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Service Handbook
COMMERCIAL GAS HIGH EFFICIENCY WATER HEATERS
FOR MODELS:
SUF 60120 THRU SUF 100250
SUF 119300 THRU SUF 119500
SERIES 300/301
500 Tennessee Waltz Parkway
Ashland City, TN 37015
INSTALLATION CONSIDERATIONS - PRE SERVICE CHECKS -
CONSTRUCTION - OPERATION & SERVICE - TROUBLESHOOTING
SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN
PRINTED 0217
100234735
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Table of Contents
Related Manuals for State Water Heaters SUF 119300
Summary of Contents for State Water Heaters SUF 119300
- Page 1 Service Handbook COMMERCIAL GAS HIGH EFFICIENCY WATER HEATERS FOR MODELS: SUF 60120 THRU SUF 100250 SUF 119300 THRU SUF 119500 SERIES 300/301 500 Tennessee Waltz Parkway Ashland City, TN 37015 INSTALLATION CONSIDERATIONS - PRE SERVICE CHECKS - CONSTRUCTION - OPERATION & SERVICE - TROUBLESHOOTING...
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Page 2: Table Of Contents
INSTRUCTIONS ...................41 Continuity Test During Operation ..........14 SPARK IGNITER ..................42 Pressure Test During Operation ..........14 GAS ORIFICE - SUF 119300 - 119500 MODELS ........44 Pressure Switch Settings ............15 Orifice Chart - SUF 119300 - 119500 Models ........44 2. Ignition Failure ................16 CCB (CENTRAL CONTROL BOARD) ..........45... -
Page 3: Introduction
INTRODUCTION This Service Handbook covers the water heater Model and Series numbers listed on the front cover only. The instructions and illustrations contained in this service handbook will provide you with troubleshooting procedures to verify proper operation and diagnose and repair common service problems. QUALIFICATIONS QUALIFIED INSTALLER OR SERVICE AGENCY Installation and service of this water heater requires ability equivalent to that of a Qualified Agency (as defined... -
Page 4: Installation Considerations
INSTALLATION CONSIDERATIONS This section of the Service Handbook covers some of the critical installation requirements that, when overlooked, often result in operational problems, down time and needless parts replacement. Costs to correct installation errors are not covered under the limited warranty. Ensure all installation requirements and instructions contained in the Instruction Manual that came with the water heater have been followed prior to performing any service procedures. -
Page 5: Features And Components
Blower Gasket Venturi Burner Sight Glass Sight Glass Gasket Burner Plate Burner Plate Gasket Pyrolite SS Heat Shield Insulation Disk Insulation Spacers SS Bolts & Washers SUF 119300 - 119500 Models Servicing should only be performed by a Qualified Service Technician... -
Page 6: Top View: Suf 60120 - 100250 Models
CCB Assembly Blocked Exhaust Switch (Label Color: Red) Exhaust/ Condensate Elbow Water Outlet 1 - 1/2” NPT Upper Temperature Probe TOP VIEW: SUF 119300 - 119500 MODELS Junction Box Assembly Burner/ Blower Assembly Ignition Transformer Blocked Air Intake Switch (Label Color: Blue) -
Page 7: Sequence Of Operation Flow Chart
SEQUENCE OF OPERATION FLOW CHART Sequence is shown with Enable/Disable Switch in the Enable position If tank temperature drops below Operating Set Point minus Differential setting a heating cycle is activated Control System performs diagnostic checks Normal State of all pressure switches and ECO are checked Control System Locks Out Displays Fault Msg Pressure switches and ECO are verified closed... -
Page 8: Fault And Alert Codes
Gas Control Valve open. **For SUF 119300-119500 natural gas models a low gas pressure kit is available for gas pressure down to 3.5" W.C.. Contact your local distributor or call the parts department phone listed on the back cover of this manual for more information. -
Page 9: Gas Supply Systems
Natural Gas SUF 60120-100250 models require a minimum gas supply pressure of 3.5" W.C., SUF 119300-119500 natural gas models require 4.8" W.C., and all models require 8.5" W.C. for propane gas. The minimum supply pressure is measured while gas is flowing (dynamic pressure) along with all additional gas appliances operating on the same gas supply system. -
Page 10: Gas Pressure Test
GAS CONTROL VALVE COMBUSTION BLOWER CONNECTION COMBUSTION AIR INLET MANIFOLD GAS SUPPLY GAS VENTURI PRESSURE PRESSURE TEST PORT TEST PORT SUF 60120 - 100250 Models SUF 119300 - 119500 Models Servicing should only be performed by a Qualified Service Technician... - Page 11 7. Record the supply gas pressure. 8. Use the Enable/Disable Switch located on the front of the water heater and put the unit in enabled mode. The settings on the water heater may need to be changed to cause the water heater to operate. Note the Operating Temperature Set Point so that the unit can be returned to this setting at the conclusion of this test procedure.
