State Industries STC-077 User Manual

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The Expert’s Choice®

SUF Service Handbook

TABLE OF CONTENTS

STC-077

Introduction . . . . . . . . . . . . . . . . . . . 2

Installation

Clearances. . . . . . . . . . . . . . . . . . . . . 3

Gas Requirements . . . . . . . . . . . . . . . 3

Venting . . . . . . . . . . . . . . . . . . . . . 4 – 8

Air Requirements . . . . . . . . . . . . 9 – 11

Contaminated Air . . . . . . . . . . . . . . . 12

Flammable Items . . . . . . . . . . . . . . . 12

Multiple Unit Piping. . . . . . . . . . . . . . 13

Condensation. . . . . . . . . . . . . . . . . . 14

Operation

Sequence of Operation . . . . . . . . . . 15

Controls . . . . . . . . . . . . . . . . . . . . . . 16

Circuit Boards. . . . . . . . . . . . . . . . . . 17

Troubleshooting

Pre-Service. . . . . . . . . . . . . . . . . . . . 18

120 VAC to Control. . . . . . . . . . . . . . 18

Transformer . . . . . . . . . . . . . . . 19 – 20

ECO Check . . . . . . . . . . . . . . . 21 – 22

Temperature Probe. . . . . . . . . . . . . . 23

Pressure Switch Continuity . . . . . . . 24

Troubleshooting (continued)

Blower . . . . . . . . . . . . . . . . . . . . . . . 25

Pressure Switch Performance . 26 – 27

120 VAC to Ignitor . . . . . . . . . . . . . . 28

Ignitor Resistance. . . . . . . . . . . . . . . 29

Gas Valve Test . . . . . . . . . . . . . . . . . 30

Gas Pressure Check . . . . . . . . . . . . 31

Component Information

Orifice Tables . . . . . . . . . . . . . . . . . . 32

Pressure Switches . . . . . . . . . . 33 – 34

Wiring Diagrams . . . . . . . . . . . . . . 35

Service Aids . . . . . . . . . . . . . . . . . . 36

SUF Muffler . . . . . . . . . . . . . . . . . . . 37

Questions & Answers . . . . . . . . . . 38

Error Codes. . . . . . . . . . . . . . . . . . . 39

Service Checklist . . . . . . . . . . . . . . 40

Parts Lists

Models 100 – 150, 100 – 199,

and 100 – 240 . . . . . . . . . . . 41 – 43

SUF SERVICE HANDBOOK

INTRODUCTION

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.

The following text and illustrations will provide you with a step by step procedure to verify proper installation, operation and troubleshooting procedures. Additional quick reference data is included to assist you in servicing this product.

The information contained in this handbook is designed to answer commonly faced situations encountered in the operation of the SUF product line and is not meant to be all inclusive. If you are experiencing a problem not covered in this handbook, please contact the S t ate Technical Information Dep artment a t 1-800-3 65-0577 or you r local State Representative for further assistance. This handbook is intended for use by licensed plumbing professionals and reference should be made to the instruction manual accompanying the product. This handbook contains supplemental information to the SUF instruction manual.

Qualifications: Installation or service of this water heater requires ability equivalent to that of a licensed tradesman in the field involved. Plumbing, venting, gas supply and electrical testing skills are required.

Tools Required:

• Phillips head and flat tip screw drivers

• Set of marked drill bits

• Electric multimeter tester

• Gas pressure gauge or manometer (gauge — part number 8099-2)

• Water pressure gauge (part number 4798)

• Digital manometer or draft gauge

• Thermometer (part number 4870 — range 0 thru 220°F)

•

/2”, 1” and 11/8” sockets

• Pipe wrench for union disconnect

NOTE Also, have a copy of the instruction manual for the model and series SUF that you are servicing.

Technical Training Department State Water Heaters STC-077

SUF SERVICE HANDBOOK

INSTALLATION

This portion of the handbook will review often overlooked installation requirements. The installation manual covers these items in detail. SUF water heaters are approved for installation on combustible flooring. The minimum clearance to combustibles or noncombustibles is 0 inches from the sides and rear, 0 inches from vent piping, and

1.5 inches from the top cover. A 24 inch clearance for all serviceable parts is recommended. Clearances may vary between SUF models. See installation manual or the label on the heater for your specific model.

CLEARANCES

GAS REQUIREMENTS

NOTE: Pressure without capacity will result in lockout. Follow the piping guidelines in the

installation manual. The supply gas pressure is normally measured at the dirt leg or at the inlet gas pressure tap on the gas valve. This reading must be measured with ‘flowing’ gas.

The manifold gas pressure is measured at the manifold pressure tap on the gas valve when the gas is flowing. The gas valves used on all SUF water heaters are 24 VAC combination step opening gas valves. They incorporate the main valve and pressure regulator into one body.

