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
198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
INTRODUCTION
The service handbook is designed to aid in inclusive. If you are experiencing a problem
servicing and troubleshooting S tate W ater not covered in this handbook, please contact
Heaters Ultra Force SUF commercial water State Water Heaters Technical Information at
heaters i n t he f ield. No duplication or
1-800-365-0024,
by
e
mail
at
without the express written authorization of State Water Heater representative for further
State Water Heaters .
assistance.
provide you with a step by step procedure to
is also a resource for installation and service
verify pr oper i nstallation, opera tion, and
information. This handbook is intended for
troubleshooting procedures. Additional quick
use by licensed plumbing professionals and
reference data is included to assist you in
reference should be made to the installation
servicing these products.
manual accom panying the prod uct. This
The information contained in this handbook handbook contains supplemental information
is designed to answer co mmonly face d to the product’s i nstallation and operation
situations encountered in the operation of manual.
this product line and is not meant to be all
QUALIFICATIONS
ANSI Z223.1 Sec 3.3.83
"Qualified Agency"
"Any individual, firm, corporation or company Service of this water heater requires ability
that ei ther i n person o r through
a
equivalent to th at of a Qual ified S ervice
representative i s e ngaged i n an d i s Agent (l icensed t radesman) i n the fi eld
responsible for (a) the installation, testing or involved. Installation skills such as plumbing,
replacement of g as p iping or (b) the
air supp ly, vent ing, gas s upply, e lectrical
connection, i nstallation, testing, re pair or supply are required in addition to electrical
servicing of appliances and equipment; that testing ski lls. S ome products may require
is experienced in such work; that is familiar combustion testi ng
equipment and
with all precautions required; and that has certification. If you do not possess these
complied with al l the requirements of the skills or do not have the proper tools you
authority having jurisdiction."
should not attem pt to serv ice thi s w ater
heater.
State Water Heaters – Technical Training Department 2
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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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.
○ UEi model EM200 or equivalent
● WATER PRESSURE GAUGE w/ LAZY HAND AND HOSE BIBB CONNECTION
● THERMOMETER
● 1-1/16 INCH SOCKET WITH EXTENSION FOR ANODE REPLACEMENT
● SET OF NUMBERED DRILL BITS
WATER PRESSURE
TEST GAUGE W/ LAZY
HAND AND HOSE BIBB
CONNECTION
DIGITAL MULTIMETER
DIGITAL MANOMETER
State Water Heaters – Technical Training Department 3
Ashland City, Tennessee © 2009
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198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
GENERAL INFORMATION
INSTALLATION REQUIREMENTS FOR THE
COMMONWEALTH OF MASSACHUSETTS
equipment is installed in a crawl space or an attic,
the hard wired carbon monoxide detector with alarm
For al l side w all terminated, hor izontally vented and battery back-up may be installed on the next
power vent, direct vent, and power direct vent gas adjacent f loor l evel. I n t he e vent t hat the
fueled w ater heat ers installed i n ev ery dwelling, requirements of this subdivision can not be met at
building or structure used in whole or in part for the t ime of c ompletion of i nstallation, the ow ner
residential pur poses, including t hose ow ned or
shall have a period of thirty (30) days to comply with
operated by the Commonwealth and where the side the above requirements provided that during said
wall exhaust vent termination is less than seven (7) thirty (30) day period, a battery operated carbon
feet above finished grade in the area of the venting, monoxide detector with an alarm shall be installed
including but not limited to decks and porches, the APPROVED CARBON MONOXIDE DETECTORS
following requirements shall be satisfied:
INSTALLATION OF CARBON MONOXIDE
DETECTORS
Each carbon monoxide de tector as r equired in
accordance with the above provisions shall comply
with NFPA 720 and be ANSI/UL 2034 listed and
At the time of installation of the side wall horizontal CSA certified.
vented gas fueled equipment, the installing plumber SIGNAGE
or gas fitter shall observe that a hard wired carbon A m etal or p lastic i dentification plate s hall b e
monoxide detector with an alarm and battery back- permanently mounted to the exterior of the building
up is installed on the floor level where the gas at a minimum height of eight (8) feet above grade
equipment is t o b e i nstalled. In add ition, t he directly in line with the exhaust vent terminal for the
installing plumber or gas fitter shall observe that a horizontally vented gas fueled heating appliance or
battery operated or hard w ired carbon monoxide equipment. The sign shall read, in print size no less
detector w ith an al arm i s i nstalled on eac h than one-half (1/2”) inch in size,
additional level of the dwelling, building or structure
served by the sidewall horizontal vented gas fueled
equipment. It s hall b e the re sponsibility o f the
property owner to secure the services of qualified
licensed pr ofessionals for the i nstallation of har d
wired carbon monoxide detectors. In the event that
the s ide wall hor izontally v ented gas fueled
“GAS VENT DIRECTLY BELOW. KEEP CLEAR
OF ALL OBSTRUCTIONS.”
