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State Water Heaters Utra-Force STC-077 manual

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Table of contents for the manual

  • Page 1

    THIS PRINT OUT IS FOR REFERENCE ONL Y! Do not use this printout for color match or critical dimensions. PRINT OUT MADE A T 100% OF FINAL SIZE. THIS FILE HAS NOT BEEN TRAPPED. This file was created with Adobe Illustrator 8.0.1 . DO NOT try to open this file with earlier versions. Marketing Support Inc. assumes no responsibility for final print qu[...]

  • Page 2

    SUF Service Handbook T ABLE OF CONTENT S STC-077 Introduction . . . . . . . . . . . . . . . . . . . 2 Inst allation Clearances . . . . . . . . . . . . . . . . . . . . . 3 Gas Requirements . . . . . . . . . . . . . . . 3 V enting . . . . . . . . . . . . . . . . . . . . . 4 – 8 Air Requirements . . . . . . . . . . . . 9 – 1 1 Contaminated Air . .[...]

  • Page 3

    SUF SERVICE HANDBOOK INTRODUCTION Technical Training Department State Water Heaters STC-077 2 Ashland City, Tennessee © 2004 INTRODUCTION This service handbo ok is designed to aid in servicing a nd troubleshooting S tate SUF 150 , 19 9 and 240 water he ater s. No duplication or reproduction of th is book may be made without the express written aut[...]

  • Page 4

    SUF SERVIC E HANDBOOK INSTALLATION State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 3 STC-077 INST ALLA TION CLEARANCES This portion of the handbook will review often overlooked inst allation require- ments. The inst allation manual covers these items in detail. SUF water heaters are approved for in stallation on co[...]

  • Page 5

    SUF SERVICE HANDBOOK INSTALLATION Technical Training Department State Water Heaters STC-077 4 Ashland City, Tennessee © 2004 VENTING Equivalent Feet of Pi pe Int ake or Exhaust 4-inch PVC may be used for a MAXIMUM intake of ONE HUNDRE D TWENTY (120) EQUIV ALENT FEET and a MAXIMUM exhaust of ONE HUNDRED TWENTY (1 20) EQUIV ALENT FEET . The maximum [...]

  • Page 6

    SUF SERVIC E HANDBOOK INSTALLATION State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 5 STC-077 VENTING CONFIGURA TIONS VENTING MA TERIALS This unit can be vented using onl y PVC (Class 160, AS TM D-2241; Schedule 40 , ASTM D-1785; or Cellular Core Schedule 40 DWV , ASTM F -891), Sche dule 40 CPVC (A TSM F- 41 1), or [...]

  • Page 7

    SUF SERVICE HANDBOOK INSTALLATION Technical Training Department State Water Heaters STC-077 6 Ashland City, Tennessee © 2004 CONCENTRIC VENT TERMINA TION The concentric vent termination kit, Part No. 9003910005 can be used on SUF 150 – 240 Ultra Force water heaters. It adds zero equivalent feet to t he vent system. Below ar e some general appli-[...]

  • Page 8

    SUF SERVIC E HANDBOOK INSTALLATION State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 7 STC-077 VENTING CLEARANCES This illustrates the exterior clea rances for these SUF units when in stalled as direct vent heaters. NOTE: 24 inches between inlet and out let is a MINIMUM. Greater distance is recommended. In colder cli[...]

  • Page 9

    SUF SERVICE HANDBOOK INSTALLATION Technical Training Department State Water Heaters STC-077 8 Ashland City, Tennessee © 2004 EXTERIOR SIDEW ALL CLEARANCES Horizont al V e nt (Using Room Air for Combustion) Horizont al Direct V ent (Usi ng Out door Air for Combustion) When multiple units are directly vented through a wall, all int ake vent terminal[...]

  • Page 10

    SUF SERVIC E HANDBOOK INSTALLATION State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 9 STC-077 AIR REQUIREMENT S MINIMUM AIR FOR COMBUSTION 10 Cubic Feet of Air Per 1000 BTUH S toichiometric or theoretical co mplete combustion requires 10 cubi c feet of air per 1000 BTUH of gas input. The National Fuel Gas Code also [...]

