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INSTALLATION AND OPERATION INSTRUCTIONS FOR Liberty US

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1. High Altitude Operation The Liberty US is designed to operate at its maximum listed capacity in installations less than or equal to 2000 ft 610 m above Sea Level Since the density of air decreases as elevation increases maximum specified capacity should be de rated for elevations above 2000 ft 610 m in accordance with Table 2 3 Table 2 3 De rate for High Altitudes 2000 ft 610 m 3000ft 914 m 4000 ft 1219 m 4500 ft 1372 m 5000 ft 1524 m de rate by 10 de rate by 10 de rate by 10 de rate by 10 de rate may vary In USA E de rate by 12 de rate by 16 de rate by 18 de rate by 20 Notes Canada Altitudes between 2000 4500 ft 610 1372 m de rate by 10 Consult local authorities for de rating capacities for altitudes above 4500 ft 1372 m USA De rate capacity by 4 for every 1000 ft 305 m if altitude is over 2000 ft 610 m Combustion At elevations above 2000 feet the combustion of the water heater must be checked with a calibrated combustion analyzer to ensure safe and reliable operation It is the Installers responsibility to check the combustion and to adjust the combustion in accordance to Section 9 0 Failure to follow these instructions may result in property damage serious injury or death US WH Series Installation and Operation Instructions Liberty US 3 0 WATER HEATER LOCATION In all cases the Liberty US must be installed indoors in a dry location where the a
2. p Wire Protection When passing any wiring through the cabinet of the water heater the INS Cte HU LET installer must use wire grommets suitable for securing the wiring and preventing chafing Failure to follow instructions may result in component failure serious injury or death PS Power Supply The Liberty US is designed to be powered using a single phase 120V AC WARNING power supply that is fused or protected via a circuit breaker to allow a maximum of 15 Amps Failure to follow instructions may result in component failure serious injury or death Labeling Label all wires prior to disconnecting them when servicing controls Wiring CAUTION errors can cause improper and dangerous operation Failure to follow instructions may result in property damage or personal injury Continuity Before connecting the line voltage wiring perform a continuity check CAUTION between all wires and ground to make sure that there are no electrical leaks that could blow a fuse or damage electrical components Also check the polarity of the line and neutral wires Line must measure 120VAC to ground neutral must measure zero Failure to follow instructions may damage the unit Max Load US400WH circulator outputs are each limited to operating a circulator with NOTICE a maximum current load of 3 Amps or a maximum 1 6 hp motor See Table 12 1 51 Liberty US Installation and Operation Instructions US WH Series Figure 12 1
3. DHW HIGH TEMPERATURE DHW HIGH TEMPERATURE SUPPLY 47 Liberty US Installation and Operation Instructions US WH Series 11 0 LEAD LAG INSTRUCTIONS Multiple Water Heater Applications The US controller has the internal capacity to stage or Lead Lag up to 8 water heaters configured in a cascade This Lead Lag capability allows a designated Master water heater to communicate with and effectively control each water heater in a multiple water heater system This function is accomplished by Daisy Chaining a 3 wire cable between each of the water heaters and enabling the Master parameter in the water heater of your choice The water heater with the Master parameter enabled becomes the single point of contact for settings and control wiring Use the instructions detailed in this section to set up and install the cascade water heater system reference Appendix A Controller and Touchscreen Display Instructions for details on more advanced settings and for assistance with navigating the touchscreen display Lead Lag Instructions Plumbing install as many as 8 Liberty water heaters in a parallel plumbing configuration as illustrated in Figure 11 1 Size common piping as per Table 11 1 Water Heater Pump each water heater must have its own circulator see Figure 11 1 which is controlled by its PUMP B output see Field Wiring Figures and Tables 12 1 a and 12 1 b The water heater pump must be sized according to