GAS PRESSURE SPECIFICATIONS
Natural
120-150
Propane
120-150
Natural
199-250
Propane
199-250
Natural
300/400/500
Propane
300/400/500
MODELS
Maximum Gas Supply Pressure
Nominal Gas Supply Pressure
10.5” WC
(2.59kPa)
14.0“WC
( 3.45kPa)
10.5“WC
(2.59kPa)
14.0“WC
( 3.45kPa)
11.0”WC
(2.74kPa)
14.00”WC
(3.49kPa)
7.0”WC
(1.74kPa)
11.0“WC
( 2.74kPa)
7.0“WC
(1.74kPa)
11.0“WC
( 2.74kPa)
7.0”WC
(1.74kPa)
11.0”WC
(2.74kPa)
Minimum Gas Supply Pressure
(Low Gas Press. Switch
Setting)
4.8”WC
(1.20kPa)
8.5“WC
( 2.12kPa)
4.8”WC
(1.20kPa)
8.5“WC
( 2.12kPa)
5.2”WC
(1.54kPa)
11.0“WC
( 2.74kPa)
Manifold Pressure
4.0”WC
10.0“WC
0“WC
0“WC
4.00“WC
10.0“WC
(0.98kPa)
(2.49 kPa)
( 0 kPa)
( 0 kPa)
( 1.25kPa)
( 2.49kPa)
State Water Heaters – Technical Training Department 4
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
INSTALLATION QUICK TIPS – SUF 120 and 150 GAS PRESSURE
ADJUSTMENT PROCEDURE:
GAS PRESSURE
a. Attach a pressure gauge (manometer) to the
manifold pressure tap and refer to page 4 for correct
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.
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 gas.)
H = Heating value of gas (in Btu’s per cubic foot of
gas).
A supply gas pressure regulator
(service regulator) must be installed on
the gas supply line within 10' (305 cm)
of the unit.
Btuh = Actual heater input rate, in Btuh.
EXAMPLE: (Using SUF-150 heater)
T = 25.25 seconds
H = 1050 Btu/ft.3
BTUH = ?
Also see gas pressure specification table on page 4.
1.Check gas line pressure with a manometer.
2.Check manifold 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 counterclockwise to decrease gas
pressure to obtain 4.0" W.C.(1 K pa) for natural gas
and 10.0" W.C. (2.5 kPa) for L.P. Gas.
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:
c. 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. (2.5kPa) on the
propane models. Clockwise to increase gas pressure
and input rate. Counterclockwise to decrease gas
pressure and input rate.
3. Cycle the burner on and off several times to check
its operation.
4. Check the operation of the limit and operating
controls.
5. Check the vent system seams and joints and
ensure that there is no discharge of flue products into
the room.
d. “Clock” the meter as in step (b) above.
e. Repeat steps (c) and (d) until the specified input
rate is achieved.
6. Check the input rate.
f. Turn the manual gas valve to “OFF”. Replace the
pressure regulator cover screw. Remove the pressure
gauge or manometer from the manifold pressure tap.
Replace the set screw in the manifold pressure tap. If
the gas pressure regulator cannot be adjusted to give
the full input rating with sufficient gas pressure at the
valve, check to ensure the unit is equipped with the
correct orifice.
HIGH ALTITUDE INSTALLATIONS
SUF 120 - 150
For appliance installation locations with elevations
above 6,500 feet (1982 meters) consult the “High
Altitude Installation” section of the owners manual.
State Water Heaters – Technical Training Department 5
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
INSTALLATION QUICK TIPS - SUF 199 AND 250 GAS PRESSURE
ADJUSTMENT PROCEDURE:
GAS PRESSURE
HIGH ALTITUDE INSTALLATION
The SUF 199 and 250 models are suitable
for installation up to 10,100 feet above sea
level with no adjustments.
