State Industries SUF100150, SUF100199 User Manual

COMMERCIAL GAS WATER HEATERS

SERVICE HANDBOOK

HIGH EFFICIENCY

FOR MODELS:

 • SUF60120

 • SUF100150

 • SUF100199

 • SUF100250

 • SUF130300

 • SUF130400

COMMERCIAL GAS SERIES

PRINTED 0509 198152-002

ULTRAFORCE COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

TABLE OF CONTENTS

INTRODUCTION...............................................................2

QUALIFICATIONS............................................................2

TOOLS REQUIRED.........................................................3

GENERAL INFORMATION................................................4

GAS PRESSURE SPECIFICATIONS ................................4

INSTALLATION QUICK TIPS – SUF 120 and 150 GAS

PRESSURE .....................................................................5

ADJUSTMENT PROCEDURE: .........................................5

GAS PRESSURE .............................................................5

SUF120 AND 150 MODELS..............................................5

HIGH ALTITUDE INSTALLATIONS ...................................5

SUF 120 - 150 .................................................................5

INSTALLATION QUICK TIPS - SUF 199 AND 250 GAS

PRESSURE .....................................................................6

ADJUSTMENT PROCEDURE:..........................................6

GAS PRESSURE .............................................................6

SUF 199 AND 250 MODELS ............................................6

HIGH ALTITUDE INSTALLATION......................................6

INSTALLATION QUICK TIPS - SUF 300, 400 GAS

PRESSURE......................................................................7

ADJUSTMENT PROCEDURE:..........................................7

GAS PRESSURE..............................................................7

SUF 300,400,....................................................................7

HIGH ALTITUDE ADJUSTMENT ......................................7

SUF 300,400,....................................................................7

INSTALLATION TIPS - SUF 300, 400 ...............................8

VENTING TABLES SUF 120 – 250....................................9

VENTING TABLES SUF 300,400,.....................................9

VENTING - ALL MODELS – SINGLE PIPE POWER VENT –

USING ROOM AIR..........................................................10

VENTING – ALL MODELS – TWO PIPE DIRECT VENT –

USING OUTSIDE AIR.....................................................11

VENT TERMINATION – DIRECT VENT – ALL MODELS. .12

DIRECT VENTING – ALL MODELS.................................13

CONTROL OVERVIEW ..................................................14

CONTROL OVERVIEW – ALL MODELS..........................14

ADJUSTING TANK TEMPERATURE – OPERATING SET

POINT - DIFFERENTIAL.................................................15

CHANGING THE DISPLAY UNITS..................................16

FAULT AND WARNING CONDITIONS – ADVANCED

DIAGNOSTIC INFORMATION.........................................17

ACCESS TO THE CURRENT FAULT OR WARNING.......18

VIEWING THE FAULT HISTORY - VIEWING

INFORMATION ABOUT THE HEATER............................19

CONTROL SEQUENCE (TYPICAL ALL MODELS).........20

CONTROL SEQUENCE FLOW CHART...........................21

CONTROLS – CENTRAL CONTROL BOARD – CCB ......22

CONTROLS – GAS VALVE SUF 120...............................23

CONTROLS – GAS VALVE SUF 150...............................23

CONTROLS – GAS VALVE SUF 199 and 250..................24

ADJUSTMENT PROCEDURE:........................................24

GAS PRESSURE ...........................................................24

SUF 199 AND 250 MODELS ..........................................24

CONTROLS – GAS VALVE SUF 199 and 250..................25

CONTROLS – GAS VALVE , ORIFICE CHART–

SUF300,400,...................................................................26

CONTROLS – PRESSURE SWITCHES – ALL MODELS..27 CONTROLS – PRESSURE SWITCHES – SUF 120 through

250.................................................................................28