4. ULC S636 PVC is approved for flue gas temperatures up to 149 F 65 C and must only be used for low temperature applications High temperature applications requiring water heater supply water temperatures greater than 140 F 60 C must use ULC S636 CPVC PP or AL29 4C The use of cellular core PVC ASTM F891 cellular core CPVC or Radel 4 WARNING polyphenolsulfone in the exhaust venting system is prohibited Failure to follow these instructions may result in property damage personal injury or death 17 Liberty US Installation and Operation Instructions US WH Series YN WARNING Covering non metallic vent pipe and fittings with thermal insulation 1s prohibited Failure to follow these instructions may result in property damage personal injury or death Vent and Air inlet Pipe Length Determination Use Table 4 5 to determine the maximum pipe length that can be used The table calculates sweep 90 elbows and 45 elbows at 5 equivalent feet each The length of one vent pipe air inlet or exhaust may not exceed the length of the other NOTICE vent pipe by more than 20 equivalent feet Table 4 5 Allowable Vent and Air Intake Pipe Size and Lengths LLL LL 1 2 J 3 4 5 6 7 8 9 NG m eefa e pepetet sem eur poen m m fale mm e nm E EECHER US700WH amp 99 1 Same e e e ls elelee Notes Only 6 exhaust vent is permissible for models US700 800 Air inlet pipe can be 4 or 6
5. Check the burner plate for signs of leaking The combustion chamber must be inspected and cleaned Listen for water flow noises indicating a drop in water flow rate The heat exchanger may need to be flushed to eliminate hard water scale LILILEIEIEIETEILI oo NaN Ch tn 5 Combustion Chamber Cleaning Procedure Units operating with LP Gas or in an industrial environment will have to be cleaned a minimum of once per year Other applications will require the combustion chamber to be cleaned after the first year of operation with subsequent cleanings scheduled based on the condition of the combustion chamber at the time Unless a step is identified as model specific the following combustion chamber cleaning procedure is the same for all models Crystalline Silica Read carefully the warnings and handling instructions pertaining to IMPORTANT Refractory Ceramic Fibers before commencing any service work in the combustion chamber Take all necessary precautions and use recommended personal protective equipment as required Cleaning Checklist 1 Initiate a post purge cycle to clear any gas from the combustion chamber then turn gas valve off 2 Danger Explosion Hazard US400WH US800WH To disconnect the fuel air metallic tubing between the blower and the high vent pressure switch loosen the compression fitting at the high vent pressure switch with a 1 2 wrench At the blower end support the brass fitting body with a 1 2 wrench t
6. O E x 67 Liberty US Installation and Operation Instructions US WH Series Commercial Models US500WH US800WH Figure 16 4 Cabinet Vent and Air inlet Parts USS00WH USS00WH e 81e AX X 3 GE A F US700 800 Elbow US500 600 c w Tabs D O SG 1 2i LO mE gt LL 68 US WH Series Installation and Operation Instructions Liberty US Figure 16 5 Heat Exchanger Gas Valve Blower and Burner Assembly USS00WH o ZS Ooo D 2 re c 69 Liberty US Installation and Operation Instructions US WH Series Figure 16 6 Heat Exchanger Gas Valve Blower and Burner Assembly US600WH US800WH Ss SS Oo go os 5 0 Heverse Angle View 70 US WH Series Installation and Operation Instructions Liberty US Figure 16 7 Electrical Housing Controller and Display Module US500WH USS00WH Table 16 1 Parts List Liberty US Description Premix burner US400 500 1 ACE84383 600 Premix burner US600 Premix burner US700 800 Premix Burner Gasket US400 500 Premix Burner Gasket US600 800 Extended Air Tube US400 500 Conical Air Gas Inlet Pipe Stabilor US600 800 O ring Venturi to Blower US400 ACE83106 O ring Venturi to Blower US400 ACE84084 600 800 O ring Venturi to Blower US600 800 CVI Venturi US400 CVI Venturi US600 800 Gas Valve Orifice 8 0mm NG US400 8 ACES301