SUF 199 AND 250 MODELS
IMPORTANT NOTE
GAS ORIFICE
The SUF 199 and 250 models do not have a
natural gas orifice. A .230” orifice is used on
LP gas models.
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 THE FAN
SPEED WHICH IN EFFECT CONTROLS
THE AMOUNT OF GAS FLOW.
THEREFORE, THE UNIT WILL SELF
ADJUST TO 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."
Venturi
Gasket
w/o orifice
Gas Control Without Orifice
Natural Gas
Venturi
Gasket w/
LP Gas
Orifice
(.230”
Brass)
Gas Control with .230” LP Orifice
Once the unit is installed and filled with water
and the inlet pressures confirmed, simply
turn the switch "on" and observe operation.
Cycle the unit "off" and "on" several times to
ensure proper operation.
A supply gas pressure
regulator
(service regulator) must be installed on
the gas supply line within 10' (305 cm)
of the unit.
State Water Heaters – Technical Training Department 6
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
INSTALLATION QUICK TIPS - SUF 300, 400 GAS PRESSURE
ADJUSTMENT PROCEDURE:
GAS PRESSURE
HIGH ALTITUDE ADJUSTMENT
SUF 300,400,
SUF 300,400,
For high altitude adjustments, contact the
help line on the front of the water heater or
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.
1. Check gas line pressure with a 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
pressure to obtain 4.0" w.c. (0.996 kPa) for
Natural Gas and 10" w.c. (2.49kPa) for LP gas.
3. Cycle the burner on and off several times to
check its operation.
4. Check the operation of the limit and operating
controls.
5. Check the vent system seams and joints and
ensure that there is no discharge of flue products
into the room.
6. Check the input rate as shown on page 5.
State Water Heaters – Technical Training Department 7
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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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
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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). Four inch
diameter 90° elbows are equivalent to 5' (1.5m) of pipe.
Vent Length Table Equivalent Feet (Meters) 120 through 250
Number of 90°
Elbows
3" Minimum
Pipe (Ft./M.)
3" Maximum
Pipe (Ft./M.)
4"Maximum
Pipe (Ft./M.)
ONE (1)
TWO (2)
THREE (3)
FOUR (4)
FIVE (5)
SIX (6)
7/2.1
7/2.1
7/2.1
7/2.1
7/2.1
7/2.1
45/13.7
40/12.2
35/10.7
30/9.1
---
115/35
110/33.5
105/32
100/30.5
95/29
---
90/27.4
VENTING TABLES SUF 300,400,
Vent Length Table Equivalent Feet (Meters) 300,400,
Number of
90°Elbows
4" PVC
Maximum Feet / meters of Pipe
ONE (1)
TWO (2)
THREE (3)
FOUR (4)
FIVE (5)
SIX (6)
65' / 19.7 m
60' / 18.2 m
55' / 16.7 m
50' / 15.2 m
45' / 13.6 m
40' / 12.1 m
State Water Heaters – Technical Training Department 9
Ashland City, Tennessee © 2009
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198152-002
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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
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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
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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).
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 the direct vent.
2. The horizontal centerline of the intake vent terminal may not be located
lower than the horizontal centerline of the exhaust vent terminal
State Water Heaters – Technical Training Department 12
Ashland City, Tennessee © 2009
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198152-002
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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.
45° PVC Elbow
Remove the balance plate and mesh
screen before gluing intake air pipe
to the fitting.
3” 120-250
4” 300- 400
Two 3” or 4” 45° PVC elbows with mesh screens are provided with each unit. Both elbows are
to be used in direct vent applications. The screens are provided to keep vermin and large
debris from entering the intake air and exhaust vent runs.
State Water Heaters – Technical Training Department 13
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
CONTROL OVERVIEW
Interaction with the water heater controller is done
through an LCD display called the Universal
The table of status icons describes graphically
operational details of the water heater. Below is a
Interface Module (UIM).This screen is also referred to legend of all the status icons:
as the “desktop” or “desktop menu”. Up and down
Status
Icon
Description
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.
The temperature of the water in the tank has
fallen and the water heater will now initialize a
new heating cycle.
While the water heater is operating, the user interface
will display the desktop screen (if there are no active
faults or warnings).
The temperature of the water in the tank has
reached the Operating Set Point.