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Page 12: Pressure Switches
PRESSURE SWITCHES The water heaters covered in this Service Handbook are factory equipped with three pressure switches (including the Low Gas Pressure Switch). "Top View" Figures on Page 6 shows the location of the two pressures switches on top of the water heater. This section of the Service Handbook covers pressure switch construction, operation and the test procedures used to diagnose operational problems associated with pressure switches. -
Page 13: Pressure Switch Tests
PRESSURE SWITCH TESTS Complete pressure switch testing involves three procedures: • "Continuity Test During Standby" below. • "Continuity Test During Operation" on Page 14. • "Pressure Test During Operation" on Page 14 thru Page 15. CONTINUITY TEST DURING STANDBY This test is performed while the Combustion Blower is not running with the water heater turned off. This is a "normal state"... -
Page 14: Continuity Test During Operation
CONTINUITY TEST DURING OPERATION This test is performed while the Combustion Blower is running at high speed during the Pre-Purge operating state. The test is performed on all three pressure switches. Disconnect the two wires to each pressure switch - one at a time, check continuity and then reconnect the wires to that switch before testing the next switch. 1. -
Page 15: Pressure Switch Settings
3.1" W.C. Nat/8.5" W.C. LP SUF 100150-100250 -2.50" W.C. 2.00" W.C. 3.1" W.C. Nat/8.5" W.C. LP SUF 119300-119500 -2.30" W.C. 2.00" W.C. 4.8" W.C. Nat/8.5" W.C. LP Pressure Test: 1. Turn off the circuit breaker that serves the water heater. -
Page 16: Ignition Failure
2. IGNITION FAILURE CAUSES: Ignition Failure • On an “Ignition Failure” error, either the burner is 0 days 0 hrs 0 mins ago not igniting or the burner is igniting, but the Flame Error Code: 2-70 Sensor is not detecting ignition (flame). Flame not detected. - Page 17 GAS CONTROL VALVE ASSEMBLY: SUF 60120 - 100250 MODELS SUPPLY GAS CONNECTION LOW GAS PRESSURE SWITCH 24 VAC SOLENOID & WIRE HARNESS GAS CONTROL VALVE ASSEMBLY: SUF 119300 - 119500 MODELS Servicing should only be performed by a Qualified Service Technician...
- Page 18 • Remove and reinsert the circuit board end of the Gas Control Valve connector. Make sure it is connected tightly and that the pins are clean. • Recycle unit again to start another ignition cycle. If you still do not see a brief blue flame through the sight glass at the moment the Gas Control Valve icon appears on the display, verify that 24 VDC is present on the connector pins 1 and 5.