7. Tank Temperature and Pressure Relief Valve C Tank Thermostat aquastat Q Thermostatic Anti Scald Mixing Valve L Safety Flow Switch Notes Refer to Table 10 2 for minimum Pressure Relief Valve specifications 2 Expansion Tank is mandatory if using a System Backflow preventer 44 US WH Series Installation and Operation Instructions Liberty US Water Heater Circulator The US water heater is equipped with three 120VAC pump outputs Pump A B and C Use only Pump Output B for the Water Heater Circulator Note that bronze or stainless steel circulators are required for potable water systems Ensure that circulators pumps are oriented as per the pump manufacturers instructions See Section 12 0 for wiring details NOTICE Circulators responsible for forcing the water flow rate through the water heater must be sized according to Table 10 5 see Figure 10 2 for details LN WARNING Failure to ensure the minimum water flow rate through the water heater when the burner is on will not only reduce the operating efficiency of the water heater but may also cause premature failure overheating and void the warranty Failure to follow instructions may result in fire property damage serious injury or death Table 10 5 Minimum Water Heater Circulator and Pipe Sizes en Min Max Minimum Pump Size Restriction Maximum Model Flow Temp Head Loss GPM Rise Current Load B amp G Grundfos Armstrong Tac
8. Under a concrete veranda porch deck or balcony Above under or near exterior stairs Into a canopy or carport Notes Canadian installations must comply with the current CSA B149 1 Natural Gas and Propane Installation Code and local building codes 2 US installations must comply with current ANSI Z223 1 NFPA 54 National Fuel Gas Code and local building codes 3 Horizontal separation center to center c c 4 12 102 305 mm 4 For US installations an exhaust vent must be 3 ft above a mechanical air supply inlet if within 10 ft 3 m horizontally 5 Horizontal clearance must be observed up to a height of 15 ft 4 6 m above below the meter regulator or relief devices 6 Concentric Vent must protrude from the roof precisely 24 610 mm measuring from the terminal end cap vanes 7 Permitted if veranda porch deck or balcony is made of concrete and a minimum of two sides are fully open beneath 8 24 1s the recommended snow level allowance above grade roofline or any surface that will support snow debris or ice 1 e for roof venting clearances roofline and snow level If living in a snowfall region consult your local weather office for the maximum typical snowfall for your area 9 Note that the vent must maintain a minimum vertical distance above the air inlet Example Vent height 18 457 mm above air inlet 12 305 mm for air inlet above grade roof line and snow level 30 762 mm above
9. 6 is highly recommended Models US600WH US800WH operate with Natural Gas only 3 Models USSOOWH amp US600WH are limited to 30 ft of 4 or 90 ft of 6 exhaust venting when using the Air Filter Kit P N ACE84093 Air Filter Kit venting restrictions Models USSOOWH amp US600WH are limited to 30 equivalent feet of 4 or 90 equivalent feet of 6 exhaust vent when using the optional Air Filter Kit When transitioning from 4 to 6 the 4 venting used must be counted 3 times to convert to an equivalent length in 6 Example An application uses one 90 elbow and 5 feet of 4 venting before converting to 6 therefore the A venting has an equivalent length of 30 5 5 x 3 of 6 venting thus allowing an additional 60 equivalent of 6 venting Note Example is only true with US500 600 models using the optional Indoor Combustion Air Kit Termination Options Direct Vent Installation The venting system of the Liberty US may be terminated using field supplied piping to construct a Two Pipe termination see Figures 4 6 b 4 7 a 4 7 b and 4 8 a alternatively the venting may be terminated using a factory kit selected from Table 4 6 Kits certified with the Liberty US are listed in Table 4 6 and available from IPEX DuraVent Centrotherm and or ACE For more information on System 636 Vent Kits or wholesaler locations contact IPEX directly USA 1 800 463 9572 or www IPEXamerica com CAN 1 866
