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SUF Service Handbook TABLE OF CONTENTS STC-077 Introduction . . . . . . . . . . . . . . . . . . . 2 Troubleshooting (continued) Blower . . . . . . . . . . . . . . . . . . . . . . . 25 Installation Pressure Switch Performance . 26 – 27 Clearances . . . . . . . . . . . . . . . . . . . . . 3 120 VAC to Ignitor . . . . . . . . . . . . . . 28 Gas Requirements . . . . . . . . . . . . . . . 3 Ignitor Resistance. . . . . . . . . . . . . . . 29 Venting . . . . . . . . . . . . . . . . . . . . . 4 – 8 Gas
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SU F SE R V I C E HA N D B O O K IN TR ODUC TI ON 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
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S U F S E RV IC E H A ND BOOK INSTAL LATION INSTALLATION CLEARANCES This portion of the handbook will review often overlooked installation require- ments. The installation manual covers these items in detail. SUF water heaters are approved for installation on com- bustible flooring. The minimum clear- ance to combustibles or non- combustibles 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
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SU F SE R V I C E HA N D B O O K INSTAL LATION VENTING Equivalent Feet of Pipe Intake or Exhaust VENT LENGTH TABLE NUMBER OF 90° 3” MINIMUM 3” MAXIMUM 4” MAXIMUM ELBOWS PIPE (FEET) PIPE (FEET) PIPE (FEET) 745 115 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 4-inch PVC may be used for a MAXIMUM intake of ONE HUNDRED TWENTY (120) EQUIVALENT FEET and a MAXIMUM exhaust of ONE HUNDRED TWENTY (120) EQUIVALENT FEET. The maximum number of 90° elbows w
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S U F S E RV IC E H A ND BOOK INSTAL LATION VENTING CONFIGURATIONS SEALED DIRECT SEALED DIRECT INDOOR CONVENTIONAL INDOOR CONVENTIONAL VENT VERTICAL VENT SIDEWALL VERTICAL SIDEWALL SEALED DIRECT VENT SEALED DIRECT VENT SEALED DIRECT VENT SEALED DIRECT VENT HORIZONTAL INTAKE VERTICAL INTAKE W/ CONCENTRIC VENT W/ CONCENTRIC VENT VERTICAL EXHAUST HORIZONTAL EXHAUST VERTICAL TERMINA- HORIZONTAL TERMINATION VENTING MATERIALS This unit can be vented using only PVC (Class 160, ASTM D-2241; Schedule 40
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SU F SE R V I C E HA N D B O O K INSTAL LATION 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 appli- cation 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
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S U F S E RV IC E H A ND BOOK INSTAL LATION 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 State Water Heaters Technical Tra
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SU F SE R V I C E HA N D B O O K INSTAL LATION 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 EX- HAUST OR INTAKE WILL BE OBJECTIONABLE. THIS INCLUDES LOCATION CLOSE TO OR ACROSS FROM WINDOWS AND DOORS. AVOID ANCH
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S U F S E RV IC E H A ND BOOK INSTAL LATION 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 mod- els. The National Fuel Code also specifies minimum make-up air opening sizes for vario
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SU F SE R V I C E HA N D B O O K INSTAL LATION 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 th
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S U F S E RV IC E H A ND BOOK INSTAL LATION 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 applia
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SU F SE R V I C E HA N D B O O K INSTAL LATION CONTAMINATED AIR RUST = CHIPS Along with adequate make-up air, the quality of the air is important. 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
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S U F S E RV IC E H A ND BOOK INSTAL LATION 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 State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 13 STC-077
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SU F SE R V I C E HA N D B O O K INSTAL LATION CONDENSATION The average dewpoint of natural gas flue products is 127° F. Propane flue products is 119° F. With 70° F ambient air temperature and 180° F stored water temperature, exhaust gas will be approxi- mately 140° F. Recommended starting point for water storage is 120° F. The extra high thermal efficiency of the SUF will result in condensation in the flue passage. The fol- lowing answers common questions about this condensation. CAN I DRAIN
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S U F S E RV IC E H A ND BOOK OP ERATI O N OPERATION SEQUENCE OF OPERATION State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 15 STC-077
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SU F SE R V I C E HA N D B O O K OP ERA T ION CONTROLS NORMAL INDICATIONS / READINGS / SETTINGS During Call for Heat • On/Off switch in the “on” position DISPLAY PANEL (CONTROL PANEL) • Water Temperature F° — current average tank water temperature displayed • 120 VAC LED light on • 24 VAC LED light on • High Limit/Vent Switch LED light on • Blower (while blower is running) LED light on • Air Pressure Switch (while blower is running) LED light on • Control Status LED light on • Gas Val
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S U F S E RV IC E H A ND BOOK OP ERATI O N CIRCUT BOARDS DISPLAY CIRCUIT BOARD IGNITION CIRCUIT BOARD State Water Heaters Technical Training Department Ashland City, Tennessee © 2004 17 STC-077
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STC-077 SU F SE R V I C E HA N D B O O K TROUBLE S HOOTING TROUBLESHOOTING PRE-SERVICE TIPS CHECK THAT: • Insure 120 VAC power supply has correct polarity — check neutral (white) wire to ground with volt meter. It should read “0” volts. • Tank is full of water • Exhaust and intake vent do not exceed allowable limits • All plugs into boards are secure • Condensate hose is drained and open • Proper (natural or propane) gas is supplied SUF SERVICE HANDBOOK 120 VAC TO CONTROL STEP 1 120 VAC TO CON
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S U F S E RV IC E H A ND BOOK TROUBLE S HOOTING TRANSFORMER STEP 2 120 VAC TO TRANSFORMER STEP 2: CHECK FOR 120 VAC TO TRANSFORMER 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 VAC between pin 1 and 2 at CN4 on the control board as illustrated above. Perform this test with the CN4 plug disconnected and the On/Off switch turned on. IF… THEN check CN1 plug connection 120 VAC is not present replace contro
