State Water Heaters 119300 Service Handbook Download Page 1

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COMMERCIAL GAS HIGH EFFICIENCY WATER HEATERS

Service Handbook

PRINTED IN THE U.S.A. 0914

329298-000

500 Tennessee Waltz Parkway

Ashland City, TN 37015

FOR MODELS:

SUF 60120 THRU SUF 100250

SUF 119300 THRU SUF 119500

SERIES 200/201

INSTALLATION CONSIDERATIONS - PRE SERVICE CHECKS -

CONSTRUCTION - OPERATION & SERVICE - TROUBLESHOOTING

SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN

Summary of Contents for 119300

Page 1: ... 000 500 Tennessee Waltz Parkway Ashland City TN 37015 FOR MODELS SUF 60120 THRU SUF 100250 SUF 119300 THRU SUF 119500 SERIES 200 201 INSTALLATION CONSIDERATIONS PRE SERVICE CHECKS CONSTRUCTION OPERATION SERVICE TROUBLESHOOTING SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN ...

Page 2: ...oltage Tests 23 Flame Sensor 24 Flame Sensing Operation 24 Flame Sensing Current Test 25 8 No Water 26 Powered Anodes 26 Power anode cleaning and removal 26 9 Anode Shorted 28 10 Temperature Probe Short Upper or Lower 29 Temperature Probe 29 Temperature Sensor Test 30 ECO Continuity Test 30 11 Temperature Probe Open Upper or Lower 32 VENTING 33 General Venting Information 33 INTAKE AIR CONNECTION ...

Page 3: ...o not attempt to perform any of the procedures described in this service handbook If you do not understand the instructions given in this service handbook do not attempt to perform any procedures outlined in this service handbook SERVICE REMINDER When performing any troubleshooting step outlined in this service handbook always consider the wiring and connectors between components Perform a close v...

Page 4: ...lief Valve operation water discharged from the valve due to excessive pressure build up This condition is not covered under the limited warranty The Temperature Pressure Relief Valve is not intended for the constant relief of thermal expansion A properly sized thermal expansion tank must be installed on all closed systems to control the harmful effects of thermal expansion Contact a local plumbing...

Page 5: ...sket Blower Adapter Burner Gasket Burner Ignition Cable Sight Glass Sight Glass Gasket Burner Plate Burner Plate Gasket 150 250 Models Only SS Heat Shield 150 250 Models Only Flue Ring Gasket Ignition Cable Air Intake Assembly Spark Igniter Flame Sensor Combustion Blower Blower Gasket Sight Glass Sight Glass Gasket Burner Venturi Burner Plate Burner Plate Gasket SS Heat Shield Pyrolite Insulation ...

Page 6: ...sembly Exhaust Condensate Elbow Ignition Control Junction Box Assembly UIM Label Color Green Label Color Blue Label Color Red Water Outlet 1 1 2 NPT TOP VIEW SUF 119300 119500 MODELS Water Outlet 1 1 2 NPT CCB Assembly Powered Anode Short Ignition Control Junction Box Assembly Burner Blower Assembly Blower Prover Switch Label Color Green Blocked Air Intake Switch Label Color Blue Blocked Exhaust S...

Page 7: ...vated Blower Prover switch contacts confirmed closed by control system Spark Ignition Control is energized 24 Volt Gas Valve is energized gas flows to Main Burner Is flame sensed at the Main Burner control system monitors the flame sensor Control System Locks Out Displays Fault Msg NO Control System Locks Out Blower Prover Open Fault Msg is displayed NO Combustion Blower is energized Pre Purge cyc...

Page 8: ...upply regulator may be operating improperly See Gas Pressure section below HIGH ALTITUDE The water heaters covered in this Service Handbook are certified for elevations up to 10 100 feet 3 078 meters For higher elevations call the toll free support phone number shown on the back cover of this Service Handbook for technical assistance GAS PRESSURE SPECIFICATIONS MODELS Natural 60120 100250 Propane ...

Page 9: ...eding 14 W C under any upstream supply pressure or condition For Natural Gas SUF 60120 100250 models require a minimum gas supply pressure of 4 4 W C SUF 119300 119500 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 The...