10. Telephone directory listing United States OSHA Telephone directory listing under Government Blue Pages Canada Health and under United States Government Department of Safety Canadian Centre for Occupational Health Labor Occupational Safety and Health and Safety or website http www ccohs ca Administration or website http www osha gov 63 Liberty US Installation and Operation Instructions US WH Series 16 0 PARTS LIST For a list of parts that corresponds to the item numbers in the bubbles refer to Table 16 1 Note that that some item numbers may appear more than once in the parts list depending on which model number is being referenced Replacement parts are available from your Local Representative Building Owners Contact your local Representative for assistance with parts Wholesalers Contact your local Representative for assistance with parts Installers Contact your local Representative for assistance with parts 64 Installation and Operation Instructions Liberty US US WH Series Figure 16 1 Electrical Housing Controller and Display Module US400WH 65 Liberty US Installation and Operation Instructions US WH Series Figure 16 2 Cabinet Vent and Air Intake Parts US400WH 66 US WH Series Installation and Operation Instructions Liberty US Figure 16 3 Heat Exchanger Gas Valve Blower and Burner Assembly US400WH Di gt
11. e On models USSOOWH US800WH the control panel is located above the heat exchanger toward the back of the unit Fuse A is accessible by removing the spring loaded knurled knob from its holder Push the knob toward the panel and twist approximately 1 4 turn counter clockwise After inspecting and if necessary replacing fuses replace the panel cover and front cover Restore power to the water heater and confirm proper operation Only replace fuses with identical parts see Figures 17 1 a and b Failure to follow this warning may result in component failure fire property damage serious injury or death 7 1 Liberty US Installation and Operation Instructions US WH Series User Interface Touch screen Display A blank screen does not necessarily indicate a problem the display may be configured to automatically blank the screen after a pre set interval Simply touch the screen to activate it Confirm that 120V power is being supplied to the water heater If the screen does not become active perform the following procedure Blank Screen 1 Remove the front cover from the water heater 2 Remove the control panel cover and check Fuse C Auto Blade Type if faulty check for shorts in the thermostat wiring correct then replace fuse see Figure 17 1 3 Ensure the 2 by 2 Molex connector located behind the display at the top is connected and that the wires are fully inserted see Figure 17 2 Verify that 24VAC
12. 1 m is permitted for piping outside a Air Inlet building 12 in 305 mm plus snow X allowance above grade Figure 4 13 Existing Chimney Chase Way It is permissible to use an existing chimney as a chase way to run the Vent Air inlet piping as long as Exhaust Vent 1 The chimney is not being used by any other water Kaz A heater l E Exhaust Vent Min 2 Flue gases do not enter the vacant chimney Chimney lis 18 in above air 3 SC KA iv Nat Only Liberty US certified venting materials are inlet used see Table 4 4 KR Air inlet N Air Inlet 4 Vent lengths are within the maximums specified Existing NS Min 12 in above 5 The top of the chimney is capped and the Chimney AE Ch roof and snow level are Wak WGA Vent Air inlet pipes are flashed to prevent used as a WHE leakage into the vacant chimney chase way V Under no circumstances may an existing chimney or chase way be used to vent or DANGER provide combustion intake air to a Liberty US Failure to follow these instructions will result in fire property damage serious injury or death 24 US WH Series Installation and Operation Instructions Liberty US 5 0 VENT AND AIR INTAKE TERMINATION CLEARANCES 4 WARNING The quick reference table below is to be read in conjunction with the numbered notes as indicated Figures 5 1 through 5 6 and the Venting Rules and Guidelines in Section 4 0 The instructions detailed in this section are a
13. 473 9462 or www ipexinc com For more information on PolyPro Vent Kits or wholesaler locations contact DuraVent directly 1 800 835 4429 or www duravent com For more information on InnoFlue Vent Kits or wholesaler locations contact Centrotherm directly at 1 877 434 3432 or www centrotherm us com 18 US WH Series Installation and Operation Instructions Liberty US Table 4 6 Optional Vent Termination Kits ZE Vent A Vent Material Description Size Supplier P N Figure EI tibili ty IPEX Low Profile 3 196985 P N ACE84357 mom Flush Mount 4 196986 P N ACE84358 Hm 196116 P N ACE82666 IPEX Concentric oce AEN sid w 4 9 b 4 10 b PVC CPVC Wall Roof gt 196021 num a ACE84355 E LEE MES e 3PPS HK Concent Wall ams nene By 3PPS VK Duriv at DOS ELO EUN 4 10 c PVC CPVC PP v x Concentric Roof APPS VK Centrotherm InnoFlue 4 ISI PTO303 4 9 PVC CPVC PP x v Flush Mount E HH amp ICTC0335 E ICWT352 amp ICTCO335 4 9 d PVC CPVC PP x Y Concentric Wall Ge ICWS4639 amp ICTC0446 B 3 ICRT3539 amp ICTC0335 on ene Nd 4 10 c PVC CPVC PP v x Concentric Roof ICRT4679 amp ICTC0446 Notes Instructions included with termination kits contain detailed assembly and installation instructions All factory termination kits are ULC S636 approved 3 Clearance requirements in this manual supersede those of the instructions included with the vent terminal Piping MUST be secured
