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Service Handbook
COMMERCIAL GAS HIGH EFFICIENCY WATER HEATERS
MODELS: SUF 60 thru 120
SUF 100 thru 250
SUF 130 thru 500
SERIES 100, 101 and 104.
500 Tennessee Waltz Parkway
Ashland City, TN 37015
SERVICING SHOULD ONLY BE PERFORMED BY A QUALIFIED SERVICE AGENT
PRINTED IN THE U.S.A. 0511 198152-003
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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 PRESSUR
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INTRODUCTION The service handbook is designed to aid in servicing and troubleshooting State Water Heaters Ultra Force SUF commercial water heaters in the field. No duplication or reproduction of this book may be made without the express written authorization of the State Water Heaters. 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 assis
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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 • THE
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GENERAL INFORMATION INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For all side wall terminated, horizontally vented power vent, direct vent, and power direct vent gas fueled water heaters installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned 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
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INSTALLATION QUICK TIPS – SUF 120 AND 150 GAS PRESSURE ADJUSTMENT PROCEDURE: GAS PRESSURE SUF 120 AND 150 MODELS Main line gas pressure to the water heater for natural gas should be between a maximum of 10.5" w.c. (2.59 kPa) for natural gas, 14.0" w.c. (3.45 kPa) for propane and a minimum of 4.8 w.c. (1.18 kPa) for Natural Gas, and 8.5" w.c. (2.08 kPa) for Propane Gas. Also see gas pressure specification table on page 4. A supply gas pressure regulator (service regulator) must be installed on
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Compare result to the de‑rated input required for the elevation at the installation 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: 3. 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. (2.5 kPa) on the propane models. Clockwise to increase gas pressure and input rate.
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INSTALLATION QUICK TIPS – 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 THE 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 THE AIR FLOW AND MAKES ADJUSTMENTS TO
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INSTALLATION QUICK TIPS – SUF 300, 400, 500 GAS PRESSURE ADJUSTMENT PROCEDURE: GAS PRESSURE SUF 300, 400, 500 A minimum dynamic gas supply pressure of 5.2" w.c. (1.29 kPa) for Natural Gas and 11" w.c. (2.74 kPa) for LP Gas is required before making any adjustment to the 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. Check gas line pressure
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INSTALLATION QUICK TIPS – SUF 300, 400, 500 SEE MANUAL FOR COMPLETE INSTALLATION INSTRUCTIONS & DETAILS 9 Servicing should only be performed by a Qualified Service Agent
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INSTALLATION – VENTING CATEGORY AND MATERIALS ULTRA FORCE VENTING Category IV • Positive pressure in vent, above atmospheric. • These models will produce excessive condensate in vent. • Vent system must not be combined with any other appliances. • Flue gas temperatures less than 140°F. • Condensing water heater, thermal efficiency of this product will produce condensate in the vent system, the heater is equipped with provision for draining condensate from vent system. • PH of condensate approx
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VENTING TABLES – SUF 120 ‑ 250 Maximum equivalent feet of intake and vent pipe using 3" PVC is 50 feet (15.2 m). Equivalent feet must include any 90° elbows (two 45° elbows equal one 90° elbow). Three inch diameter 90° elbows are equivalent to 5' (1.5 m) of pipe. Maximum equivalent feet of intake and vent pipe using 4" PVC is 120 feet (36.6 m). Equivalent feet must include any 90° elbows (two 45° elbows equal one 90° elbow). Four inch diameter 90° elbows are equivalent to 5' (1.5 m) of pipe.
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CONCENTRIC VENTING Concentric venting allows for a single wall penetration. For multiple water heater installation using this vent practice any additional vents of this type may be located 12" on centerline to either side of the first vent or 12" on centerline vertically above the first vent. Concentric kits may be extended to a maximum allowable length of 5 feet (152 cm). Schedule 40 PVC pipe must be carefully measured and cut to the desired length. Do not use couplings when extending the l
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VENT CONDENSATION 6” PIPE FIELD SUPPLIED 6” x 4” REDUCER FIELD SUPPLIED 4” PIPE FIELD SUPPLIED EXHAUST ELBOW VENT CONNECTION FACTORY INSTALLED VENT (EXHAUST) CONNECTION Failure to properly install the drain line on the condensate elbow will result in a water heater shut down and a “blocked exhaust” fault message. The average dew point 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
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v v VENTING – ALL MODELS – SINGLE PIPE DIRECT VENT – USING OUTSIDE AIR TERMINATION CLEARANCES SIDEWALL POWER VENT POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION D E L B VENT TERMINAL AIR SUPPLY INLETAREA WHERE TERMINAL IS NOT PERMITTED V X Figure 2 V ent terminal clearances for “Power V ent” installations. Power V ent configurations use room air for combustion. 1 2 1 2 CANADIAN INSTALLATIONS US INSTALLATIONS CANADIAN INSTALLATIONS US INSTALLATIONS
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v v VENTING – ALL MODELS – TWO PIPE DIRECT VENT – USING OUTSIDE AIR TERMINATION CLEARANCES SIDEWALL DIRECT VENT DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION D E L B VENT TERMINAL AIR SUPPLY INLETAREA WHERE TERMINAL IS NOT PERMITTED V X Figure 3 V ent terminal clearances for “Direct V ent” installations. Direct V ent configurations use outdoor air for combustion. 1 2 1 2 CANADIAN INSTALLATIONS US INSTALLATIONS CANADIAN INSTALLATIONS US INSTALLA
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VENT TERMINATION – DIRECT VENT – ALL MODELS WHEN LOCATING THE TERMINALS ON A SIDEWALL, THE FOLLOWING SPECIFICATIONS PERTAINING TO 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" (61 cm) from the vertical centerline of the exhaust vent terminal (see Figure below). In colder climates increasing this separation to atleast 48" (122 cm) will reduce possibility of frost ov
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DIRECT VENTING – ALL MODELS The air intake provided on the unit contains a mesh screen to prevent large particles from entering the unit. 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. 45° PVC Elbow Remove the balance plate (SUF 400/ 3" 120-250 500 only) and mesh screen before gluing intake air pipe to the fitting. 4" 300-500
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CONTROL OVERVIEW Interaction with the water heater controller is through an LCD display called the Universal Interface Module (UIM). This screen is also referred to as the “desktop” or “desktop menu”. Up and down buttons and three operation buttons allow navigation through the control menus and to make adjustments to the water heater. Operation of the three lower buttons is defined immediately above them on the screen. While the water heater is operating, the user interface will display the d