CONTROLS – PRESSURE SWITCHES – SUF 300,400,. .29 CONTROLS – CONNECTIONS, IGNITER, FLAME

SENSOR, SIGHT GLASS, POWERED ANODES.............30

HOT SURFACE IGNITER / FLAME SENSOR / CONTROL

TIMING...........................................................................31

BLOWER SPEED CONTROL SUF 199 AND 250.............32

VARIABLE FREQUENCY DRIVE – SUF 400...................33

VARIABLE FREQUENCY DRIVE - BLOWER SPEED AND

PRESSURE READINGS..................................................34

WIRING DIAGRAM – SUF 120 – 300 ..............................35

WIRING DIAGRAM – SUF 400,.......................................36

Servicing should only be performed by a Qualified Service Agent 198152-002

INTRODUCTION

ULTRAFORCE COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

The service handbook is designed to aid in servicing and trou bleshooting S tate W ater Heaters Ultra Force SUF commercial water heaters i n t he f ield. No duplication or reproduction of t his bo ok m ay be m ade without the ex press w ritten authorization o f State Water Heaters .

The fol lowing tex t and i llustrations w ill provide you with a step by step procedure to verify pr oper i nstallation, opera tion, and troubleshooting procedures. Additional quick reference da ta i s i ncluded to ass ist you in servicing these products.

The information contai ned i n this handbook is designed to answer co mmonly face d situations enc ountered in the ope ration of this product l ine and is not meant to be all

QUALIFICATIONS

inclusive. If you are experiencing a problem not covered in this handbook, please contact State Water Heaters Technical Information at 1-800-365-0024, by e mail at

help@statewaterheaters.com

or your local State Water Heater representative for further assistance.

Our website:www.statewaterheaters.com

is also a resource for installation and service information. Thi s handbook i s i ntended for use by licensed plumbing professionals and reference should be made to the installation manual accom panying the prod uct. This handbook contains supplemental information to the produ ct’s i nstallation and ope ration manual.

ANSI Z223.1 Sec 3.3.83

"Qualified Agency"

"Any individual, firm, corporation or company that ei ther i n person o r through a representative i s e ngaged i n an d i s responsible for (a) the installation, testing or replacement of g as p iping or (b) the connection, i nstallation, testing, re pair or servicing of appliances and equipment; that is experienced i n such work; that is familiar with all precautions required; and that has complied w ith al l the re quirements o f the authority having jurisdiction."

Service of this water heater requires ability equivalent to th at of a Qual ified S ervice Agent (l icensed t radesman) i n the fi eld involved. Installation skills such as plumbing, air supp ly, vent ing, gas s upply, e lectrical supply are r equired i n addition to electrical testing ski lls. S ome pro ducts m ay requ ire combustion testi ng equipment and certification. If you do not possess these skills or do not h ave the pr oper t ools y ou should not attem pt to serv ice thi s w ater heater.

Servicing should only be performed by a Qualified Service Agent 198152-002

ULTRAFORCE COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

TOOLS REQUIRED

● ELECTRICAL MULTIMETER CAPABLE OF MEASURING CONTINUITY/ OHMS, AC

& DC VOLTS, AMPERES, MICROAMPERES, MILLIVOLTS, and FREQUENCY(Hz)

○ UEi Model DL289 or equivalent

● DIGITAL MANOMETER + 60” W. C. in .01” increments

Note: A digital manometer is required for testing pressure switches and can replace a gas pressure gauge, draft gauge or slack tube manometer for checking gas pressure.

○ UEi model EM200 or equivalent

● WATER PRESSURE GAUGE w/ LAZY HAND AND HOSE BIBB CONNECTION

● THERMOMETER

● 1-1/16 INCH SOCKET WITH EXTENSION FOR ANODE REPLACEMENT

● SET OF NUMBERED DRILL BITS

WATER PRESSURE

TEST GAUGE W/ LAZY

HAND AND HOSE BIBB

CONNECTION

DIGITAL MANOMETER

DIGITAL MULTIMETER

Servicing should only be performed by a Qualified Service Agent 198152-002

ULTRAFORCE COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

GENERAL INFORMATION

INSTALLATION REQUIREMENTS FOR THE COMMO NWEALTH OF MASSACHUSETTS

For al l side w all terminated, hor izontally vented power v ent, direct vent, and power direct v ent gas fueled w ater heat ers installed i n ev ery dwelling, building or structure used in w hole or i n p art for residential pur poses, including t hose ow ned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

