COMMERCIAL GAS WATER HEATERS SERVICE HANDBOOK HIGH EFFICIENCY COMMERCIAL GAS SERIES FOR MODELS: • SUF 60 120 • SUF 100 150 • SUF 100 199 • SUF 100 250 • SUF 130 300 • SUF 130 400 PRINTED 0509 1 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 .........
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK INTRODUCTION 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 o f State Water Heaters . inclusive.
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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK GENERAL INFORMATION INSTALLATION REQUIREMENTS FOR THE COMMONWEALTH OF MASSACHUSETTS For al l side w all terminated, hor izontally vented power vent, direct vent, and power direct vent gas fueled w ater heat ers installed i n ev ery dwelling, building or structure used in w hole or i n p art f or residential pur poses, including t hose ow ned or operated by the Commonwealth and where the side wall exhaust vent termination is less than s
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 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK INSTALLATION QUICK TIPS - SUF 300, 400 GAS PRESSURE ADJUSTMENT PROCEDURE: GAS PRESSURE SUF 300,400, 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK INSTALLATION TIPS - SUF 300, 400 State Water Heaters – Technical Training Department 8 Ashland City, Tennessee © 2009 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).
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK VENTING - ALL MODELS – SINGLE PIPE POWER VENT – USING ROOM AIR State Water Heaters – Technical Training Department 10 Ashland City, Tennessee © 2009 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 State Water Heaters – Technical Training Department 11 Ashland City, Tennessee © 2009 Servicing should only be performed by a Qualified Service Agent 198152-002
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK 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" (61cm) from the vertical centerline of the exhaust vent terminal (see Figure 9).
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROL OVERVIEW – ALL MODELS Interaction with the water heater controller is done 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK ADJUSTING TANK TEMPERATURE – OPERATING SET POINT - DIFFERENTIAL The Operating Set Point of this water heater determines the regulated temperature for the water in the tank. This parameter is adjusted in the desktop Temperature menu. Items in this menu allow you to monitor different temperature readings in the tank along with adjusting the Operating Set Point and Differential.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CHANGING THE DISPLAY UNITS The desktop menu has the option of selecting between degrees Fahrenheit and 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: Press Update to accept the change or Cancel to reject it.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK FAULT AND WARNING CONDITIONS – ADVANCED DIAGNOSTIC INFORMATION This w ater heat er c ontrol has t he abil ity t o m onitor almost all aspects of the water heater's operation. In the c ase t hat there i s an undes irable or uns afe condition t hat o ccurs, t he water heat er control will detect t his c ondition and de termine the appropriate action.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK ACCESS TO THE 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: Press the DOWN button for more information.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK VIEWING THE FAULT HISTORY - VIEWING INFORMATION ABOUT THE HEATER The controller for this water heater will store a history of ten of the last Fault and Warning conditions that occurred. This is stored in the Fault History. The information about the fault or warning will include diagnostic information as well as an estimate of how long ago the fault occurred. ACTION: Press the SELECT button for more information.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROL SEQUENCE (TYPICAL ALL MODELS) TYPICAL SEQUENCE 1. When the control is powered it should display “waiting for connection” and “UIM v2.06”*. The manufacturer and unit model will be next. The next display will include water temperature, temperature setting and heater status. * This number may change as software revisions are made. 2. The control performed selected system diagnostic checks immediately upon power up.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROL SEQUENCE FLOW CHART Power on Control displays model, temperature setting and status If checks are not passed the control will display an error or warning . The control performs internal system checks and determines tank temperature is below set point If all checks are passed and there is a call for heat the blower is energized for a pre purge cycle When the pre purge is complete power is applied to the igniter for Warm-up.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROLS – CENTRAL CONTROL BOARD – CCB The Central Control Board or CCB is contained in the housing shown below. Access to the board and the wiring harness plugs can be accomplished by removing two Phillips screws holding the cover. This view shows the cover removed from the CCB. Remove these screws to release cover The CCB is controlled by the settings given through the desk top menu (UIM).
