State Industries SUF 100 THRU 250 manual

MODEL S: SUF 60 thru 120 SUF 100 thru 250 SUF 130 thru 500 SERIES 100, 101 and 104. 500 T ennessee W altz Parkway Ashland City , TN 37015 PRINTED IN THE U . S .A. 051 1 198152-003 SERVICING SHOULD ONL Y BE PERFORMED BY A QUALIFIED SERVICE AGENT Service Handbook COMMERCIAL GAS HIGH EFFICIENCY W A TER HEA TERS[...]

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1 Servicing should only be performed by a Qualied Service Agent T ABLE OF CONTENTS INTRODUCTION ...................................................................... 2 QUALIFICA TIONS ..................................................................... 2 TOOLS REQUIRED .................................................................... 3 GENE[...]

2 Servicing should only be performed by a Qualied Service Agent INTRODUCTION The service handbook is designed to aid in servicing and troubleshooting State W ater 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 W ater Hea[...]

3 Servicing should only be performed by a Qualied Service Agent T OOLS REQUIRED • ELECTRICAL MUL TIMETER CAP ABLE OF MEASURING CONTINUITY/ OHMS, AC & DC VOL TS, AMPERES, MICROAMPERES, MILLIVOL TS, and FREQUENCY (Hz) • UEi Model DL289 or equivalent • DIGIT AL MANOMETER + 60" W . C. in .01" increments Note: A digital manomet[...]

4 Servicing should only be performed by a Qualied Service Agent GENERAL INFORMA TION INST ALLA TION REQUIREMENTS FOR THE COMMONWEAL TH 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 pa[...]

5 Servicing should only be performed by a Qualied Service Agent INST ALLA TION QUICK TIPS – SUF 120 AND 150 GAS PRESSURE ADJUSTMENT PROCEDURE: 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. (2.59 kPa) for natural gas, 14.0" w .c. (3.45 kPa) for[...]

6 Servicing should only be performed by a Qualied Service Agent Compare result to the de‑rated input required for the elevation at the installation location. Should it be necessary to adjust the gas pressure to the burner , to obtain the full input rate, the steps below should be followed: 3. Remove the pressure regulator cover screw and adjus[...]

7 Servicing should only be performed by a Qualied Service Agent INST ALLA TION QUICK TIPS – SUF 199 AND 250 GAS PRESSURE ADJUSTMENT PROCEDURE: GAS PRESSURE SUF 199 AND 250 MODELS IMPORT ANT NOTE THE SUF 199 AND 250 MODELS INCORPORA TE A NEW GAS CONTROL, WHICH OPERA TES A T A MANIFOLD PRESSURE OF 0" w.c. (0 kPa) FOR BOTH NA TURAL AND PROP [...]

8 Servicing should only be performed by a Qualied Service Agent INST ALLA TION QUICK TIPS – SUF 300, 400, 500 GAS PRESSURE ADJUSTMENT PROCEDURE: GAS PRESSURE SUF 300, 400, 500 A minimum dynamic gas supply pressure of 5.2" w.c. (1.29 kPa) for Natural Gas and 1 1" w.c. (2.74 kPa) for LP Gas is required before making any adjustment to t[...]

9 Servicing should only be performed by a Qualied Service Agent INST ALLA TION QUICK TIPS – SUF 300, 400, 500 SEE MANUAL FOR COMPLETE INST ALLA TION INSTRUCTIONS & DET AILS[...]

10 Servicing should only be performed by a Qualied Service Agent INST ALLA TION – VENTING CA TEGOR Y AND MA TERIALS UL TRA FORCE VENTING Category IV • Positive pressure in vent, above atmospheric. • These models will produce excessive condensate in vent. • V ent system must not be combined with any other appliances. • Flue gas temperat[...]

11 Servicing should only be performed by a Qualied Service Agent VENTING T ABLES – 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.[...]

12 Servicing should only be performed by a Qualied Service Agent 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" on centerline to either side of the first vent or 12" on centerline vertically [...]

13 Servicing should only be performed by a Qualied Service Agent VENT CONDENSA TION Failure to properly install the drain line on the condensate elbow will result in a water heater shut down and a “blocked exhaust” fault message. The average dew point of natural gas flue products is 127°F . Propane flue products is 1 19°F . With 70°F ambi[...]