●
●
An example of this screen is shown below.
The first temperature on this screen is the
temperature of the water 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 operating state of the water
heater is also indicated graphically by status
icons.
The control i s unable t o i nitiate any f urther
heating cycles. This is usually caused by a fault
condition detected by the control, but can also
occur when an external system (like an energy
management sys tem) has as ked t he w ater
heater to discontinue any further heat cycles.
●
●
The blower is being energized.
●
The blower pressure switch has been made.
The igniter has been energized.
The igniter has been energized and sufficient
current for ignition has been detected.
The control has requested that the gas valve
be turned on.
The control has sensed flame in the burner.
The control has detected a fault condition. A
fault condition will cause the water heater to
discontinue operation.
The control has detected a warning condition.
These conditions w ill not cause t he water
heater to discontinue further heating cycles, but
does merit attention.
UP AND
DOWN
BUTTONS
OPERATION
BUTTONS
State Water Heaters – Technical Training Department 14
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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.
ACTION:
Press Change then use the UP and DOWN buttons to
change the temperature Set Point.
DISPLAY:
ACTION:
From the desktop screen, press Menu.
DISPLAY:
Note: This procedure can also be used to change the
Differential. The tank Upper and Lower Temperatures
are not user changeable. They are determined by the
temperature probes on the heater.
ACTION:
Press Update to accept the change or Cancel to reset
it.
DISPLAY:
ACTION:
From the Main Menu, press Select to enter the
"Temperatures" screen.
DISPLAY:
State Water Heaters – Technical Training Department 15
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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.
DISPLAY:
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 buttons to scroll through the options
for that setting.
DISPLAY:
State Water Heaters – Technical Training Department 16
Ashland City, Tennessee © 2009
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198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
FAULT AND WARNING CONDITIONS – ADVANCED DIAGNOSTIC INFORMATION
This water heater control has the ability to monitor Faults: This is a safety related condition that has been
almost all aspects of the water heater's operation. In detected by the heater.
the c ase t hat there i s an undes irable or uns afe
condition t hat occurs, t he water heat er control will NOTE: When these conditions occur, the water heater
detect this c ondition and determine the appropriate WILL NOT CONTINUE any further heating cycles and
action. T he w ater heat er c ontrol will di splay t he the water will no longer be heated until the condition is
information on the desktop in plain text that accurately corrected and, in most cases, power has been cycled.
describes the condition and diagn ostics i nformation
that can be used to correct the issue.
Example of a Fault:
There are t wo t ypes of c onditions t hat c an oc cur
during operation. These are Warnings 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:
Advanced Diagnostic Information
When a fault or warning has been declared, advanced
information can be found in the control. By pressing
the A dvanced but ton, det ailed i nformation can be
found regarding diagnosing and resolving the problem.
WARNING: Usage of the Advanced information
requires ability equivalent to that of a licensed
tradesmen in the field involved.
State Water Heaters – Technical Training Department 17
Ashland City, Tennessee © 2009
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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.
DISPLAY:
ACTION:
To get to the current fault information screen, press
Menu.
DISPLAY:
State Water Heaters – Technical Training Department 18
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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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.
Viewing Information About the Water Heater
The control for this water heater monitors many
different aspects of the water to ensure safe and
optimal operation. Much of the information monitored
is available to view in two areas of the control. The
first is the "Heater Status" and; the second is
"Heater Information."
ACTION:
Press the SELECT button for more information.
These items can be selected through the desktop
menu. In these menus, detailed information about the
water heater and the current status of specific
conditions can be found.
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:
State Water Heaters – Technical Training Department 19
Ashland City, Tennessee © 2009
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198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
CONTROL SEQUENCE (TYPICAL ALL MODELS)
TYPICAL SEQUENCE
10. The combustion blower will run for the duration of
the post purge cycle to purge the system of all
combustion gases. When the post purge cycle is
complete, the blower is de-energized and will coast to
a stop.
11. The control will now enter the idle state while
continuing to monitor the internal tank water
temperature and the state of other system devices. If
the temperature drops below the set-point value less
differential, the control will automatically return to
step 2 and repeat the entire operating cycle.
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. This includes
confirming the proper state of the air/gas switches and
ECO limit device and powered anodes.
3. If the control determines that the actual water
temperature inside the tank is below the programmed
temperature set-point less the differential, a call for
heat is activated.
