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State Water Heaters SUF 100 150, Service Handbook

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State Water Heaters SUF 100 150 Service Handbook Download Page 32

ULTRAFORCE   COMMERCIAL GAS WATER HEATER

SUF 120 thru 400 SERVICE HANDBOOK

State Water Heaters – Technical Training Department 31

Ashland City, Tennessee © 2009

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

HOT SURFACE IGNITER / FLAME SENSOR / CONTROL TIMING

HOT SURFACE IGNITER

This water i s equipped with an  electric hot
surface  i gniter.    The  i gniter  m aterial  i s

silicone carbide and  should not be  handled
with bare hands because of possible damage

to the igniter.  
The  normal  ohm  read ing  at   77°F   is   listed

between  40  and   70  ohm s.    T he  minimum
igniter current monitored by the  CCB is 2.7

amps.   Once   this   threshold   is   met   a   check
mark  will  appear  by  the  i gniter i con i n  the

UIM (display).

FLAME SENSOR

This   water  hea ter   is  eq uipped  w ith   an
electronic flame sensor.   The flame  sensor

senses  fl ame   by  passi ng   a  s mall   electric
current through the burner flame.   This type

of  f lame  s ensing   is  al so  k nown  a s  fl ame
rectification.  T he  CCB  is  l ooking  fo r  a

minimum current of .7 micro amperes for the
water heater to operate. Once this current is

established the UIM will display a flame icon.

CONTROL TIMING

Pre-purge

25 seconds

Igniter Warm-up

17 seconds

Trial for ignition
Gas Control Open

5 seconds

Inter/Post Purge

30 seconds

 

Summary of Contents for SUF 100 150

Page 1: ...1 PRINTED 0509 198152 002 COMMERCIAL GAS WATER HEATERS FOR MODELS SUF 60 120 SUF 100 150 SUF 100 199 SUF 100 250 SUF 130 300 SUF 130 400 SERVICE HANDBOOK HIGH EFFICIENCY COMMERCIAL GAS SERIES ...

Page 2: ... 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 CONT...

Page 3: ...er tools you should not attem pt to serv ice thi s w ater heater 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 express written authorization of State Water Heaters The fol lowing tex t and i llustrations w ill provide you...

Page 4: ...OLTS 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 AN...

Page 5: ...ired carbon monoxide detectors In the event that the s ide wall hor izontally v ented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next 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 of i nstallation the ow ne...

Page 6: ...ttach a pressure gauge manometer to the manifold pressure tap and refer to page 4 for correct pressure 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 g...

Page 7: ...O 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 Once the unit is installed and filled with water and the inlet pressures confirmed simply turn the switch on and observe oper...

Page 8: ...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 pressur...

Page 9: ...TER HEATER SUF 120 thru 400 SERVICE HANDBOOK State Water Heaters Technical Training Department 8 Ashland City Tennessee 2009 Servicing should only be performed by a Qualified Service Agent 198152 002 INSTALLATION TIPS SUF 300 400 ...

Page 10: ...ke 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 VENTING TABLES SUF 300 400 Number of 90 Elbows 4 PVC Maximum Feet meters of Pipe ONE 1 65 19 7 m TWO 2 60 18 2 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 Vent Length Table Equivalent Feet ...

Page 11: ... 120 thru 400 SERVICE HANDBOOK State Water Heaters Technical Training Department 10 Ashland City Tennessee 2009 Servicing should only be performed by a Qualified Service Agent 198152 002 VENTING ALL MODELS SINGLE PIPE POWER VENT USING ROOM AIR ...

Page 12: ... 120 thru 400 SERVICE HANDBOOK State Water Heaters Technical Training Department 11 Ashland City Tennessee 2009 Servicing should only be performed by a Qualified Service Agent 198152 002 VENTING ALL MODELS TWO PIPE DIRECT VENT USING OUTSIDE AIR ...

Page 13: ...O TERMINAL LOCATION MUST BE FOLLOWED 1 The intake vent terminal and the exhaust vent terminal must terminate on the same exterior wall and must be located at a minimum of 24 61cm from the vertical centerline of the exhaust vent terminal see Figure 9 In colder climates increasing the 24 61cm minimum will reduce possibility of frost over from side winds blowing exhaust vapors to the air intake of th...