14. CPVC minimum 4 long factory supplied Flue Outlet Stainless Steel Adapter factory supplied Air Inlet Pipe Coupling hS 4 16 x4 PVC Coupling 4 Removable factory supplied 90 elbow typical or tee and ge 7 drain cap option for easy cleanouts 15 Liberty US Installation and Operation Instructions US WH Series Figure 4 4 a Near Water Heater Venting CPVC PVC Models US800WH amp US600WH Swing Joint to attain slope in horizontal runs Air Inlet 4 Pipe Exhaust Vent 4 CPVC OR Exhaust Vent 4 PVC check local codes and Table 4 3 Air Inlet Adapter 4 stainless steel factory supplied PX LA d ei Zeie Flue Outlet 4 stainless steel factory supplied Transition 4 CPVC Mandatory Vent Pipe Transition Piece j 90 elbow typical or tee 4 CPVC factory supplied E SC EEN for 16 US WH Series Installation and Operation Instructions Liberty US Figure 4 5 a Near Water Heater Venting CPVC Models US700WH amp US800WH Swing Joint to attain slope in horizontal runs GO Air Inlet 4 Pipe Exhaust Vent 6 CPVC Air Inlet Adapter 4 stainless steel factory supplied Flue Outlet 6 stainless steel elbow factory supplied 90 elbow typical or tee and drain cap option for easy cleanouts Air Inlet check with applicable local codes for acceptable pipe material
15. Faulty sensor Check resistance of sensor and compare to thermistor resistance chart see Table 17 2 Lockout 109 Ignition failure Spark cable disconnected Ensure that the high voltage spark cable is occurred securely connected to the spark generator and the US500 800 only igniter electrode Check that the green ground wire is securely attached to the 1 4 quick connect Or tab on the igniter electrode Hold 92 Outlet sensor fault Hold 95 Stack sensor fault 8 l Insufficient gas line pressure Ensure the manual gas shutoff valve is open Hold 110 Ignition failure Refer to manual section 9 0 GAS VALVE AND occurred failure to prove BURNER SETUP flame after 3 ignition attempts Se US400 only Flame rod disconnected Verify that the flame rod signal wire is securely attached to the flame rod which is located bottom center of the burner door No 120VAC to Spark Generator Check wiring from controller to spark generator With an AC voltmeter measure voltage across J5 6 and ground the controller chassis is connected to the 120VAC supply ground during trial for ignition Faulty Spark Generator During trial for ignition check for arc on spark electrode via the observation port located next to the spark electrode in the burner door If the spark generator is receiving 120VAC and no spark is Observed replace the spark generator No 24V AC to Gas Valve Check the wiring harness for loose or interrupted connect
16. US with Propane will result in extremely dangerous burner operation leading to property damage serious injury or death Refer to section titled ATTENTION LIQUEFIED PETROLEUM LP PROPANE for applicable conversion kit and LP orifice numbers US WH Series Liberty US Installation and Operation Instructions ATTENTION LIQUEFIED PETROLEUM LP PROPANE The Liberty US is factory set to operate with Natural Gas BEFORE OPERATING WITH PROPANE the specified LP Conversion Kit and Orifice must be installed to convert the water heater so it will operate safely with LP Propane The correct kit and LP orifice is listed below Each kit comes with conversion instructions Liquefied Petroleum LP propane gas is heavier than air therefore it is imperative that your Liberty US water heater is not installed in a pit or similar location that will permit heavier than air gas to collect Local Codes may require water heaters fueled with LP gas be provided with an approved means of removing unburned gases from the room Check your local codes for this requirement Natural to LP Propane Conversion Kit Model Number Kit Number LP Orifice US400WH ACES3017 1 62 6 2mm USS00WH ACE84386 1 No Orifice Water heater Vent Air Inlet Piping The Liberty US is certified as a Category IV water heater and requires a Special A BEULAH Venting System designed for pressurized venting The exhaust gases must be piped directly to the outdoors