4. If all checks are successfully passed, the
combustion blower is energized for the pre-purge
cycle.
5. When the pre-purge cycle is complete, power is
applied to the igniter element for the igniter warm-up
period.
6. At the conclusion of the igniter warm-up period, the
gas valve will open, allowing gas to enter the burner
chamber.
7. The igniter will remain on for a short predetermined
time period, then will be turned off.
Check mark in the box
indicates the blow er
proving sw itch contacts
are made
Blow er icon
indicates
pow er to the
blow er
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 try for ignition two more times before
lockout.
Flame icon indicates
burner is ignited and
that flame has been
sensed.
9. If a flame is confirmed, the control will enter the
heating mode where it will continue heating the tank
water until the set point temperature plus differential is
reached. At this point, the gas valve is closed and the
control enters the post-purge cycle.
State Water Heaters – Technical Training Department 20
Ashland City, Tennessee © 2009
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198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
CONTROL SEQUENCE FLOW CHART
Power on
Control displays
model,
temperature
setting and
status
The control
If all checks are
passed and there is
a call for heat the
blower is energized
for a pre purge
cycle
If checks are not
passed the
control will
display an error
or warning.
performs internal
system checks
and determines
tank temperature
is below set point
When the pre
purge is complete
power is applied to
the igniter for
The control will
store an error
history to show
what fault occurred
and the time
Warm-up.
elapsed since the
fault.
If the control fails
to see flame the
At the conclusion
of the igniter
warm up the gas
valve will open for
4 seconds.
blower will continue to
run for a 30 second
Inter purge. There will
be 3 trials for ignition
before a fault is
declared.
If the control
senses flame the
water heater will
fire until the set
point is reached.
At the conclusion
of the inter purge
the igniter will
warm and the gas
valve will open.
At the conclusion
of the heating
cycle the blower
will enter a post
purge cycle and
the control will
enter an idle state.
State Water Heaters – Technical Training Department 21
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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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). The CCB also
monitors all pressure switches, the hot surface
igniter, tank temperatures, the gas valve, the
anodes, and the flame sensor.
This is the back of the UIM.
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: Improper operation may be the result of a
loose connection. Please check all wiring
connections and the power supply to the water
heater.
State Water Heaters – Technical Training Department 22
Ashland City, Tennessee © 2009
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198152-002
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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 adjustable pressure regulator. T he
adjustment screw is accessed 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).
CONTROLS – GAS VALVE SUF 150
The gas control valve on the SUF 150 is has
a built in pressure regulator. The regulator
may be adjusted by removing the cap screw
marked “regulator” in the illustration.
Inlet gas pressure may be read at the inlet
pressure tap only if the manual switch is set
the “ON” position.
State Water Heaters – Technical Training Department 23
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
CONTROLS – GAS VALVE SUF 199 and 250
Once the unit is installed and filled with water
and the in let p ressures c onfirmed, simply
turn the switch "on" and observe operation.
Cycle the unit "off" and "on" several times to
ensure proper operation.
ADJUSTMENT PROCEDURE:
GAS PRESSURE
SUF 199 AND 250 MODELS
IMPORTANT NOTE
HIGH ALTITUDE INSTALLATION
The SUF 199 and 250 models are suitable
for installation up to 10,100 feet above sea
level with no adjustments.
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 THE FAN
SPEED WHICH IN EFFECT CONTROLS
THE AMOUNT OF GAS FLOW.
GAS ORIFICE
The SUF 199 and 250 models do not have a
natural gas orifice. A .230” orifice is used on
LP gas models.
Venturi
Gasket
w/o orifice
THEREFORE, THE UNIT WILL SELF
ADJUST TO ACQUIRE THE CORRECT
AMOUNT OF INPUT.
Gas Control Without Orifice
Natural Gas
Supply 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.
Venturi
Gasket w/
LP Gas
Orifice
(.230”
Brass)
Gas Control with .230” LP Orifice
A supply gas pressure
regulator
(service regulator) must be installed on
the gas supply line within 10' (305 cm)
of the unit.
State Water Heaters – Technical Training Department 24
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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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.
WARNING: Do not attempt adjustments on
this gas valve unless you have a
combustion analyzer. Contact the “help
line” listed on the water heater for
assistance.