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Page 19: Blocked Air Intake
3. BLOCKED AIR INTAKE CAUSES: locked ntake • The Blocked Air Intake Switch has detected a 0 days 0 hrs 0 mins ago possible restriction in the air intake pipe. 7-1201 Error Code: Restriction in air intake. Check intake pipe and termination for blockage. -
Page 20: Blocked Exhaust
4. BLOCKED EXHAUST CAUSES: locked xhaust • The Blocked Exhaust Switch has detected a possible restriction in the exhaust pipe. 0 days 0 hrs 0 mins ago Error Code: 8-1201 Restriction in exhaust pipe. Check exhaust pipe and termination for blockage. Press the Advanced button for BACK ADVANCED... -
Page 21: Flame Sensor Error
5. FLAME SENSOR ERROR CAUSES: lame Sensor(error) • The Flame Sensor has detected flame when the 0 days 0 hrs 1 mins ago Gas Control Valve is supposed to be off. Error Code: 9-17 Flame Sensor rod detected flame when gas valve should be off. Shut off gas until repaired. -
Page 22: Gas Control Valve Voltage Tests
SWITCH 24 VAC SOLENOID & WIRE HARNESS GAS CONTROL VALVE ASSEMBLY: SUF 119300 - 119500 MODELS GAS CONTROL VALVE VOLTAGE TESTS 1. The animated Gas Control Valve Status Icon is displayed on the Control System UIM during these operating states. See "(UIM) User Interface Module Screen" Figure on Page 51. Check for 24 VAC supplied to the 24 Volt Gas Control Valve at pins 11 and 12 of the J14 Plug on the CCB, see "CCB Cover... -
Page 23: Flame Sensor
FLAME SENSOR Ignition of the Burner is controlled electronically. The principle of operation for electronic ignition relies on flame sensing current to prove the fuel gas flowing to the Burner has been ignited. Flame sensing requires an adequate earth ground to the water heater's Burner, see "Electrical Connections –... -
Page 24: Flame Sensing Current Test
FLAME SENSING CURRENT TEST During the heating cycle the flame sensing current is normally greater than 8.0 μA with a clean Flame Sensor. Over time the Flame Sensor can degrade and this will reduce flame sensing current. With heavier use, more heating cycles/greater load, this will occur more quickly. -
Page 25: No Water
6. NO WATER CAUSES: No Water • The controller has not detected a voltage potential 0 days 0 hrs 0 mins ago of water in the tank. Error Code: D6-8 • No water or low water in tank. No water detected by Powered •... - Page 26 CLEANING METHOD: If corrosion is present on the air side of the anode, use a wire brush to clean the outer nut and brass wire terminal tab. To clean the inner nut, remove the outer nut and the brass wire terminal tab. DO NOT REMOVE inner nut.
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Page 27: Anode Shorted
7. ANODE SHORTED CAUSES: Anode horted • The controller has detected a low resistance or 0 days 0 hrs 0 mins ago short to earth ground or the tank. Error Code: CC-B The Powered Anode is shorted to earth ground or the tank. The control indicates a problem with the anode ADVANCED... -
Page 28: Temperature Probe Short (Upper Or Lower)
8. TEMPERATURE PROBE SHORT (UPPER OR LOWER) Upper Temp Probe (Short) CAUSES: • The Upper or Lower Temperature Probe appears 0 days 0 hrs 0 mins ago to be shorted (very low resistance). This fault code Error Code: 45- 0 often means the connector has been corroded by The indicated temperature Probe cleaning chemicals or other substances. -
Page 29: Temperature Sensor Test
If the resistance of the Temperature Sensor is below 390 ohms the Control System will lock out and display Temp Probe Short on the UIM. If the resistance of the temperature sensor is above 56,000 ohms the Control System will lock out and display Temp Probe Open on the UIM. The electrical circuit breaker that serves the water heater must be turned off and on again to reset the Control System. - Page 30 Results/Actions • If the ohm meter shows continuity (closed circuit) between the two outside pins (red wires/Pins 2 & 3) the ECO switch has reset properly. If the Control System continues to lock out displaying Energy Cut Out (ECO) on the UIM with continuity through the ECO present call the toll free support phone number listed on the back cover of this manual for further assistance.