17. a timer BAS or other device SENSOR TE COM 14 System Common Common port for field inputs DHW OD Sensor and System Sensor 4 20mA External Modulation Control Using a 4 20mA signal an external control can be used to directly modulate the burner firing rate or adjust the active set point This can be useful for applications using external staging controls or Building Automation Systems Lead Lag Connects internally to the controllers MB2 Modbus communication port Terminals 17 18 and 14 common can be daisy chained to multiple water heaters up to 8 in total for the purpose of staging Building Management System BMS Connects internally to the display s COM2 Modbus communication port Terminals 19 20 and 14 common can be connected to a Gateway for communication to a BMS or other device Communications Normally Open Alarm Contacts Contacts close during a lockout or other alarm condition May be connected to a BMS maximum capacity of 0 63Amps at 24V AC Notes For applications requiring a High Gas Pressure Switch see supplemental instructions included with ACE High Gas Pressure Switch Kit P N ACE84094 Note this is the only High Gas Pressure Switch that has been tested with the unit and preapproved for field installation within the appliance cabinet Tank Sensor when operating in a cascade system the water heater controls do not support the use of a tank sensor a tank thermostat switch must be
18. alcove installations in US and Canada require approved CPVC vent and air inlet pipe fittings cements and primers Table 4 3 Ventilation Air Opening 1 in per 1000 Btu hr min 100 in Ventilation Air Openings are not required if the Ventilation Air Opening 1 in per 1000 Btu hr min 100 in appliance area meets the listed Recommended 6 152 mm max below vent opening Clearances in Table 3 1 iS T Right Side 12 305 mm US WH Series Installation and Operation Instructions Liberty US Figure 3 1 c Closet Installation Minimum Clearances US500WH US800WH Model US800 shown 3 E 1 25 mm gt clearance for i hot water and vent pipes Ventilation Air Openings Openings are not required if the appliance area meets the Recommended Clearances in Table 3 1 Top 12 305 mm E 6 152 mm 1 max above vent opening Ventilation Air Opening 1 in per 1000 Btu hr min 100 in Removable Surface or Closet Door Ventilation Air Opening 1 in per 1000 Btu hr min 100 in 6 152 mm Be max below M Pra vent opening Rear 14 P T 356 mm 1 E ae Right Side 4 102 mm Access Ensure rear of unit is accessible for wiring and flue gas testing See Table 3 1 SN Left Side 24 P4 SCH 610 mm Front 24 610 mm Table 3 1 Minimum Clearances for Installation and Service Dimensions inches unn ll
19. bathing Before proceeding read the following carefully and take all necessary pre cautions to avoid potential illness and or injury that can result from Legionella or scalding hazards i Legionella Hazard This bacteria is naturally occurring in surface water and ponds It WARNING can also be found in man made water systems around the world such as water storage tanks water distribution systems fountains hot tubs humidification systems refrigeration systems and grocery produce misters Health authorities agree that Legionella bacteria most often enter the lungs due to aspiration when contaminated water spray is breathed in as opposed to ingesting drinking water contaminated with the bacteria Typical illnesses attributed to Legionella include flue like symptoms Pontiac Fever and a potentially fatal type of pneumonia Legionnaires disease Failure to follow instructions may result in illness or death AN High Risk Application Combination space heating systems can present a significantly WARNING higher risk of developing Legionella than dedicated domestic hot water systems especially during non heating seasons or low temperature water applications Using higher temperature tank water routinely maintaining your water system and having your water tested annually are considered good practice when it comes to controlling conditions that contribute to Legionella See Table 10 1 Failure to monitor and maintain your combinati
