOARDS DISPLAY CIRCUIT BOARD IGNITION CIRCUIT BOARD State Water Heaters Technical Training Department Ashland City, Tennessee ©... -
Page 19: Troubleshooting
S U F CHECK THAT: • Insure 120 VAC power supply has correct polarity — check neutral (white) wire to ground with volt meter. It should read “0” volts. • Tank is full of water • Exhaust and intake vent do not exceed allowable limits •... -
Page 20: Transformer
S U F STEP 2 120 VAC TO TRANSFORMER STEP 2: CHECK FOR 120 VAC TO TRANSFORMER FROM PIN 1 AND 2 ON CONTROL BOARD CN4 TERMINAL. Condition: • Disconnect CN4 plug from control board. • On/Off switch is on. Check for 120 VAC between pin 1 and 2 at CN4 on the control board as illustrated above. - Page 21 S U F TRANSFORMER (CONTINUED) STEP 3 24 VAC FROM TRANSFORMER STEP 3: CHECK FOR 24 VAC AT TRANSFORMER CN4 PLUG ON CONTROL BOARD. Condition: • CN4 is plugged into control board. • On/Off switch is on. Insert meter probes into back of CN4 plug on pins 3 and 4 (blue and yellow wires) with CN4 plugged in and power on.
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Page 22: Eco Check
S U F STEP 4 24 VAC TO ECO STEP 4: CHECK FOR 24 VAC BETWEEN PIN 4 ON CONTROL BOARD TERMINAL CN3 AND GROUND. Condition: • Disconnect CN3 plug from control board. • On/Off switch is on. Check for 24 VAC between pin 4 of the CN3 terminal on the control board and ground. IF…... - Page 23 S U F STEP 5 24 VAC FROM ECO STEP 5: CHECK FOR 24 VAC BETWEEN PIN 1 ON CN3 PLUG AND GROUND. Condition: • Reconnect CN3 plug to control board. • On/Off switch is on. Insert one meter probe into the back of CN3 plug pin 1, check for 24 VAC between here and ground with CN3 plugged in and power on.
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Page 24: Temperature Probe
S U F STEP 6 TEMPERATURE PROBE RESISTANCE UPPER TEMPERATURE PROBE PLUG STEP 6: CHECK RESISTANCE OF THERMISTOR IN UPPER AND LOWER TEMPERATURE PROBES. Condition: • Disconnect CN3 and CN8 plugs from control board. • On/Off switch is off. • Multimeter is set to lowest ohms scale above expected resistance. Check resistance between black wire connects on CN3 and CN8 plugs as shown in illustration above. -
Page 25: Pressure Switch Continuity
S U F PRESSURE SWITCH CONTINUITY STEP 7 PRESSURE SWITCH CONTINUITY TEST STEP 7: CHECK FOR CONTINUITY BETWEEN PRESSURE SWITCH TERMINALS WITH WIRES REMOVED. Condition: • On/Off switch is off. • All wires are disconnected from all pressure switches. • Multimeter is set to lowest ohms scale. IF…... -
Page 26: Blower
S U F STEP 8 120 VAC TO BLOWER STEP 8: CHECK FOR 120 VAC TO BLOWER FROM CN2 PLUG PIN 1 AND 2. Condition: • Reconnect all plugs to control board. • On/Off switch is on. • Call for heat is activated. Insert meter probes into back of CN2 plug on pins 1 and 2 with CN2 plugged in, power on, and a call for heat activated. -
Page 27: Pressure Switch Performance
S U F PRESSURE SWITCH PERFORMANCE STEP 9A TAKE AIR AND GAS PRESSURE READINGS. Blower prover and blocked outlet pressure STEP 9A: CHECK PRESSURE AT SENSING PORTS ON BURNER, BLOWER INLET AND GAS VALVE. Condition: • All wires are reconnected to all pressure switches. •... - Page 28 S U F PRESSURE SWITCH PERFORMANCE (CONTINUED) STEP 9B PRESSURE SWITCH CONTINUITY TEST — OPERATIONAL Air pressure switches STEP 9B: CHECK FOR CONTINUITY BETWEEN PRESSURE SWITCH TERMINALS WITH WIRES REMOVED AND BLOWER RUNNING. Condition: • All wires are disconnected from all pressure switches — ends are taped off. •...