Page 14: ...t WHEN THE UNIT IS TO BE SET UP AS A DIRECT VENT THE BALANCE PLATE AND MESH SCREEN MUST BE REMOVED BEFORE GLUING PIPE TO THE CONNECTOR THE INLET VENT PIPE MAY THEN BE GLUED TO THE AIR INTAKE PROVIDED ON THE UNIT Remove the balance plate and mesh screen before gluing intake air pipe to the fitting 3 120 250 4 300 400 45 PVC Elbow Two 3 or 4 45 PVC elbows with mesh screens are provided with each uni...

Page 15: ...nal State of the water heater The operating state of the water heater is also indicated graphically by status icons 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 temperature o...

Page 16: ...mperature menu Items in this menu allow you to monitor different temperature readings in the tank along with adjusting the Operating Set Point and Differential ACTION From the desktop screen press Menu DISPLAY ACTION From the Main Menu press Select to enter the Temperatures screen DISPLAY ACTION Press Change then use the UP and DOWN buttons to change the temperature Set Point DISPLAY Note This pro...

Page 17: ...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 the LCD screen ACTION From the Main Menu press the DOWN button to highlight Display Settings then press Select DISPLAY ACTION Use the UP and DOWN buttons to highlight the desired setting Then press Change Again use the UP and DOWN ...

Page 18: ...s and Faults Warnings This is a non safety related condition that the control has detected that m ay cause the water heater to operate in a less than optimal condition but does not pose a safety concern NOTE When t hese conditions oc cur continued heating cycles will continue and the heater will attempt to regulate the water in the tank to the Operating Set Point Example of a Warning Faults This i...

Page 19: ...CURRENT FAULT OR WARNING 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 to the fault through the display menu through the menu ACTION To get to the current fault information screen press Menu DISPLAY ACTION Press...

Page 20: ...f how long ago the fault occurred ACTION Press the SELECT button for more information DISPLAY ACTION Press the DOWN key to scroll through the fault history If you select a specific fault or warning you may press the VIEW button to view details regarding this fault DISPLAY Viewing Information About the Water Heater The control for this water heater monitors many different aspects of the water to en...

Page 21: ...ing gas to enter the burner chamber 7 The igniter will remain on for a short predetermined time period then will be turned off 8 The control will monitor the flame sense probe to confirm a flame is present If a flame is not verified within predetermined time period the gas valve will immediately be closed and the blower will continue to run for approximately 30 seconds inter purge The control will...

Page 22: ...wer is energized for a pre purge cycle The control will store an error history to show what fault occurred and the time elapsed since the fault When the pre purge is complete power is applied to the igniter for Warm up At the conclusion of the igniter warm up the gas valve will open for 4 seconds If the control senses flame the water heater will fire until the set point is reached If the control f...

Page 23: ...ing the cover The CCB is controlled by the settings given through the desk top menu UIM The CCB also monitors all pressure switches the hot surface igniter tank temperatures the gas valve the anodes and the flame sensor The CCB directly controls blower speed on the SUF199 and 250 models and indirectly controls blower speed on the SUF 400 by means of a Variable Frequency Drive see page 33 Note Impr...

Page 24: ... by removing the cap screw m arket regulator i n t he illustration Inlet gas pressure may be read at the inlet pressure tap only if the manual shut off valve gas cock is in the ON position Leaving the knob in the OFF position will not allow the burner to fire and will generate a fault code on th e UIM Universal I nterface Module The gas control valve on the SUF 150 is has a built in pressure regul...

Page 25: ...y gas pressure to the water heater for natural gas should be between a maximum of 10 5 2 59kPa for natural gas W C 14 0 3 45kPa for propane and a minimum as shown on page 4 that is for Natural Gas 4 98kPa W C And 9 0 1 97kPa for Propane Gas The inlet gas pressure must not exceed the maximum value Once the unit is installed and filled with water and the in let p ressures c onfirmed s imply turn the...

Page 26: ...valve by connecting to the pressure ports on the valve The manifold pressure on this valve is 0 w c 0kPa when the water heater is running Refer to the gas pressure chart on page 4 Note Tubing shown on pressure connections is installed for manometer connections It is not supplied with the water heater Manifold gas Pressure 0 WC 0kPa Supply gas pressure WARNING Do not attempt adjustments on this gas...