Page 10: ...ater heater is experiencing a sustained drop in supply gas pressure of 1 5 W C or more and the water heater is experiencing repeated Ignition Failure fault conditions intermittent loss of flame or rough starting ensure the supply gas line is sized in accordance with the current edition of National Fuel Gas Code ANSI Z223 1 NFPA 54 or the Natural Gas and Propane Installation Code CAN CSA B149 1 GAS...

Page 11: ...Point to end the heating cycle Use the Enable Disable Switch located on the front of the water heater and put the unit in disabled mode 11 Close the main gas shutoff valve serving the water heater 12 Disconnect manometer sensing tube 13 Close the Supply Gas Pressure Test Port on the Gas Control Valve Turn the needle valve slotted head clockwise until tight 14 Open the main gas shutoff valve servin...

Page 12: ...r is energized the Control System enters the Input Verification operating state During Input Verification the Control System monitors all three pressure switches to ensure their contacts are in the correct normal state The Blower Prover switch contacts must be open The contacts for the Blocked Air Intake Switch and Blocked Exhaust Switches must be closed If any of the pressure switch contacts are ...

Page 13: ...sure switch see Figure below 5 After completing the tests confirm that all of the pressure switch wires are reconnected including the replacement part if necessary based on the Results Actions listed below Restore the electrical power to the water heater Reset the Operating Temperature Set Point if it was adjusted Run the water heater through a complete heating cycle before leaving to ensure it is...

Page 14: ... complete heating cycle before leaving to ensure it is operating properly Draw water from the nearest faucet to make sure that the water temperature does not pose a scalding hazard due to the increased temperature set points that were used in this procedure Results Actions Passed Results If the Blower Prover switch contacts activate close zero ohms direct short during this test the switch has pass...

Page 15: ... Restore power to the water heater if the water heater does not begin a heating cycle raise the Operating Set Point to activate a heating cycle 5 When the Combustion Blower comes on and ramps up to full speed record the pressure reading 6 Repeat this test for all three pressure switches as necessary 7 Compare the pressure readings taken to the activation pressures in the Table above 8 Ensure all s...

Page 16: ...ir termination outdoors Check for condensate water in the sensing tube switch if the sensing tube has water in it replace the Blocked Air Intake Switch and the tube Ensure the sensing port is oriented properly see Intake Air Connection on Page 34 Blocked Exhaust If the pressure reading taken at the Blocked Exhaust switch sensing tube does not reach or rise above the activation pressure given in th...

Page 17: ...SES The control has detected an open Blower Prover Pressure Switch during operation Blower Prover Pressure Switch sensing tube disconnected or kinked Loose or open wiring connections to Blower Prover Pressure Switch Blower not running when expected Blower Prover Pressure Switch not operating Replace Blower Prover Switch CHECK REPAIR The blower prover pressure switch will close its contacts on a pr...

Page 18: ...f the burner ignites briefly then shuts off with an Ignition Failure error message follow these steps Remove the connector from flame sense rod picture of connector showing location on unit Inspect the connector for corrosion Replace if corroded or damaged Remove Flame Sensor and clean metal end with steel wool Check insulator for soot cracks or other damage and replace if necessary CHANGE BACK AD...

Page 19: ...problem If you do not see a brief blue flame through the sight glass during the ignition cycle at the moment the Gas Control Valve icon appears on the display follow these steps Remove and reinsert the Gas Control Valve electrical connector Make sure the electrical connections pins are clean and that the connector fits tightly VENTURI LOW GAS PRESSURE SWITCH SUPPLY GAS CONNECTION GAS CONTROL VALVE...

Page 20: ...ur meter This electrical signal will only last for 2 3 seconds if the burner does not ignite or the flame sensor does not detect ignition 24 VDC PRESENT If 24 VDC is present on the Gas Control Valve connector during the beginning of an ignition cycle reinstall the connector and recycle the unit again Check the gas supply pressure during ignition using test procedure from Gas Pressure Test on Page ...

Page 21: ...sional Your Company Name Here press DOWN for more CAUSES The Blocked Air Intake Switch has detected a possible restriction in the air intake pipe CHECK REPAIR Check pipe for restriction or excessive equivalent length See Instruction Manual for pipe size length and maximum number of elbows Check actual pipe pressure with a manometer during blower operation See Pressure Switch Tests section on Page ...