INSTA LLATION OF CARBON MONOXIDE DETECTORS

At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gas fitter s hall observe that a hard wired carbon monoxide detector with an alarm and battery backup is in stalled on t he f loor le vel wh ere t he g as equipment is t o b e i nstalled. In add ition, t he installing plumber or gas fitter shall obs erve t hat a battery operated or har d w ired carbon monoxide detector w ith an al arm i s i nstalled on eac h additional level of the dwelling, building or structure served by the sidewall horizontal vented gas fueled equipment. It s hall b e the re sponsibility o f the property owner to secure t he services of q ualified licensed pr ofessionals for the i nstallation of har d wired carbon monoxide detectors. In the event that the s ide wall hor izontally v ented gas fueled

equipment is installed i n a c rawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the nex t adjacent f loor l evel. I n t he e vent t hat the requirements of this subdivision can not be met at the t ime of c ompletion o f i nstallation, t he ow ner shall have a period of thirty (30) days to comply with the a bove requirements p rovided t hat dur ing said thirty ( 30) day p eriod, a bat tery op erated carbon monoxide detector with an alarm shall be installed

APPROVED CARBON MONOXIDE DETECTORS

Each carbon monoxide de tector as r equired in accordance with the above provisions shall comply with N FPA 720 and be AN SI/UL 20 34 listed and CSA certified.

SIGNAGE

A m etal or p lastic i dentification plate s hall b e permanently mounted to the exterior of the b uilding at a minimum height of eight ( 8) feet ab ove grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2”) inch in size,

“GAS VENT DIRECTLY BELOW. KEEP CLEAR

OF ALL OBSTRUCTIONS.”

GAS PRESSURE SPECIFICATIONS

MODELS

Maximum Gas Supply Pressure

Nominal Gas Suppl y Pressure

Minimum Gas Supply Pressure (Low Gas Press. Switch Setting)

Manifold Pressure

Natural

120-150

10.5” W C

(2.59kPa)

7.0”WC

(1.74kPa)

4.8”WC

(1.20kPa)

4.0”WC

(0.98kPa)

Servicing should only be performed by a Qualified Service Agent 198152-002

Propane

120-150

14.0“WC

( 3.45kPa)

11.0“WC

( 2.74kPa)

8.5“WC

( 2.12kPa)

10.0“WC

(2.49 kPa)

Natural

199-250

10.5“WC

(2.59kPa)

7.0“WC

(1.74kPa)

4.8”WC

(1.20kPa)

0“WC

( 0 kPa)

Propane

199-250

14.0“WC

( 3.45kPa)

11.0“WC

( 2.74kPa)

8.5“WC

( 2.12kPa)

0“WC

( 0 kPa)

Natural

300/400/500

11.0”WC

(2.74kPa)

7.0”WC

(1.74kPa)

5.2”WC

(1.54kPa)

4.00“WC

( 1.25kPa)

Propane

300/400/500

14.00”W C (3.49kPa)

11.0”WC

(2.74kPa)

11.0“WC

( 2.74kPa)

10.0“WC

( 2.49kPa)

ULTRAFORCE COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

INSTALLATION QUICK TIPS – SUF 120 and 150 GAS PRESSURE

ADJUSTMENT PROCEDURE: GAS PRESSURE SUF120 AND 150 MODELS

a. Attach a pressure gauge (manometer) to the manifold pressure tap and refer to page 4 for correct pressure.

Main line gas pressure to the water heater for natural

gas should be between a maximum of 10.5"W.C.

(2.59kPa) for natural gas, 14.0"W.C.(3.45kPa) for

propane and a minimum of 4.8W.C.(1.18kPa) for

Natural Gas, and 8.5"W.C. (2.08kPa) for Propane Gas.

A supply gas pressure regulator (service regulator) must be installed on the gas supply line within 10' (305 cm) of the unit.

Also see gas pressure specification table on page 4.

1.Check gas line pressure with a manometer.

2.Check manifold pressure gauge (manometer) connected to the manifold pressure tap on the gas control valve, If full rate adjustment is required, remove cover screw from top of the gas control valve. Using a small screwdriver, turn adjusting screw clockwise to increase or counterclockwise to decrease gas pressure to obtain 4.0" W.C.(1 K pa) for natural gas and 10.0" W.C. (2.5 kPa) for L.P. Gas.