20. be considered in determining the adequacy of a space to provide combustion air requirements Failure to ensure adequate make up air to all appliances may result in personal injury or death NOTICE Controller RPM Adjustments To avoid the potential water heater lockouts due to wind and static pressure differences the Lightoff and Minimum Modulaiton RPM Rates must be adjusted as per Figures 4 11 and 4 21 in Appendix A when using indoor combustion air Air Filter Kit P N ACE84093 When using indoor combustion air non Direct Vent it is highly recommended to use the optional Air Filter Kit P N ACE84093 to limit the amount of dust that enters the combustion system The Filter Kit can be installed on water heater models USSOOWH US800WH as illustrated in Figure 4 1 comprehensive installation instructions are provided with the Filter Kit NOTICE Venting Limitation When using the Air Filter Kit on models USSOOWH amp US600WH the maximum equivalent exhaust vent length is limited to 30 ft with 4 piping or 90 ft with 6 piping see warning below Table 4 5 Figure 4 1 Installation of Optional Air Filter Kit P N ACE84093 0 Remove factory appliance O secure filter kit using factory secure the filter in place air inlet adapter keep screws screws removed in step 1 with the brackets and knurled from installation of filter kit Reuse the factory gasket
21. chimney openings in vacant chimney applications Venting Below Grade For installations that exit the wall below grade refer to Figure 4 11 Vent Screens Install factory supplied vent screens on the outside of the last elbow for both the inlet and exhaust vent terminal elbows Install the screen into the female opening of the elbow and then cut a small piece of pipe to sandwich the screen into the elbow NOTE ensure the small piece of pipe cut does not extend past the end of the elbow Two screens are provided in the package See Figures 4 9 and 4 10 Condensate Hazard Do not locate vent over public walkways driveways or parking lots Condensate could drip and freeze resulting in a slip hazard or damage to vehicles and machinery Warning Plate For Sidewall Venting install the warning plate Gas Vent Directly Below directly above within 4 ft vertically the location of the air inlet pipe so it is visible from at least 8 ft away See Figure 4 9 Wall Thickness Direct vent terminations are designed to work with any standard wall thickness Installation guidelines for min max wall thickness are as follows Min 1 in Max 60 in Venting Options Due to potential moisture loading build up along the exterior wall sidewall venting may not be the preferred venting option Refer to Figures 4 8 and 4 10 for roof top venting options The vent for this water heater shall not terminate over public walkways or near soffit vents or crawl
22. combination of Liberty US specific and National Gas Code restrictions Compliance alone doesn t insure a satisfactory installation as good common sense must also be applied Failure to follow these instructions may result in fire property damage serious injury or death Table 5 1 Termination Clearances Quick Reference Table Clearances to Air Inlet Termination Clearances Mo Termination Va ut ae A Above grade roofline and snow level in 305mm 12 in 305 mm B Above roof line Concentric Vent 9 13 in 610mm 24in 610mm C To exhaust vent from any other water heater in 915mm I2in 305 mm Above grade roofline and snow level Minimum vertical separation above air inlet Minimum horizontal separation from air inlet Window or door that may be opened or other building opening To combustion air inlet of any other appliance Non mechanical air supply inlet to building Mechanical air supply inlet to building 4 Soffit overhang eave or parapet Soffit vent or vent opening in an overhang eave or parapet Outside corner 0 Inside corner of an L shaped structure including walls and fences Service regulator vent outlet Each side of center line above or below meter regulator assembly Above a paved sidewalk driveway or parking lot on public property if adjacen t Above a public walkway Above a sidewalk or paved driveway that is located between two single family dwellings and services both dwellings