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Page 31: Temperature Probe Open (Upper Or Lower)
9. TEMPERATURE PROBE OPEN (UPPER OR LOWER) CAUSES: Lower Temp Probe (Open) • The Upper or Lower Temperature Probe appears 0 days 0 hrs 0 mins ago to be open (very high resistance). This fault code Error Code: 48- 0 often means the connector has been corroded by cleaning chemicals or other substances. -
Page 32: Venting
VENTING This section of the Service Handbook is not a complete venting installation instruction. Refer to the Instruction Manual that came with the water heater; ensure the venting has been installed per all Instruction Manual requirements. Costs to correct installation errors are not covered under the limited warranty. GENERAL VENTING INFORMATION The water heaters covered in this Service Handbook are Category IV appliances and may be installed in either a Power Vent or Direct Vent configuration. -
Page 33: Intake Air Connection
INTAKE AIR CONNECTION DETAIL INTAKE AIR CONNECTION DETAIL SUF 60120 - 100250 Models SUF 119300 - 119500 Models AIR INTAKE SCREEN Service Notes: • Plastic debris left on the edges of intake air pipe sections after cutting must be removed on Direct Vent installations. -
Page 34: Electrical Connections - All Models
ELECTRICAL CONNECTIONS – ALL MODELS The water heaters covered in this Service Handbook require a 120 VAC, 1Ø (single phase), 60Hz, 15 amp power supply and must also be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70 or the Canadian Electrical Code, CSA C22.1. -
Page 35: Enable/ Disable Switch
5. Connect the ground wire from the power supply to the grounding lug inside the junction box. See Junction Box Assembly Figure below and "Wiring Diagram" on Page 50. 6. Replace junction box cover when connections are complete. Note: Do not apply power to the water heater before installation is complete and the water heater is filled with water. -
Page 36: Installation Check List
INSTALLATION CHECK LIST The list below represents some of the most critical installation requirements that, when overlooked, often result in operational problems, down time and needless parts replacement. Before performing any troubleshooting procedures use the list below to check for installation errors. Costs to correct installation errors are not covered under the limited warranty. -
Page 37: Operation And Service
OPERATION AND SERVICE HOW IT WORKS This section of the Service Handbook will cover operation, common service procedures and water heater construction. The water heater covered in this Service Handbook has a helical shaped coil heat exchanger that is submerged in the storage tank. These water heaters use a top mounted down fired radial design Burner. - Page 38 COMBUSTION BLOWER ASSEMBLY (SUF 60120 - 100250 MODELS) 5 PIN BLOWER WIRING HOUSING SOCKET BLOWER MOTOR AND ELECTRONIC SPEED CONTROL 3 PIN WIRING SOCKET COMBUSTION BLOWER ASSEMBLY (SUF 119300-119500 MODELS) Servicing should only be performed by a Qualified Service Technician...
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Page 39: Blower Speed Control
3000 5185 90°F SUF 100199 6480-7920 6880 2725 3000 5185 90°F SUF 100250 8145-9955 8700 2725 3000 5185 90°F SUF 119300 3105-3795 3450 2350 4500 3450 80°F SUF 119400 4163-5088 4625 2350 4500 3450 80°F SUF 119500 5220-6380 5750 2350... -
Page 40: Burner Assembly
See the exploded view of the "Combustion Blower & Burner Assembly" section on Page 5 also. SUF 60120 - 100250 Models SUF 119300 - 119500 Models Servicing should only be performed by a Qualified Service Technician... -
Page 41: Combustion Blower And Burner Removal/ Installation Instructions
11. Using a socket wrench with a ½” deep well socket remove the four (SUF 60120), six (SUF 100150-100250), or seven (SUF 119300-119500) ½” nuts from the studs holding the burner plate in place. 12. Slide the three burner ground wire eyelet connectors up and off of the studs. -
Page 42: Spark Igniter
SPARK IGNITER The water heaters covered in this Service Handbook use a Spark Igniter. The Spark Igniter has two rods: the sparking rod that has ceramic insulation and the grounding rod, see Figure below. During trial for ignition, the Control System powers a high voltage transformer (Ignition Control) from J6, and the Ignition Control supplies high voltage to the sparking rod via the ignition cable. - Page 43 (13/16" Gap from Burner at the tip of Sensor Rod) SUF 119300 - 119500 Models The Control System is programmed to start sparking a few seconds before the Gas Control Valve opens. See the "Sequence Of Operation Flow Chart" on Page 7.