  • Page 11

    SUF SERVICE HANDBOOK INSTALLATION Technical Training Department State Water Heaters STC-077 10 Ashland City, Tennessee © 2004 MAKE-UP AIR Direct Communication A fresh supply of make-up air fo r combustion can be supplied to the heat er through make-up air openings, which directly communicate with t he out of doors. T wo openi ngs are required — [...]

  • Page 12

    SUF SERVIC E HANDBOOK INSTALLATION State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 11 STC-077 MAKE-UP AIR Horizont al Duct s When the heater is inst alled in an interior room with no roof access fo r vertical ducts, horizont al make-up ducts should be inst all ed. When using horizontal duc ts, two openings are requ[...]

  • Page 13

    SUF SERVICE HANDBOOK INSTALLATION Technical Training Department State Water Heaters STC-077 12 Ashland City, Tennessee © 2004 CONT AMINA TED AIR Along with adequate make-up air , th e quality of the air is import ant. Contaminants in combustion air can lead to premature heater failur e. V apors from bleaches, soaps, salts, etc. are drawn into the [...]

  • Page 14

    SUF SERVIC E HANDBOOK INSTALLATION State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 13 STC-077 MUL TIPLE UNIT — W A TER PIPING NOTES APPLY TO ALL SYSTEMS: *ADD GATE VALVES TO IN LET AND OU TLET OF EACH UNIT FOR ISOLATION FLEXIBILITY. LOCATE AT THE SAME POINT FROM TEE. ** ADD THERMAL EXPANSION TANK TO COLD WATER SU[...]

  • Page 15

    SUF SERVICE HANDBOOK INSTALLATION Technical Training Department State Water Heaters STC-077 14 Ashland City, Tennessee © 2004 CONDENSA TION The average dewpoint of nat ural gas flue pr oducts is 127° F . Prop ane flue products is 1 19° F . With 70° F ambient air temperature and 180° F stored water temperatur e, exhaust gas will be approxi- mat[...]

  • Page 16

    SUF SERVIC E HANDBOOK OPERATION State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 15 STC-077 OPERATION SEQUENCE OF OPERATION[...]

  • Page 17

    SUF SERVICE HANDBOOK OPERATION Technical Training Department State Water Heaters STC-077 16 Ashland City, Tennessee © 2004 CONTROLS NORMAL INDICA TIONS / READINGS / SETTINGS During Call for Heat • On/Off switch in the “on” position • W ater T emperature F° — current average tank water temperature displayed • 120 V A C LED light on •[...]

  • Page 18

    SUF SERVIC E HANDBOOK OPERATION State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 17 STC-077 CIRCUT BOARDS DISPLA Y CIRCUIT BOARD IGNITION CIRCUIT BOARD[...]

  • Page 19

    SUF SERVICE HANDBOOK TROUBLESHOOTING Technical Training Department State Water Heaters STC-077 18 Ashland City, Tennessee © 2004 TROUBLESHOOTING PRE-SER VICE TIPS SUF SERVICE HANDBOOK 120 VAC TO CONTROL STEP 1: CHECK FOR 120 V AC TO CONT ROL BOARD CN1 TERMINAL. Condition: • Disconnect plug from CN1 terminal. • On/Off switch is on. Check for 12[...]

  • Page 20

    SUF SERVIC E HANDBOOK TROUBLESHOOTING State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 19 STC-077 TRANSFORMER STEP 2: CHECK F OR 120 V AC TO TR ANSFORMER 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 V AC between pin 1 an[...]

  • Page 21

    SUF SERVICE HANDBOOK TROUBLESHOOTING Technical Training Department State Water Heaters STC-077 20 Ashland City, Tennessee © 2004 TRANSFORMER (CONTINUED) STEP 3: CHECK FOR 24 V AC A T 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 [...]

  • Page 22

    SUF SERVIC E HANDBOOK TROUBLESHOOTING State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 21 STC-077 ECO CHECK STEP 4: CHECK FOR 24 V AC BETWEEN PIN 4 ON CONTROL BOA RD TERMINAL CN3 AND GROUND. Condition: • Disconnect CN3 plug from control board. • On/Off switch is on. Check for 24 V AC between pin 4 of the CN3 ter[...]

  • Page 23

    SUF SERVICE HANDBOOK TROUBLESHOOTING Technical Training Department State Water Heaters STC-077 22 Ashland City, Tennessee © 2004 ECO CHECK (CONTINUED) STEP 5: CHECK FOR 24 V AC 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, c[...]