Page 22: ...ssional Your Company Name Here press DOWN for more CAUSES The Blocked Exhaust Switch has detected a possible restriction in the exhaust pipe CHECK REPAIR Check pipe for restriction or excessive equivalent length See Instruction Manual for pipe size length and maximum number of elbows Check actual pipe pressure with a manometer during blower operation See Pressure Switch Tests section on Page 12 th...

Page 23: ...oper operation If flame is not present cycle the unit Off by turning the Enable Disable switch to Disable wait for 5 seconds and cycle the unit On by turning the Enable Disable switch to Enable to see if the error clears See Flame Sensor section on Page 24 thru Page 25 GAS CONTROL VALVE The 24 Volt Gas Control Valve on these water heaters is DC voltage valve The CCB sends 24 VAC to the valve and t...

Page 24: ...ication or Heating operating states see Figure below 24 VAC should be present Note that the Gas Control Valve Voltage is only present for a short period of time during the ignition period 2 Check for 24 VDC at the plug end of the 24 Volt Gas Control Valve wiring harness during the Ignition Verification operating state Loosen the retaining screw for the 24 Volt Gas Control Valve wiring harness plug...

Page 25: ... Page 2 SPARK IGNITER BURNER FLAME BURNER MUST BE GROUNDED CERAMIC INSULATOR FLAME SENSOR METAL CONDUCTOR CONTROL SYSTEM APPLIES AC CURRENT TO FLAME SENSOR AC CURRENT FLOWS FROM THE FLAME SENSOR TO THE BURNER THE BURNER MUST BE GROUNDED FOR CURRENT TO FLOW DURING THIS PROCESS THE AC CURRENT IS RECTIFIED AND BECOMES A DC CURRENT DC MICRO AMP CURRENT THEN FLOWS BETWEEN THE FLAME SENSOR AND THE BURNE...

Page 26: ...method shown in Figure below Enable water heating and ensure a call for heat is active when the Control System energizes the 24 Volt Gas Control Valve the meter will measure flame sensing current during normal operation Service Notes The most common cause of Ignition Failure lock out is a worn Flame Sensor The Flame Sensor should be inspected and cleaned anytime the measured flame sensing current ...

Page 27: ... shown below CHECK REPAIR POWERED ANODES The water heaters covered by this Service Handbook are equipped with powered anodes SUF 60120 models only use 1 powered anode all others will have two These anodes do not need to be replaced unless damaged The CCB monitors the current through the anodes and will declare a fault if there is a disconnected wire or if there is no water in the tank POWER ANODE ...

Page 28: ... to allow for socket tool to fit properly REAR ANODE REPLACEMENT METHOD 1 Remove the two blower connectors from the blower remove gas valve power plug and the two wires from the low gas pressure switch 2 Remove air intake rubber boot from blower 3 Disconnect gas supply connection from gas valve 4 Remove the four 4 blower mounting screws to remove blower Using a T handle or hex head wrench usually ...

Page 29: ...ank Note This is an alert The unit will continue to heat water in press DOWN for more CAUSES The controller has detected a low resistance or short to earth ground or the tank CHECK REPAIR Bent anode shorting to tank Contamination solder loctite water Etc between anode top and surrounding metal Power anode shorted to ground at wire connection See Powered Anodes section shown under No Water section ...

Page 30: ...ly monitors the state of the ECO switch contacts If the ECO activates contacts open due to abnormally high water temperature the Control System will lock out and display Energy Cut Out ECO on the UIM Should the ECO activate the water temperature must drop below 140 F 60 C before the Control System can be reset Once the water temperature has cooled below this point the electrical circuit breaker th...

Page 31: ...from the Temperature Probe see Figures on next page Compare the measured resistance to the values given in Temperatures Table below Temperature Probes are very reliable and should only be replaced when The resistance is above 56 000 ohms open or below 390 ohms shorted The nature of the service problem is temperature control and the resistance readings are considerably 25 different than the values ...

Page 32: ...nd the tank temperature is known to be at or below 100 F 38 C replace the Temperature Probe Follow the draining and filling instructions in the maintenance section of the Instruction Manual that came with the water heater when replacing the Temperature Probe If the Control System continues to lock out displaying Energy Cut Out ECO on the UIM and the water temperature inside the water heater is bec...