Supply
gas
pressure
Manifold
gas
Pressure
0” WC
(0kPa)
State Water Heaters – Technical Training Department 25
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
CONTROLS – GAS VALVE , ORIFICE CHART– SUF300,400,
The gas control valve has a built in field ORIFICE CHART – SUF 300,400,
adjustable pressure regulator. The regulator
Model
Natural .27
LP
300
4”
.189”
400
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.
.314”
.219”
Manual Gas
Control Knob
Low Gas
24V
Pressure
Solenoid
Switch
connection
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.
State Water Heaters – Technical Training Department 26
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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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. These switches are essential to the
safe an d pr oper op eration o f the uni t. T he
switches are wired to the central control board
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 pipe for the specific model has not been
exceeded. Check the vent length tables on page 9
(CCB)
individually an d ea ch i s monitored
individually. The (CCB) is set up to shut the unit
down whenever there is a failure of any of the
switches and declare a fault for each individual
switch. It is important to understand the purpose
of each switch.
Low Gas Pressure
Sw itch
BLOCKED INLET PROVING SWITCH
The Blocked Inlet Proving switch electrical contacts
are normally closed. The blocked inlet proving
switch el ectrical c ontacts w ill op en when an
increase in negative pressure (vacuum) occurs
in the intake vent pipe. The switch is connected to
the pressure tap on the PVC flange connected to
the inlet of the blower. When this switch prevents
the u nit f rom ig niting, most li kely the in take is
blocked by some means. Verify that the air intake
pipe and ai r i ntake v ent t erminal ar e f ree of
obstructions that may prevent air from entering the
unit. Also check the that the equivalent feet of vent
pipe for the specific model has not been exceeded.
Check the vent length tables on page 9
Pressure
Sw itches
LOW GAS PRESSURE SWITCH
BLOWER PROVING SWITCH
The Blower Proving S witch i s pr ovided on t he
heater to v erify that the f an is operating. It is a
positive pressure switch whose electrical contacts
are normally open. The blower p roving switch
electrical contacts will close on a rise in pressure
as the blower increases the pressure in the burner.
This switch is connected to the burner tap by a
piece of Tygon (soft plastic) tubing. This tubing
must be connected in order for the switch to close
the electrical contacts. The controller requires that
the electrical contacts on this pressure switch be
open before it will allow the blower to come on. The
control w ill declare a f ault on the U IM if ei ther
condition occurs.
The Low Gas Pressure Switch electrical contacts
are normally open. The low gas pressure switch
electrical contacts will close on a rise pressure.
The c ontacts w ill open w hen t he p ressure falls
below the fixed set point. If this happens during a
heating cycle a the burner will be shut down and a
fault will be declared on the UIM.
State Water Heaters – Technical Training Department 27
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
CONTROLS – PRESSURE SWITCHES – SUF 120 through 250
BLOCKED OUTLET
PRESSURE SWITCH
BLOCKED INLET
PRESSURE SWITCH
LOW GAS PRESSURE
SWITCH
MODEL
120N
150N
199N
250N
120LP
150LP
199LP
250LP
Normally Closed /
Open on a Rise in
Pressure
SWITCH
+1.2”WC
+0.98”WC
+1.06”WC
+4.0”WC
+1.3”WC
+1.3”WC
+4.0”WC
+2.0”WC
MODEL
All
Normally Closed /
Open on a Rise in
Pressure
PRESSURE
0.85”WC
MODEL
Natural
LP
Norm ally Open / Close
on a Rise in Pressure
Tolerance +/-.05”WC
PRESSURE
4.0”WC
8.0”WC
BLOWER PROVER
PRESSURE SWITCH
MODEL
All
PRESSURE
+.075”WC
Tolerance +/-.05”WC
Normally Open / Close
on a Rise in Pressure
Tolerance +/-.05”WC
Tolerance +/-.05”WC
Top View of Pressure Switches
Pressure Switches” under “Literature/Service Handbooks”
State Water Heaters – Technical Training Department 28
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
CONTROLS – PRESSURE SWITCHES – SUF 300,400,
BLOWER PROVER
PRESSURE SWITCH
LOW GAS PRESSURE
SWITCH
MODEL
PRESSURE
+1.0”WC
+2.5”WC
+4.5 'WC
MODEL
Natural
LP
PRESSURE
+4.6”WC
+9.0”WC
300
400
500
Norm ally Open/
BLOCKED INLET
Close on a Rise in
Pressure
Tolerance +/-.05”WC
PRESSURE SWITCH
Normally Open / Close on
a rise in Pressure
MODEL
PRESSURE
-.085”WC
-1.25”WC
-1.35”WC
300
400
500
BLOCKED EXHAUST
PRESSURE SWITCH
Tolerance +/-.05”WC
MODEL
300
400
PRESSURE
+1.15”WC
+1.39”WC
+1.77”WC
Norm ally Closed/
Open on a Rise in
Pressure
500
Tolerance +/-.05”WC
Normally Closed /
Open on a Rise in
Pressure
Tolerance +/-.05”WC
Top View of Pressure Switches
SUF 300,400,
Pressure Switches” under “Literature/Service Handbooks”
State Water Heaters – Technical Training Department 29
Ashland City, Tennessee © 2009
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198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
CONTROLS – CONNECTIONS, IGNITER, FLAME SENSOR, SIGHT GLASS, POWERED
ANODES
The connections for the hot surface igniter The new U ltra Force com mercial w ater
and the flame sense rod are shown below. heater i s eq uipped w ith pow ered an odes.