REGULATED GAS SUPPLY LINE

MAIN GAS SHUTOFF VALVE

DIRT LEG TEE

PIPE CAP

GAS SUPPLY SPECIFICATIONS

NATURAL GAS NATURAL GAS PROPANE GAS

PRESSURE REGULATOR ADJUSTMENT (COVER SCREW)

INLET PRESSURE TAP

GAS INLET

SUF 240 SUF 150 & 199 SUF 150 & 199

GAS VALVE ON/OFF

TH & TR TERMINALS (MAIN VALVE)

MANIFOLD PRESSURE TAP

GAS OUTLET

Max

. Gas Supply Pressure Inches W.C.

Inches

W.C.

Nominal Gas Supply Pressure

Minimal Gas Supply Pressure

Manifold Pressure

12.0 (3 kPa) 12.0 (3 kPa) 14.0 (3.45 kPa)

7.0 (1.75 kPa) 7.0 (1.75 kPa) 11.0 (2.74 kPa)

5.5 (1.37 kPa) 4.5 (1.12 kPa) 11.0 (2.74 kPa)

4.0 (1 kPa) 3.5 (0.8 kPa) 10.0 (2.5 kPa)

3 STC-077

SUF SERVICE HANDBOOK

INSTALLATION

VENTING

Equivalent Feet of Pipe Intake or Exhaust

VENT LENGTH TABLE

NUMBER OF 90°

ELBOWS

ONE (1)

TWO (2) 7 40 110

THREE (3) 7 35 105

FOUR (4) 7 30 100

FIVE (5) 7 -- 95

SIX (6) 7 -- 90

3” MINIMUM PIPE (FEET)

745115

3” MAXIMUM

PIPE (FEET)

4” MAXIMUM

PIPE (FEET)

4-inch PVC may be used for a MAXIMUM intake of ONE HUNDRED TWENTY (120) EQUIV ALENT FEET and a MAXIMUM exhaust of ONE HUNDRED TWENTY (120) EQUIVALENT FEET. The maximum number of 90° elbows with the 4-inch venting is six (6) on the intake and six (6) on the exhaust. A 90° elbow is equal to five (5) equivalent feet of pipe. One (1) 90° elbow is equal to two (2) 45° elbows. Any venting configuration using less than 50 equivalent feet should use 3-inch venting. See Vent Length Table.

The 3-inch venting terminals (provided) must be used with the 4-inch venting by adding 4 x 3 reducing coupling at the venting terminals. A reducing coupling is also needed immediately after the condensate elbow (exhaust) and immediately before the 3-inch blower adapter (intake) if direct venting is installed. See Vent Length Table.

DIRECT VENTING

The air intake provided on the unit contains a mesh screen (see Figure below) to prevent large particles from entering the unit.

3” (7.6CM) 45° PVC ELBOW WITH MESH SCREEN

WARNING

WHEN THE UNIT IS TO BE SETUP AS A DIRECT VENT, THE MESH SCREEN MUST BE REMOVED. THE INLET VENT PIPE MAY THEN BE GLUED TO THE AIR INTAKE (see following Figure) PROVIDED ON THE UNIT.

Technical Training Department State Water Heaters STC-077

SUF SERVICE HANDBOOK

INSTALLATION

VENTING CONFIGURATIONS

SEALED DIRECT VENT VERTICAL

SEALED DIRECT VENT

HORIZONTAL INTAKE

VERTICAL EXHAUST

SEALED DIRECT VENT SIDEWALL

SEALED DIRECT VENT

VERTICAL INTAKE

HORIZONTAL EXHAUST

INDOOR CONVENTIONAL

VERTICAL

SEALED DIRECT VENT

W/ CONCENTRIC VENT

VERTICAL TERMINA-

INDOOR CONVENTIONAL

SIDEWALL

SEALED DIRECT VENT

W/ CONCENTRIC VENT

HORIZONTAL TERMINATION

VENTING MATERIALS

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. The fittings, other than the TERMINATIONS should be equivalent to PVC-DWV fittings meeting ASTM D-2665 (Use CPVC fittings, ASTM F-438 for CPVC pipe and ABS fittings, ASTM D-2661/3311 for ABS pipe. If CPVC or ABS pipe and fittings are used, then the proper cement must be used for all joints, including joining the pipe to the Termination Tee (PVC Material). PVC Materials should use ASTM D-2564 Grade Cement; CPVC Material should use ASTM F-493 Grade Cement and; ABS Materials should use ASTM D-2235 Grade Cement.

For water heaters in locations with high ambient temperatures (above 100°F) and/or insufficient dilution air, it is recommended that CPVC or ABS pipe and fittings (MUST USE SUPPLIED VENT TERMINAL) be used.

5 STC-077

SUF SERVICE HANDBOOK

INSTALLATION

CONCENTRIC VENT TERMINATION

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 the vent system. Below are some general application and installation guidelines for the concentric vent kit. Refer to the accompanying literature and the water heater installation manual for complete venting installation instructions.