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROLS – GAS VALVE SUF 120 The gas control valve on the SUF 120 has a built i n adj ustable pre ssure regulator. T he adjustment screw i s a ccessed 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROLS – GAS VALVE SUF 199 and 250 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROLS – GAS VALVE SUF 199 and 250 Pressure readings may be taken on the gas 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROLS – GAS VALVE , ORIFICE CHART– SUF300,400, The gas cont rol va lve h as a bu ilt in field adjustable 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. ORIFICE CHART – SUF 300,400, Model Natural .27 LP 300 400 4” .314” .189” .
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROLS – PRESSURE SWITCHES – ALL MODELS All SUF models are provided with four pressure switches. T hese s witches ar e es sential to the safe an d pr oper op eration o f the uni t. T he switches are wired to the c entral c ontrol board (CCB) individually an d ea ch i s monitored individually. The (CCB) is set up to shut the unit down w henever there i s a failure of any of the switches and declare a fault for each individual switch.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROLS – PRESSURE SWITCHES – SUF 120 through 250 BLOCKED INLET PRESSURE SWITCH M ODEL PRESSURE All 0.85”WC Norm ally Clos e d / Ope n on a Ris e in Pres s ure LOW GAS PRESSURE SWITCH M ODEL PRESSURE Natural 4.0”WC LP 8.0”WC Norm ally Ope n / Clos e on a Ris e in Pre s s ure Tole rance +/-.05”WC Tolerance +/-.05”WC BLOCKED OUTLET PRESSURE SWITCH M ODEL SWITCH 120N +1.2”WC 150N +0.98”WC 199N +1.06”WC 250N +4.0”WC 120LP +1.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROLS – PRESSURE SWITCHES – SUF 300,400, BLOCKED INLET PRESSURE SWITCH M ODEL PRESSURE 300 -.085”WC 400 -1.25”WC 500 -1.35”WC Norm ally Clos ed/ Ope n on a Ris e in Pres s ure Tolerance +/-.05”WC LOW GAS PRESSURE SWITCH M ODEL PRESSURE Natural +4.6”WC LP +9.0”WC Norm ally Ope n/ Clos e on a Ris e in Pre s s ure Tole rance +/-.05”WC BLOWER PROVER PRESSURE SWITCH M ODEL PRESSURE 300 +1.0”WC 400 +2.5”WC 500 +4.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK CONTROLS – CONNECTIONS, IGNITER, FLAME SENSOR, SIGHT GLASS, POWERED ANODES The connections for the h ot surface i gniter 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK HOT SURFACE IGNITER / FLAME SENSOR / CONTROL TIMING HOT SURFACE IGNITER CONTROL TIMING This water i s eq uipped with a n 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK BLOWER SPEED CONTROL SUF 199 AND 250 The i nput of the SUF 199 and SUF 250 is determined by the blower. The input of the water heater may be determined by clocking the meter as shown on page 5 or by making sure the b lower i s rece iving the pro per Hz signal. The blower rpm is controlled by the Central Control Board (CCB).
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK VARIABLE FREQUENCY DRIVE – SUF 400 The Ultra Force SUF 400 model has a variable frequency drive (VFD) that controls the rpm of the blower motor. The VFD receives 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK VARIABLE FREQUENCY DRIVE - BLOWER SPEED AND PRESSURE READINGS The instructions for the VFD are sent from the CCB to in the form of a DC current. The chart below lists the current readings, the frequency signal displayed by the VFD, 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.
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK WIRING DIAGRAM – SUF 120 – 300 State Water Heaters – Technical Training Department 35 Ashland City, Tennessee © 2009 Servicing should only be performed by a Qualified Service Agent 198152-002
ULTRAFORCE COMMERCIAL GAS WATER HEATER SUF 120 thru 400 SERVICE HANDBOOK WIRING DIAGRAM – SUF 400, State Water Heaters – Technical Training Department 36 Ashland City, Tennessee © 2009 Servicing should only be performed by a Qualified Service Agent 198152-002
500 Tennessee Waltz Parkway Ashland City, TN 37015 www.statewaterheaters.