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Page 29: 120 Vac To Ignitor
S U F STEP 10 120 VAC TO IGNITOR STEP 10: CHECK FOR 120 VAC TO IGNITOR FROM PIN 1 AND 2 ON CONTROL BOARD TERMINAL CN5. Condition: • Disconnect CN5 plug from control board. • On/Off switch is on. •... -
Page 30: Ignitor Resistance
S U F STEP 11 IGNITOR RESISTANCE CHECK STEP 11: CHECK RESISTANCE BETWEEN TWO WIRE CONNECTS AT CN5 IGNITOR PLUG END. Condition: • On/Off switch is off. • Disconnect CN5 ignitor plug from circuit board. • Multimeter is set to lowest ohms scale above 300 ohms. IF…... -
Page 31: Gas Valve Test
S U F STEP 12 24 VAC TO GAS VALVE STEP 12: CHECK FOR 24 VAC TO GAS VALVE DURING TRIAL FOR IGNITION. Condition: • All wires are reconnected. • On/Off switch is on. • Call for heat is activated. •... -
Page 32: Gas Pressure Check
S U F STEP 13 SUPPLY GAS PRESSURE TEST SUF 150, 199 Propane SUF 240 Natural Gas Valve STEP 13: CHECK AND ADJUST SUPPLY GAS PRESSURE. Attach manometer or gas pressure gauge to pressure tap on gas valve or use adapter to check pressure ahead of valve as near as possible to valve. -
Page 33: Component Information
S U F C O M P O N E N T COMPONENT INFORMATION FLAME SENSING ROD PART NUMBER FLAME SENSING CURRENT 192478 HOT SURFACE IGNITOR (HSI) PART NUMBER VOLTAGE 192638 120 VAC MAIN BURNER SUF MODEL ORIFICE NO. 192477-1 192477-0 192477-2 150 Prop... - Page 34 S U F S E R V I C E H A N D B O O K C O M P O N E N T I N F O R M A T I O N PRESSURE SWTCHES State Water Heaters Technical Training Department Ashland City, Tennessee ©...
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Page 35: Pressure Switches
S U F C O M P O N E N T PRESSURE SWITCHES (CONTINUED) Model Blocked Inlet Normally Closed Opens on a fall SUF 150 193363-000 / -0.76” 193355-000 / -1.80” 193355-000 / -1.80” SUF 199 193363-000 / -0.76” 193356-000 / -2.00”... -
Page 36: Wiring Diagrams
S U F S E R V I C E H A N D B O O K W I R I N G D I A G R A M S WIRING DIAGRAMS State Water Heaters Technical Training Department Ashland City, Tennessee ©... -
Page 37: Service Aids
S U F 1. This type product is polarity sensitive. Be certain that your electrical supply wire neutral has no voltage. 2. This unit will produce condensation — quite heavily at times. The outlet drain hose must be allowed to drain. Exhaust Vent piping must also drain condensate. Code 11 error would imply that these must be checked. -
Page 38: Suf Muffler
S U F N O T E S : 1. Install muffler in vertical position only. 2. Muffler must be a minimum of 8” from top of condensate elbow. 3. The muffler inlet and outlet are 4” PVC. If venting with a 4” PVC, a 4” x 4” PVC coupling (field supplied) must be cemented to each end of the muffler. -
Page 39: Questions & Answers
S U F Q U E S T I O N S QUESTIONS AND ANSWERS Q. How much electrical power is required for a SUF water heater? A. The SUF models draw approximately 5.0 Amps Max. Q. When should SUF’s be delimed? A. -
Page 40: Error Codes
S U F CODE INDICATION This is normal operation, 00 is displayed each time the heater is powered up. Indicates the pressure switch circuit was not open during the prediagnostic system check when the proper state of the Draft Prover Switches are verified. The Blower Prover Switch is normally open, the circuit should therefore be open during the prediagnostic system check at the beginning of each cycle. -
Page 41: Service Checklist
This is not intended to be and all-inclusive list of the problem 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: TYPE —... -
Page 42: Parts Lists Models 100 - 150, 100 - 199, And 100 - 240
970 & 973 Series S TC- 077 S U F S E R V I C E H A N D B O O K P A R T S L I S T SUF SERVICE HANDBOOK PARTS LIST SUF MODELS 100 – 150, 100 – 199 AND 100 – 240 STATE WATER HEATERS 500 LINDHAL PARKWAY, ASHLAND CITY, TN 37015 PHONE: 1-800-821-2017 •... - Page 43 ULTRA FORCE SUF MODELS REPLACEMENT PARTS ITEM DESCRIPTION 1 Anode 2 *Barb,Hose 3 Blower 4 Board,Display Panel 5 Burner Assembly 6 Clamp, 3 7 Clamp, Hose 8 Clamp,Hose,Nylon 9 Condensate Hose 10 *Direct Vent Kit 11 Elbow, 90 Degree 12 Exhaust Terminal 13 Flame Rod Assembly 14 Flange, Inlet 15 Gasket, C.O...
- Page 44 ULTRA FORCE SUF CONTROLS PARTS LIST ITEM DESCRIPTION 1 Blocked Inlet Switch 2 Blocked Outlet Proving Switch 3 Blower Proving Switch 6 Cable to Control 7 Control Board 8 Display Board 9 E.C.O./Upper Probe 10 Lower Temperature Probe 12 Switch-On/Off 13 Transformer 14 Tubing, Connector 15 Tubing, Pressure...
- Page 45 S U F S E R V I C E H A N D B O O K P A R T S L I S T N O T E S : Technical Training Department State Water Heaters STC-077 Ashland City, Tennessee ©...
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