Page 27: ...table pressure regulator The regulator may be adjusted by removing the cap screw marked regulator The adjustment screw is underneath The g as val ve for the SUF Natural gas model is shown above This is a 24V solenoid operated gas valve Refer to the replacement parts information at the back of this manual for part numbers for Natural and LP gas valves for all SUF 300 400 and models ORIFICE CHART SU...

Page 28: ...urs BLOCKED OUTLET PROVING SWITCH The blocked outlet proving switch electrical contacts are normally closed The blocked outlet proving switch electrical contacts will open on a rise in pressure Check t o see i f t he c ondensate i s allowed to flow freely from the exhaust elbow and for obstructions in the exhaust venting and exhaust vent terminal Also check the that the equivalent feet of vent pip...

Page 29: ...ice Handbooks Top View of Pressure Switches BLOCKED INLET PRESSURE SWITCH MODEL PRESSURE All 0 85 WC Normally Closed Open on a Rise in Pressure Tolerance 05 WC LOW GAS PRESSURE SWITCH MODEL PRESSURE Natural 4 0 WC LP 8 0 WC Norm ally Open Close on a Rise in Pressure Tolerance 05 WC BLOCKED OUTLET PRESSURE SWITCH MODEL SWITCH 120N 1 2 WC 150N 0 98 WC 199N 1 06 WC 250N 4 0 WC 120LP 1 3 WC 150LP 1 3 ...

Page 30: ...e Handbooks Top View of Pressure Switches SUF 300 400 BLOCKED INLET PRESSURE SWITCH MODEL PRESSURE 300 085 WC 400 1 25 WC 500 1 35 WC Norm ally Closed Open on a Rise in Pressure Tolerance 05 WC LOW GAS PRESSURE SWITCH MODEL PRESSURE Natural 4 6 WC LP 9 0 WC Norm ally Open Close on a Rise in Pressure Tolerance 05 WC BLOCKED EXHAUST PRESSURE SWITCH MODEL PRESSURE 300 1 15 WC 400 1 39 WC 500 1 77 WC ...

Page 31: ...ns 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 The new U ltra Force com mercial w ater heater i s eq uipped w ith pow ered an odes These anodes never need replacement The CCB monitors the cur rent th rough t he anodes and will declare a fault if there is a disconnected wire or if there is no wate...

Page 32: ...listed between 40 and 70 ohms The minimum igniter current monitored by the CCB is 2 7 amps Once this threshold is met a check mark will appear by the igniter icon in the UIM display FLAME SENSOR This water hea ter is eq uipped w ith an electronic flame sensor The flame sensor senses fl ame by passi ng a s mall electric current through the burner flame This type of f lame s ensing is al so k nown a...

Page 33: ...g the proper Hz signal The blower rpm is controlled by the Central Control Board CCB The signal to the blower may be measured by attaching a MULTIMETER that has a Hertz Hz setting as shown in the illustration to the right If the Hz signal is within Model Hz Hz 199 N 133 87 250 N 133 87 199 LP 200 156 250 LP 266 96 Note R emoving the plug show n in the illustration will cause the blower to accelera...

Page 34: ...ves a signal from the 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 15V 3 The ignition control board sends ...

Page 35: ...and the pressure switch settings needed for the CCB to let the burner operate The frequency numbers displayed may vary slightly with slight variations in the DC voltage generated by the CCB If the water heater exhibits poor run characteristics check the frequency display If the frequency is more than 5 out of range check the DC volt signal at the terminals shown on page 33 Voltage Frequency Speed ...

Page 36: ...ATER HEATER SUF 120 thru 400 SERVICE HANDBOOK State Water Heaters Technical Training Department 35 Ashland City Tennessee 2009 Servicing should only be performed by a Qualified Service Agent 198152 002 WIRING DIAGRAM SUF 120 300 ...

Page 37: ... WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK State Water Heaters Technical Training Department 36 Ashland City Tennessee 2009 Servicing should only be performed by a Qualified Service Agent 198152 002 WIRING DIAGRAM SUF 400 ...

Page 38: ...2 500 Tennessee Waltz Parkway Ashland City TN 37015 www statewaterheaters com ...

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