  • Page 24

    SUF SERVIC E HANDBOOK TROUBLESHOOTING State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 23 STC-077 T EMPERATURE PROBE STEP 6: CHECK RESIST ANCE OF THERMISTOR IN UPPER AND LOWER TEMPERA TURE PROBES. Condition: • Disconnect CN3 and CN8 pl ugs from control board. • On/Off switch is off. • Multimeter is set to lowe[...]

  • Page 25

    SUF SERVICE HANDBOOK TROUBLESHOOTING Technical Training Department State Water Heaters STC-077 24 Ashland City, Tennessee © 2004 PRESSURE SWITCH CONTINUITY STEP 7: CHECK FOR CONTINUITY BETWEEN PRESSURE SWIT CH TERMINALS WITH WIRES REMOVED. Condition: • On/Off switch is off. • All wires are disconnected fr om all pressure switches. • Multimet[...]

  • Page 26

    SUF SERVIC E HANDBOOK TROUBLESHOOTING State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 25 STC-077 BLOWER STEP 8: CHECK F OR 120 V AC 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 [...]

  • Page 27

    SUF SERVICE HANDBOOK TROUBLESHOOTING Technical Training Department State Water Heaters STC-077 26 Ashland City, Tennessee © 2004 PRESSURE SWITCH PERFORMANCE STEP 9A: CHECK PRESSURE A T SENS ING PORTS ON BURNER, BLOWER INLET AND GAS VA LV E . Condition: • All wires are reconnected to all pressure switches. • On/Off switch is on. • Call for he[...]

  • Page 28

    SUF SERVIC E HANDBOOK TROUBLESHOOTING State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 27 STC-077 PRESSURE SWITCH PERFORMANCE (CONTINU ED) STEP 9B: CHECK FOR CONTINUITY BETWEEN PRESSURE SWIT CH TERMINALS WITH WIRES REMOVED AND BLOWER R UNNING . Condition: • All wires are disconnecte d from all pressure sw itches ?[...]

  • Page 29

    SUF SERVICE HANDBOOK TROUBLESHOOTING Technical Training Department State Water Heaters STC-077 28 Ashland City, Tennessee © 2004 120 VAC TO IGNITOR STEP 10: CHECK F OR 120 V AC TO IGNIT OR FROM PIN 1 AND 2 ON CONTROL BOARD TERMINAL CN5. Condition: • Disconnect CN5 plug from control board. • On/Off switch is on. • Call for heat is activated. [...]

  • Page 30

    SUF SERVIC E HANDBOOK TROUBLESHOOTING State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 29 STC-077 IGNITOR RESIST ANCE STEP 1 1: CHECK RESIST ANCE BETWEEN TWO WIRE CONNECTS A T CN5 IGNITOR PLUG END. Condition: • On/Off switch is off. • Disconnect CN5 ignitor plug from circuit board. • Multimeter is set to lowes[...]

  • Page 31

    SUF SERVICE HANDBOOK TROUBLESHOOTING Technical Training Department State Water Heaters STC-077 30 Ashland City, Tennessee © 2004 GAS V AL VE TEST STEP 12: CHECK F OR 24 V AC TO GAS V AL V E DURING TRIAL FOR IGNITION. Condition: • All wires are reconnected. • On/Off switch is on. • Call for heat is activated. • Perform test at end of ignito[...]

  • Page 32

    SUF SERVIC E HANDBOOK TROUBLESHOOTING State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 31 STC-077 GAS PRESSURE CHECK STEP 13: CHECK AND ADJUST SUPPL Y GAS PRESSURE. Attach manometer or gas pressure gauge to pressure t ap on gas valve or use ad apter to check pressure ahead of valve as near as possible to va lve. All[...]

  • Page 33

    SUF SERVICE HANDBOOK COMPONENT INFORMATION Technical Training Department State Water Heaters STC-077 32 Ashland City, Tennessee © 2004 COMPONENT INFORMA TION ORIFICE T ABLE * -4 and -5 stamped wi th “P” for Prop ane NOTE: Hex head of main burner orifice is upstre am end — gas flows out of tapered end. FLAME SENSING ROD PART NUMBER FLAME SENS[...]