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Page 44: Gas Orifice - Suf 119300 - 119500 Models
GAS ORIFICE - SUF 119300 - 119500 MODELS Refer to Orifice Chart below for correct gas orifice size. SUF 60120 - 100250 Models and all Natural gas models do not use a factory installed gas orifice. w/LP Gas Orifice Without Orifice... -
Page 45: Ccb (Central Control Board)
CCB (CENTRAL CONTROL BOARD) The CCB is a printed circuit board mounted inside a protective plastic enclosure, see Figures below and on next page. The CCB circuit board is the main control. All instructions for ignition and temperature control originate from this circuit board. Diagnostic and operational messages are generated by the CCB and sent to the UIM, see "(UIM) User Interface Module Screen"... -
Page 46: Ccb Cover Removal And Replacement
CCB COVER REMOVAL AND REPLACEMENT The cover on the CCB enclosure must be removed for various service procedures outlined in this Service Handbook. Refer to the instructions below when removing and replacing the CCB cover. Wiring to and from the CCB and other water heater components enters the CCB enclosure on the bottom. Removing the enclosure cover is a simple procedure. -
Page 47: Ccb Circuit Board Layout
CCB CIRCUIT BOARD LAYOUT CCB (CENTRAL CONTROL BOARD) POWER BOARD ASSEMBLY Servicing should only be performed by a Qualified Service Technician... -
Page 48: Ccb Connection Identification
CCB CONNECTION IDENTIFICATION J1 Socket - High Voltage In PIN # DESCRIPTION Ground AUX NC AUX NO AUX Common Not Used AUX NO AUX Common Line Voltage Neutral J3 Socket - UIM Pin # DESCRIPTION AIN Reset Data + Data - D Grd J5 Socket - Blower Logic PIN #... - Page 49 J14 Socket - Limit String PIN # DESCRIPTION Anode Grounding Flame Sensor Condensate Not Used Condensate Gas Pressure Switch Gas Pressure Switch Gas Control Valve Gas Control Valve 24V Return J15 Socket - Pressure Switches PIN # DESCRIPTION Blocked Air Intake Pressure Switch Blocked Air Intake Pressure Switch / Blocked Exhaust Pressure Switch Not Used Blocked Exhaust Pressure Switch...
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Page 50: Wiring Diagram - Suf 60120 - 119500
WIRING DIAGRAM – SUF 60120 - 119500 Servicing should only be performed by a Qualified Service Technician... -
Page 51: Control Overview
CONTROL OVERVIEW Interaction with the water heater controller is through an UIM Touch Display called the User Interface Module (UIM). This screen is also referred to as the “desktop” or “desktop menu”. While the water heater is operating, the user interface will display the UIM screen (if there are no active faults or warnings). -
Page 52: Icomm
ICOMM (SUF 119300 - 119500 MODELS) Remote Monitoring System SOLID STATE This water heater is equipped with iCOMM connectivity hardware. iCOMM allows users to actively connect and manager a single water heater or a fleet of water heaters right from the convenience of a tablet or smart phone without annual fees or subscriptions. -
Page 53: Notes
NOTES... - Page 54 NOTES For additional information contact: State Water Heaters 500 Tennessee Waltz Parkway Ashland City, TN 37015 Tech Support: 800-365-0024 Parts: 800-821-2017 www.statewaterheaters.com Copyright © 2017 State Water Heaters, All rights reserved.
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