14 Servicing should only be performed by a Qualied Service Agent VENTING – ALL MODELS – SINGLE PIPE DIRECT VENT – USING OUTSIDE AIR TERMINA TION CLEARANCES SIDEW ALL POWER VENT V X VENT TERMINAL AIR SUPPL Y INLE TA RE A WHERE TERMINAL IS NO T PERMITTED v v A G V FIXED CLOSED FIXED CLOSED OPERABLE OPERABLE V C B B B B F B V V A J V H M X X [...]

15 Servicing should only be performed by a Qualied Service Agent VENTING – ALL MODELS – TWO PIPE DIRECT VENT – USING OUTSIDE AIR TERMINA TION CLEARANCES SIDEW ALL DIRECT VENT V X VENT TERMINAL AIR SUPPL Y INLE TA RE A WHERE TERMINAL IS NO T PERMITTED v v A G V FIXED CLOSED FIXED CLOSED OPERABLE OPERABLE V C B B B B F B V V A J V H M X X V [...]

16 Servicing should only be performed by a Qualied Service Agent VENT TERMINA TION – DIRECT VENT – ALL MODELS WHEN LOCA TING THE TERMINALS ON A SIDEW ALL, THE FOLLOWING SPECIFICA TIONS PERT AINING TO TERMINAL LOCA TION MUST BE FOLLOWED. 1. The intake vent terminal and the exhaust vent terminal must terminate on the same exterior wall and mus[...]

17 Servicing should only be performed by a Qualied Service Agent DIRECT VENTING – ALL MODELS The air intake provided on the unit contains a mesh screen to prevent large particles from entering the unit. WHEN THE UNIT IS TO BE SET UP AS A DIRECT VENT , THE BALANCE PLA TE AND MESH SCREEN MUST BE REMOVED BEFORE GLUING PIPE TO THE CONNECT OR. THE [...]

18 Servicing should only be performed by a Qualied Service Agent CONTROL OVERVIEW Interaction with the water heater controller is through an LCD display called the Universal 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 throug[...]

19 Servicing should only be performed by a Qualied Service Agent 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 tempera[...]

20 Servicing should only be performed by a Qualied Service Agent ADJUSTING T ANK TEMPERA TURE – OPERA TING 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 T emperature menu. Items in this menu allow you to monitor d[...]

21 Servicing should only be performed by a Qualied Service Agent ACTION: Press Change then use the UP and DOWN buttons to change the temperature Set Point. DISPLA Y : Note: This procedure can also be used to change the Differential . The tank Upper and Lower T emperatures are not user changeable. They are determined by the temperature probes on [...]

22 Servicing should only be performed by a Qualied Service Agent CHANGING THE DISPLA Y UNITS The desktop menu 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 [...]

23 Servicing should only be performed by a Qualied Service Agent ACTION: Press Update to accept the change or Cancel to reject it. DISPLA Y :[...]

24 Servicing should only be performed by a Qualied Service Agent F AUL T AND W ARNING CONDITIONS – ADV ANCED DIAGNOSTIC INFORMA TION 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 thi[...]

25 Servicing should only be performed by a Qualied Service Agent ACCESS T O THE CURRENT F AUL T OR W ARNING 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 t[...]

26 Servicing should only be performed by a Qualied Service Agent F AUL T 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 er[...]

27 Servicing should only be performed by a Qualied Service Agent VIEWING THE F AUL T HIST OR Y – VIEWING INFORMA TION ABOUT THE HEA TER The controller for this water heater will store a history of ten of the last Fault and W arning conditions that occurred. This is stored in the Fault History . The information about the fault or warning will i[...]

28 Servicing should only be performed by a Qualied Service Agent 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 s[...]

29 Servicing should only be performed by a Qualied Service Agent CONTROL SEQUENCE FLOW CHART[...]

30 Servicing should only be performed by a Qualied Service Agent 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 The CC[...]

31 Servicing should only be performed by a Qualied Service Agent This is the back of the UIM.[...]

32 Servicing should only be performed by a Qualied Service Agent CONTROLS – GAS V AL VE 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 market regulator in the illustration. Inlet gas pressure may be read at the inlet pressure tap only if the[...]