This concentric vent termination kit may be used with 3 or 4 in. diameter pipe systems. When connecting to a 4 in. diameter pipe system a 3 x 4 in. field supplied reducer is to be installed at the intake and exhaust connection of the concentric vent termination kit. See water heater installation and operation manual for venting specification

Dimension 211/8 in. may be lengthened to 60 in. maximum. Dimension 211/8 in. may also be shortened by cutting the pipes, provided in the kit, to 12 in. minimum. Dimension 39 will change accord-

ingly as dimension 211/8 in. is lengthened or shortened

Horizontal

Installation

Vertical Installation

Technical Training Department State Water Heaters STC-077

SUF SERVICE HANDBOOK

INSTALLATION

VENTING CLEARANCES

This illustrates the exterior clearances for these SUF units when installed as direct vent heaters. NOTE: 24 inches between inlet and outlet is a MINIMUM. Greater distance is recommended.

In colder climates increasing the 24” minimum to a maximum practical distance will reduce the possibility of frost over from side winds blowing exhaust vapors into the air intake.

SUF MODEL 150 – 199

SUF MODEL 240

7 STC-077

SUF SERVICE HANDBOOK

INSTALLATION

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 EXHAUST OR INTAKE WILL BE OBJECTIONABLE. THIS INCLUDES LOCATION CLOSE TO OR ACROSS FROM WINDOWS AND DOORS. AVOID ANCHORING THE VENT AND INTAKE PIPES DIRECTLY TO FRAMED WALLS, FLOORS OR CEILINGS UNLESS RUBBER ISOLATION PIPE HANGERS ARE USED. THIS PREVENTS ANY VIBRATIONS FROM BEING TRANSMITTED INTO THE LIVING SPACES.

Technical Training Department State Water Heaters STC-077

SUF SERVICE HANDBOOK

INSTALLATION

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. The National Fuel Gas Code also recommends an additional 2.5 cu.ft. of “excess air”. This 12.5 cu.ft. minimum supply air per 1000 BTUH input applies to natural and propane gas models.

The National Fuel Code also specifies minimum make-up air opening sizes for various building installations (Ref: NFPA 54, ANSI Z223.1, sec 5.3).

MAKE-UP AIR

Direct Vent Installation

This model is approved for direct venting either horizontally or vertically or conventional venting horizontal or vertical. Direct venting avoids using room air for combustion and eliminates the need for additional air intake ducts.

9 STC-077

SUF SERVICE HANDBOOK

INSTALLATION

MAKE-UP AIR

Direct Communication

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.

The lower opening is primarily providing combustion air. The upper opening is providing vent dilution air and acts as a relief opening for flue gases should the vent become obstructed or a down draft condition occur.

MAKE-UP AIR V ertical Ducts

Often it is more practical to install vertical make-up air ducts to the outdoors. Again, two openings are required — within 12 inches (30 cm) of the top of the enclosure and one within 12 inches (30 cm) 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.

Technical Training Department State Water Heaters STC-077

SUF SERVICE HANDBOOK

INSTALLATION

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. When using horizontal ducts, two openings are required — within 12 inches (30 cm) of the top of the enclosure and one within 12 inches (30 cm) of the bottom of the enclosure. Each opening shall have a free area of not less than 1 square inch per 2000 BTUH of the total input of all appliances within the enclosure.

INSUFFICIENT MAKE-UP AIR

Backdraft

Insufficient make-up air is a major cause of combustion problems. One common example is in a restaurant installation where exhaust vent equipment was not considered in sizing make-up air requirements. This may result in air being backdrafted by the restaurant exhaust equipment through the heater causing flue gas spillage, flame roll out, improper combustion, inconsistent pilot operation, and/or erratic heater shutdown.

A possible solution to this situation would be to use a SUF with direct venting. A less common service issue associated with a backdraft or negative pressure room would be the

opening or closing of air pressure switches. This may result in erratic or no heater operation.

11 STC-077

SUF SERVICE HANDBOOK

INSTALLATION

CONTAMINATED AIR

RUST

CHIPS

Along with adequate make-up air, the quality of the air is import ant. Contaminants in combustion air can lead to premature heater failure. Vapors from bleaches, soaps, salts, etc. are drawn into the combustion chamber with the make-up air and, once fired, mix with water vapor in the gasses to form extremely corrosive hydrochloric or hydrofluoric acid and other corrosive by-products. Dust drawn in may build up on the blower or clog the main burner ports. Also, be certain to examine the exterior area around the air intake of a direct vent installation for the contaminants.

FLAMMABLE ITEMS

Flammable items or pressurized containers or any other potentially hazardous articles must never be placed on or adjacent to the heater. Open cont ainers of flammable material should not be stored or used in the same room with the heater or in the area of the exterior air intake of a direct vent installation. Direct venting does not eliminate the need to remove flammable or corrosives from the area surrounding the heater.

Technical Training Department State Water Heaters STC-077

SUF SERVICE HANDBOOK

INSTALLATION

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.

CONDENSATION HOSE MUST BE ALLOWED TO DRAIN. NOTE: T&P VALVES MUST BE PIPED TO OPEN DRAIN OR

PER LOCAL CODE

13 STC-077

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