3. Cycle the burner on and off several times to check its operation.

4. Check the operation of the limit and operating controls.

5. Check the vent system seams and joints and ensure that there is no discharge of flue products into the room.

6. Check the input rate.

HIGH ALTITUDE INSTALLATIONS SUF 120 - 150

For appliance installation locations with elevations

above 6,500 feet (1982 meters) consult the “High

Altitude Installation” section of the owners manual.

b. Use this formula to “clock” the meter. Be sure

other gas consuming appliances are not operating during this interval.

Btuh = 3600 X H/ T

T = Time in seconds to burn 1 cubic foot of gas. (With a stopwatch read the gas meter and measure the amount of time required for the heater to consume 1 cubic foot of gas.) H = Heating value of gas (in Btu’s per cubic foot of gas). Btuh = Actual heater input rate, in Btuh. EXAMPLE: (Using SUF-150 heater) T = 25.25 seconds H = 1050 Btu/ft.3 BTUH = ?

Compare result to the de-rated input required for the elevation at the installat ion 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: c. Remove the pressure regulator cover screw and adjust the pressure by turning the adjusting screw with a small screwdriver. Do not exceed 4.0" (1 kPa) natural gas models and 10.0" w.c. (2.5kPa) on the propane models. Clockwise to increase gas pressure and input rate. Counterclockwise to decrease gas pressure and input rate. d. “Clock” the meter as in step (b) above. e. Repeat steps (c) and (d) until the specified input rate is achieved. f. Turn the manual gas valve to “OFF”. Replace the pressure regulator cover screw. Remove the pressure gauge or manometer from the manifold pressure tap. Replace the set screw in the manifold pressure tap. If the gas pressure regulator cannot be adjusted to give the full input rating with sufficient gas pressure at the valve, check to ensure the unit is equipped with the correct orifice.

Servicing should only be performed by a Qualified Service Agent 198152-002

ULTRAFORCE COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

INSTALLATION QUICK T IPS - SUF 199 AND 250 GAS PRESSURE

ADJUSTMENT PROCEDURE: GAS PRESSURE SUF 199 AND 250 MODELS

IMPORTANT NOTE

THE SUF 199 AND 250 MODELS INCORPORATE A NEW GAS CONTROL, WHICH OPERATES AT A MANIFOLD PRESSURE OF 0" W.C. (0 kPa) FOR BOTH NATURAL AND PROPANE GAS. SEE T HE GAS PRESSURE CHART ON PAGE 4. THESE MODELS ARE CONFIGURED PRIOR TO BEING SHIPPED FROM THE FACTORY AND NO ADJUSTMENTS ARE NECESSARY PRIOR TO STARTUP. THE CONTROLLER MONITORS T HE AIR FLOW AND MAKES ADJUSTMENTS TO THE FAN SPEED WHICH IN EFFECT CONTROLS THE AMOUNT OF GAS FLOW. THEREFORE, THE UNIT WILL SELF ADJUST TO ACQUIRE THE CORRECT AMOUNT OF INPUT.

"Supply gas pressure to the water heater must not exceed a maximum of 10.5" w.c. (295kPa) for natural gas, or 14" w.c. (3.45 kPa) for propane. The minimum supply gas pressure is 4.8" w.c. (1.20 kPa) for natural gas and 8.5" w.c. (2.12 kPa) for propane gas."

HIGH ALTITUDE INSTALLATION

The SUF 199 and 250 models are suitable for installation up to 10,100 feet above sea level with no adjustments.

GAS ORIFICE

The SUF 199 and 250 models do not have a natural gas orifice. A .230” orifice is used on LP gas models.

Venturi Gasket

w/o orifice

Gas Control Without Orifice

Natural Gas

Venturi

Gasket w/

LP Gas

Orifice

(.230”

Brass)

Gas Control with .230” LP Orifice

Once the unit is installed and filled with water and the inlet pressures confirmed, simply turn the switch "on" and observe operation. Cycle the unit "off" and "on" several times to ensure proper operation.