33 Servicing should only be performed by a Qualied Service Agent CONTROLS – GAS V AL VE SUF 199 AND 250 ADJUSTMENT PROCEDURE: GAS PRESSURE SUF 199 AND 250 MODELS IMPORT ANT NOTE THE SUF 199 AND 250 MODELS INCORPORA TE A NEW GAS CONTROL, WHICH OPERA TES A T A MANIFOLD PRESSURE OF 0" w.c. (0 kPa) FOR BOTH NA TURAL AND PROP ANE GAS. SEE THE [...]

34 Servicing should only be performed by a Qualied Service Agent CONTROLS – GAS V AL VE SUF 199 AND 250 Pressure readings may be taken on the gas 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 chart on page 4. Note: T [...]

35 Servicing should only be performed by a Qualied Service Agent CONTROLS – GAS V AL VE, ORIFICE CHART – SUF 300/400 The gas control valve has a built-in field adjustable pressure regulator . The gas valve for the SUF Natural gas model is shown below . This is a 24V . solenoid operated gas valve. Low Gas Pressure Switch Refer to the replacem[...]

36 Servicing should only be performed by a Qualied Service Agent CONTROLS – GAS V AL VE, ORIFICE CHART – SUF 500 The gas control valve has a built-in field adjustable pressure regulator . The regulator may be adjusted by removing the cap screw marked “regulator”. The adjustment screw is underneath. The gas valve for the SUF 500 Natural g[...]

37 Servicing should only be performed by a Qualied Service Agent 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 individuall[...]

38 Servicing should only be performed by a Qualied Service Agent CONTROLS – PRESSURE SWITCHES – SUF 120 THROUGH 250 Note: Check the website www .statewaterheaters.com for T echnical Bulletin S023-06 “Air Pressure Switches” under “Literature/Service Handbooks”[...]

39 Servicing should only be performed by a Qualied Service Agent CONTROLS – PRESSURE SWITCHES – SUF 300, 400, 500 Note: Check the website www .statewaterheaters.com for T echnical Bulletin S023-06 “Air Pressure Switches” under “Literature/Service Handbooks”[...]

40 Servicing should only be performed by a Qualied Service Agent CONTROLS – CONNECTIONS, IGNITER, FLAME SENSOR, SIGHT GLASS, POWERED ANODES The connections for the hot surface igniter and the flame sense rod are shown below . Also shown is the burner sight glass. These features are typical for all models. Flame Sensor Hot Surface Igniter Mount[...]

41 Servicing should only be performed by a Qualied Service Agent HOT SURF ACE IGNITER / FLAME SENSOR / CONTROL TIMING HOT SURF ACE 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 o[...]

42 Servicing should only be performed by a Qualied Service Agent 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. The blower rpm is controlled by [...]

43 Servicing should only be performed by a Qualied Service Agent V ARIABLE 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[...]

44 Servicing should only be performed by a Qualied Service Agent V ARIABLE FREQUENCY DRIVE – BLOWER SPEED AND PRESSURE READINGS The instructions for the VFD are sent from the CCB to 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[...]

45 Servicing should only be performed by a Qualied Service Agent WIRING DIAGRAM – SUF 120 ‑ 300 2 GREEN WHITE RED BLACK 1 1 2 BLACK 3 WHITE COMBUSTION BLOWER U PPER TEMPERATURE PROB E 1 RED (ECO) 4 RED (ECO) 2 BLACK 3 BLACK 1 BLACK120 VAC HOT 3 WHITE 120 VAC NEUTRAL 4 YEL 24 VAC 4 YEL 24 VAC LOWER TEMPERATURE PROBE HOT SURFACE IGNITER FLAME [...]

46 Servicing should only be performed by a Qualied Service Agent WIRING DIAGRAM – SUF 400, 500 1 2 5 6 WHITE GREEN BLACK BLACK WHITE RED COMBUSTION BLOWER NOTE: COMBUSTION BLOWER MOTORS ON 400,000 & 500,000 Btu/hr MODELS ARE THREE PHASE (3Ø) MOTORS. BLACK, WHITE AND RED WIRES MUST BE WIRED AS SHOWN OR THE MOTOR WILL TURN BACKWARDS. THIS M[...]

COMMERCIAL GAS HIGH EFFICIENCY W A TER HEA TERS 47 500 T ennessee Waltz Parkway Ashland City , TN 37015 www .statewaterheaters.com[...]