Page 33: ...e Advanced button for press DOWN for more CAUSES The Upper or Lower Temperature Probe appears to be open very high resistance This fault code often means the connector has been corroded by cleaning chemicals or other substances CHECK REPAIR Make sure connector is clean and tight Check probe s resistance Replace the Temperature Probe if open resistance exceeds 56 000 Ohms See Temperature Probe sect...

Page 34: ...ation Power Vent configurations derive all combustion air from the room where they are installed and discharge all flue gases to the outdoor atmosphere through a sealed vent exhaust pipe Power vent configurations have one vent pipe connected to the water heater which can be terminated in a vertical or horizontal arrangement Direct Vent Configuration Direct Vent configurations derive all combustion...

Page 35: ...llect inside and clog the Burner which can cause poor combustion sooting rough starting rough operation and Ignition Failure fault conditions and Control System lock outs The Burner is a radial design that can trap debris see Combustion Blower Burner Assembly section on Page 4 Exceeding the equivalent length limitations for the vent piping will cause Blocked Exhaust fault conditions and Control Sy...

Page 36: ...n the absence of local codes with the National Electrical Code ANSI NFPA 70 or the Canadian Electrical Code CSA C22 1 If any of the original wire as supplied on the water heater must be replaced it must be replaced with UL Listed Power Limited Circuit Cable of the same size and rating as original wiring POWER SUPPLY CONNECTIONS The 120 VAC black hot wire from the power supply must connect to the b...

Page 37: ...heating is disabled The display CCB and other electrical components will still be energized and the display will read Water Heating Disabled The Enable Disable Switch can be used to disable operation and reset error codes To operate the water heater make sure the switch is set to Enabled position Turn power off at the source circuit breaker during installation and servicing POWER SUPPLY TEST Prope...

Page 38: ...ent piping are within the maximum equivalent lengths required in the Instruction Manual that came with the water heater Exceeding the maximum length or number of elbows allowed will also lead to Blocked Exhaust and or Blocked Air Intake fault conditions and Control System lock outs 6 The metal condensate elbow supplied with the water heater has a built in water trap thus it is not necessary to for...

Page 39: ...m the Junction Box The CCB sends a signal from the J5 socket to a 5 pin wiring socket on the SUF 60120 100250 blower and VFD on the SUF 119300 119500 top cover control assembly The signal is an electronic instruction to start stop and control blower speed The Combustion Blower runs at higher speeds during the Pre Post Purge operating states and runs at a lower speed during the Trial For Ignition o...

Page 40: ...on operating state If blower speed reduction does not occur during the Trial For Ignition operating state ensure the 5 pin plug from the CCB is securely plugged into the matching 5 pin socket on the blower assembly and that the J5 plug is securely plugged into the J5 socket on the CCB circuit board Perform a close visual inspection of the pins inside the plugs and sockets at the Combustion Blower ...

Page 41: ... Hertz Readings for those rpms displayed on the VFD Note These models are capable of modulating their input rate Therefore the RPM readings can be in between the Heating Speed and Minimum Modulation Speed RPMs The input rate should be verified with the water heater operating at full input rate Model Heating Speed RPM Heating Speed VFD Hertz Reading Minimum Modulation RPM Minimum Modulation VFD Her...

Page 42: ... central control board that instructs the VFD to transmit the proper frequency to the blower to produce the proper blower speed and proper input Three conditions must be met for the frequency drive to start the blower 1 120VAC must be supplied to the VFD 120VAC input 2 The ignition control board closes an enable circuit terminals LI1 and 24V 3 The ignition control board sends a 1 10VDC instruction...

Page 43: ...eel fiber jacket on the outer surface and is part of a larger Burner Assembly Figures below show side views of the complete Burner Assembly removed from the water heater with key components identified See the exploded view of the Combustion Blower Burner Assembly section on Page 4 also SUF 60120 100250 Models SUF 119300 119500 Models ...

Page 44: ...wires at the three spade connectors connecting the blower to the VFD and unplug the blower speed feedback connector from the wiring harness 9 Disconnect the 24 Volt power wires to the Gas Control Valve at the two spade connectors in the wiring harness to the valve 10 Disconnect the Blower Prover Switch sensing tube light blue soft tubing from the Combustion Blower outlet sensing port 11 Using a so...