A supply gas pressure regulator (service regulator) must be installed on the gas supply line within 10' (305 cm) of the unit.

Servicing should only be performed by a Qualified Service Agent 198152-002

ULTRAFORCE COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

INSTALLATION Q UICK TIPS - SUF 300, 400 GAS PRESSURE

ADJUSTMENT PROCEDURE: GAS PRESSURE SUF 300,400,

A minimum dynamic gas suppl y pressure of

5.2" w.c. (1.29 kPa) for Natural Gas and 11" w.c. (2.74 kP a) for LP Gas is requir ed befo re making any adjustment to th e gas control pressure regulator. Attempts to adjust the

regulator during periods of low gas supply pressure could result in over firing of the water heater when the gas supply pressure returns to normal.

1. Check gas line pressure with a manometer, adjust the gas supply line pressure Gas Pressure table on page 4.

2. Check manifold pressure using a pressure gauge (manometer) connected to the manifold pressure tap on the gas control valve, If full rate adjustment is required, remove cover screw from top of the gas control valve. Using a small screwdriver, turn adjusting screw clockwise to increase or counter clockwise to decrease gas pressure to obtain 4.0" w.c. (0.996 kPa) for Natural Gas and 10" w.c. (2.49kPa) for LP gas.

3. Cycle the burner on and off several times to check its operation.

4. Check the operation of the limit and operating controls.

5. Check the vent system seams and joints and ensure that there is no discharge of flue products into the room.

6. Check the input rate as shown on page 5.

HIGH ALTITUDE ADJUSTMENT SUF 300,400,

For high altitude adjustments, contact the help line on the front of the water heater or contact help@statewaterheaters.com .

Servicing should only be performed by a Qualified Service Agent 198152-002

ULTRAFORCE COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

INSTALLATION TIPS - SUF 300, 400

Servicing should only be performed by a Qualified Service Agent 198152-002

ULTRAFORCE COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

VENTING TABLES SUF 120 – 250

Maximum equivalent feet of intake and vent pipe using 3” PVC is 50 feet (15.2m). Equivalent feet must include any 90° elbows (two 45° elbows equal one 90° elbow). Three inch diameter 90° elbows are equivalent to 5' (1.5m) of pipe.

Maximum equivalent feet of intake and vent pipe using 4” PVC is 120 feet (36.6m). Equivalent feet must include any 90° elbows (two 45° elbows equal one 90° elbow). Four inch diameter 90° elbows are equivalent to 5' (1.5m) of pipe.

Vent Length Table Equi valent Feet (Meters) 120 thro ugh 25 0

Number of 90°

Elbows ONE (1) 7/2.1 45/13.7 115/35 TWO (2) 7/2.1 40/12.2 110/33.5

THREE (3) 7/2.1 35/10.7 105/ 32

FOUR (4) 7/2.1 30/9.1 100/30.5

FIVE (5) 7/2.1 --- 95/29

SIX (6) 7/2.1 --- 90/27.4

3" Minimum

Pipe (Ft./M.)

3" Maximum

Pipe (Ft./M.)

VENTING TABLES SUF 300,400,

Vent Length Table Equivalent Feet (Meters) 300,400,

Number of 90°Elbows

ONE (1) 65' / 19.7 m

TWO (2) 60' / 18.2 m

Maximum Feet / meters of Pipe

4" PVC

4"Maximum

Pipe (Ft./M.)

THREE (3) 55' / 16.7 m

FOUR (4) 50' / 15.2 m

FIVE (5) 45' / 13.6 m

SIX (6) 40' / 12.1 m

Servicing should only be performed by a Qualified Service Agent 198152-002

ULTRAFORCE COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

VENTING - ALL MODELS – SINGLE PIPE POWER VENT – USING ROOM AIR

Servicing should only be performed by a Qualified Service Agent 198152-002

ULTRAFORCE COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

VENTING – ALL MODELS – TWO PIPE DIRECT VENT – USING OUTSIDE AIR

Servicing should only be performed by a Qualified Service Agent 198152-002

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