Also shown is the burner sight glass. These These anodes never need replacement. The
features are typical for all models.
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 water in
the tank.
Flame
Sensor
Hot Surface Igniter
Powered anode connection
Burner Mounting
Bolts
Burner Sight Glass
State Water Heaters – Technical Training Department 30
Ashland City, Tennessee © 2009
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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 is equipped with an electric hot
surface i gniter. The i gniter m aterial i s
silicone carbide and should not be handled
Pre-purge
25 seconds
17 seconds
Igniter Warm-up
with bare hands because of possible damage Trial for ignition
5 seconds
to the igniter.
Gas Control Open
Inter/Post Purge
30 seconds
The normal ohm reading at 77°F is 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 flame sensing is al so known as 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.
State Water Heaters – Technical Training Department 31
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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ULTRAFORCE COMMERCIAL GAS WATER HEATER
SUF 120 thru 400 SERVICE HANDBOOK
BLOWER SPEED CONTROL SUF 199 AND 250
The input of the SUF 199 and SUF 250 is Meter black lead is connected to ground (not
determined by the blower. The input of the shown) and the red lead is connected to an
water heater may be determined by clocking open te rminal o n bl ower spee d con trol
the meter as shown on page 5 or by making connection.
sure the blower is receiving 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
199 N 133
250 N 133
199 LP 200
250 LP 266
Hz
87
87
156
96
Meter red probe
connected to
open terminal on
plug
Note: R emoving the plug show n in the
illustration will cause the blower to accelerate
and the input of the water heater to increase
to a much higher rate.
State Water Heaters – Technical Training Department 32
Ashland City, Tennessee © 2009
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198152-002
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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. 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 a 1-10VDC instruction – terminals 0V and AI1. See table
on the next page for voltage and frequency information.
VARIABLE FREQUENCY DRIVE
GROUND HOT NEUTRAL
155
R/L1
N
G
BLOWER MOTOR WIRES
BLACK WHITE
RED
U/T1
V/T2
W/T3
NOTE: BE SURE TO MATCH WIRE
COLORS WHEN CONNECTING BLOWER
WIRES OR BLOWER MAY RUN
BACKWARD AND CAUSE A FAULT.
RC
RA
0V
AI1
+5V
DO
LI1
LI2
LI3
LI4
+15V
1-10 VDC Speed Instruction
Enable Disable Circuit
State Water Heaters – Technical Training Department 33
Ashland City, Tennessee © 2009
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198152-002
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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. 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 Instructions - VFD
Model
SUF
400
0 – 10
VDC
Instruction Volts DC
Terminals 0V and AI1
Volts
Frequency
Pressure
W.C.”
Ignition (low speed)
Purge (high speed)
VFD Part Number
7.53
7.77
150 Hz+/- 2
155 Hz+/- 2
5.3”
5.85”
197500-000
155
Frequency is displayed
in the red LED. 155Hz
State Water Heaters – Technical Training Department 34
Ashland City, Tennessee © 2009
Servicing should only be performed by a Qualified Service Agent
198152-002
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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
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198152-002
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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
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198152-002
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500 Tennessee Waltz Parkway
Ashland City, TN 37015
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