Page 45: ...nding 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 The high voltage potential across the gap between the sparking rod and the grounding rod generate a spark Flame Sensor 1 2 Gap from Burner Spark Igniter 1 8 Spark Gap Spark Ignite...

Page 46: ...ocket on the CCB and the Burner Adapter are not broken pinched or disconnected Ensure there is approximately 120 VAC at the J6 Socket on the CCB It is a good practice to check for any crack or damage to the ceramic insulator If any crack is found replace the Spark Igniter Do not contaminate the ceramic insulator as this could make a shortage pass between the spark rod and grounding rod Ensure good...

Page 47: ...t gas orifice size SUF 60120 thru 100250 Models and all Natural gas models do not use a gas orifice ORIFICE CHART SUF 119300 THRU 119500 MODELS Models 119300 119400 119500 Natural N A N A N A Propane LP 0 344 0 344 0 344 Gas Control With Orifice Propane LP Gas Control Without Orifice Natural Gas w LP Gas Orifice Without Orifice SUF 119300 119500 Models ...

Page 48: ...cuit board Diagnostic and operational messages are generated by the CCB and sent to the UIM see UIM User Interface Module Screen on Page 54 Most of the water heater s components such as the Spark Igniter Combustion Blower 24 Volt Gas Control Valve and Temperature Probe are directly connected to one of the CCB s socket connectors CCB Circuit Board 120 VAC X 24 VAC 50 VA Transformer Molded Clips CCB...

Page 49: ...ally unplugged Cover Removal Procedure Refer to CCB section on Page 47 for these instructions 1 Ensure power to the water heater is turned off 2 Remove the upper and lower temperature probe connectors 3 Unlock clips on both sides and remove the cover Cover Replacement Procedure 1 Follow Cover Removal Procedure in reverse order to replace cover Service Notes If any operational problems fault condit...

Page 50: ...ician CCB CIRCUIT BOARD LAYOUT 11 12 1 J16 J5 J3 J13 J4 J17 J10 J9 J14 J15 J1 J6 J12 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6 6 6 6 7 7 8 8 8 9 9 7 10 8 CCB CENTRAL CONTROL BOARD POWER BOARD ASSEMBLY ...

Page 51: ...Common 5 Not Used 6 AUX NO 7 AUX Common 8 Line Voltage 9 Neutral J5 Socket Blower Logic VFD Blower PIN DESCRIPTION 1 24V 2 PWM Signal 3 Not used 4 Blower Speed Feedback 5 Grounding J6 Socket 120V Out PIN DESCRIPTION 1 Neutral 2 Line Voltage Out J9 Socket Temperature Probe PIN DESCRIPTION 1 ECO 2 Thermistor 3 Thermistor 4 ECO J12 Socket Configuration Key J13 Socket Display AIN ...

Page 52: ...ure Switch 9 Gas Control Valve 10 Gas Control Valve 11 24V 12 24V Return J15 Socket Pressure Switches PIN DESCRIPTION 1 Blower Prover Pressure Switch Blocked Air Intake Pressure Switch 2 Blocked Air Intake Pressure Switch Blocked Exhaust Pressure Switch 3 Blower Prover Pressure Switch 4 Blocked Exhaust Pressure Switch J16 Socket Low Voltage In PIN DESCRIPTION 1 24V AC 2 24V AC 3 Not Used 4 12V DC ...

Page 53: ...52 Servicing should only be performed by a Qualified Service Technician WIRING DIAGRAM SUF 60120 THRU 100250 ...

Page 54: ...53 Servicing should only be performed by a Qualified Service Technician WIRING DIAGRAM SUF 119300 THRU 119500 ...

Page 55: ...r inside the tank The second temperature on this screen is the Operating Set Point The Operating Set Point is the temperature at which the water heater will maintain the water inside the tank The third line on the screen is a text description of the Operational State of the water heater The operational state of the water heater is also indicated graphically by status icons Tank Temperature 103 F O...

Page 56: ...Central link of www statewaterheaters com for a listing of available Service Handbooks For additional information contact State Water Heaters 500 Tennessee Waltz Parkway Ashland City TN 37015 1 800 527 1953 www statewaterheaters com 2014 State Industries Inc 329298 000 ...

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