  • Page 34

    SUF SERVIC E HANDBOOK COMPONENT INFORMATION State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 33 STC-077 PRESSURE SWTCHES[...]

  • Page 35

    SUF SERVICE HANDBOOK COMPONENT INFORMATION Technical Training Department State Water Heaters STC-077 34 Ashland City, Tennessee © 2004 PRESSURE SWITCHES (CONTINUED) PRESSURE SWITCHES PART NUMBER / ACTIVATION PR ESSURE † †. Pressure values are given in inches of water colum n pressure (“W .C.). Negative pressure values in this t able are prec[...]

  • Page 36

    SUF SERVIC E HANDBOOK WIRING DIAGRA MS State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 35 STC-077 WIRING DIAGRAMS[...]

  • Page 37

    SUF SERVICE HANDBOOK SERVICE AIDS Technical Training Department State Water Heaters STC-077 36 Ashland City, Tennessee © 2004 SER VICE AIDS 1. This type product is polarity sensitive . Be certain that your electr ical supply wire neutral has no voltage. 2. This unit will produce condens ation — quite heavily at ti mes. The outlet drain hose must[...]

  • Page 38

    SUF SERVIC E HANDBOOK SERVICE AIDS State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 37 STC-077 SUF MUFFLER NOTES: 1. Install muf fler 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”[...]

  • Page 39

    SUF SERVICE HANDBOOK QUESTIONS AND ANSWERS Technical Training Department State Water Heaters STC-077 38 Ashland City, Tennessee © 2004 QUESTIONS AND ANSWERS Q. How much electrical power is required for a SU F water heater? A. The SUF models draw appr oximately 5.0 Amps Max. Q. When should SUF’ s be delimed? A. Many variables affect the lime buil[...]

  • Page 40

    SUF SERVIC E HANDBOOK ERROR CODES State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 39 STC-077 ERROR CODES CODE INDICATION 00 This is normal operat ion , 00 is displayed each time the heater is powered up. 01 Indicates th e pressure switch circuit w as not op en during th e prediagn ostic system check when the proper[...]

  • Page 41

    SUF SERVICE HANDBOOK SERVICE CHECKLIST Technical Training Department State Water Heaters STC-077 40 Ashland City, Tennessee © 2004 SER VICE 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 [...]

  • Page 42

    SUF SERVICE HANDBOOK PARTS LIST State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 41 STC-077 SUF SERVICE HANDBOOK PARTS LIST SUF MODELS 100 – 150, 10 0 – 199 AND 100 – 240 ST A TE W A TER HEA TERS 500 LINDHAL PARKWAY, ASHLAND CITY, TN 37015 PHONE: 1-800-821-2017 • FAX 1 -800- 644-9306 WWW.STATEWATERHEATERS.CO[...]

  • Page 43

    SUF SERVICE HANDBOOK PARTS LIST Technical Training Department State Water Heaters STC-077 42 Ashland City, Tennessee © 2004 UL TRA FORCE SUF MODELS REPLACEMEN T P ARTS Shaded parts are recommended stock items for emergency r eplacement. Consider gas used in your area only . *Not illustrated. ITEM DESCRIPTION SUF 100 150 SUF 100 199 SUF 100 240 SUF[...]

  • Page 44

    SUF SERVICE HANDBOOK PARTS LIST State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 43 STC-077 UL TRA FORCE SUF CONTROLS P ARTS LIST Shaded parts are recommended stock items for emergency r eplacement. Consider gas used in your area only . ITEM DESCRIPTION SUF 100 150 SUF 100 199 SUF 100 240 SUF 100 150-LP SUF 100 199-[...]

  • Page 45

    SUF SERVICE HANDBOOK PARTS LIST Technical Training Department State Water Heaters STC-077 44 Ashland City, Tennessee © 2004 NOTES:[...]

  • Page 46

    THIS PRINT OUT IS FOR REFERENCE ONL Y! Do not use this printout for color match or critical dimensions. PRINT OUT MADE A T 100% OF FINAL SIZE. THIS FILE HAS NOT BEEN TRAPPED. This file was created with Adobe Illustrator 8.0.1 . DO NOT try to open this file with earlier versions. Marketing Support Inc. assumes no responsibility for final print qu[...]