23. flow through the metering elbow Incorrect air switch setting Contact Ace technical support Faulty air proving switch If venting and air inlet are clear temporarily jumper the air switch If the unit lights and operates smoothly replace air switch If the unit fails to light or lights but runs rough or abruptly shuts down check water heater internals for blockage Only jumper the air switch for diagnosing purposes Tripped High Vent Pressure Switch The high vent pressure switch will trip when the US400 only combustion chamber is blocked Clean combustion chamber and reset switch Tripped Thermal Fuse Check Thermal Fuse on the back of the heat US400 only exchanger accessed from the rear of the cabinet If tripped contact Ace Heating Solutions Tripped Door Reset Safety Switch The Door Reset Safety Switch will trip with the US400 800 only combustion chamber gets dirty or the door insulation fails Clean the combustion chamber inspect the door insulation and reset the switch Incorrect air switch wiring Check that the red and orange wires are connected to quick connect tabs 3 and 1 respectively Hold 66 Interrupted air Incorrect air switch setting Contact Ace technical support switch ON and blower is off Incorrect air switch wiring Check that the red and orange wires are connected to quick connect tabs 3 and 1 respectively Faulty air switch Disconnect red and orange wires from air swi
24. follow instructions could result in explosion causing property damage serious injury or death IN If you do not follow these instructions exactly a fire or explosion may result causing 4 WARNING property damage serious injury or death E Should overheating occur or the gas supply fail to shut off turn off the manual gas SAUER control valve to the water heater Failure to follow instructions could result in explosion causing property damage serious injury or death FOR YOUR SAFETY READ BEFORE OPERATING This water heater does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the water heater area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any water heater Do not touch any electric switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this water heater if any part has been
25. grade and snow level 10 Clearances to an outside corner to be in accordance with local installation codes 11 In Canada concentric vent materials are subject to approval by local inspectors See Termination Kits in Section 4 0 12 Above public walkways driveways or parking lots if adjacent to it and condensate cannot drip freeze or create a hazard 13 Contact the manufacturer for special exemptions relating to multiple water heater installations using concentric vents X Not permitted by National gas code s and or recommended by water heater manufacturer Liberty US Installation and Operation Instructions US WH Series Figure 5 1 Termination Clearances Quick Reference Diagram 2 AF P a P P Ke SUPPLY INLET NOT PERMITTED KX OTHER WY TERMINAL INSIDE CORNER DETAIL LEGEND D AIR INLET QD VENT TERMINAL OO OTHER VENT TERMINAL 26 US WH Series Installation and Operation Instructions Liberty US Figure 5 2 Sidewall Termination Clearances See Table 5 1 Clearances F and G Canada Minimum 3 ft 915 mm The US Minimum 1 ft 305 mm Clearance Q Adjacent to Public Walkway or Driveway Minimum 7ft 2 13 m Concentric Vent Termination G Letter represents a specific Termination Position Refer to Table 5 1 for corresponding termination clearances 2 Liberty US Installation and Operation Instructions US WH Series 6 0 CONDE
26. gt BL J45 Lt N THERMOSTAT 1 THERMOSTAT 2 BL Ta M o BL BL E N T2 5 0 J24 A NL T2 6 B B o a GAS VALVE ROBINET GAZ PRESSURE MANIFOLD SWITCH m PRESSION DE LA TUBULURE T2 4 Ee m E EE A EE HERE 0 5 2 LECH lJ15 4 lJ15 5 PEE S Kale satt LN J3 MB1 A J3 MB1 B EO oat J46 GE ee V a p xar yt E ag Tee el Y Kees B FUSIBLE THERMIQUE INLET SENSOR SONDE ALIMENTATION Ka R B OUTLET SENSOR SONDE SORTIE R STACK SENSOR SONDE TUYAU D EVACUATION H0LBZH TLIMA3NOH G e 12 13 W e 12 14 1 LNGAG 7 SNYO MOES IMH 20 MCL eC HOUMS ES LNSA HEH W 12 17 2 7 R PR e12 18 DHW ECD AQUASTAT E OUTDOOR SENSOR SON EXTERIEURE e B SENSOR SONDE SYSTEME IER RD E EXTERNAL CONTROL CONTROLE T2 12 R EXT RIEURE 4 20 m TZ 11e BK WIRE COLOR CODE CODE COULEUR DE FILS D ORANGE PR PURPLE VIOLET R RED ROUGE W WHITE BLANC Y YELLOW JAUNE LEGEND L GENDE POMPE FACTORY WIRING CABLAGE D USINE FIELD WIRING CABLAGE DE CHAMP PUMP BK BLACK NOIR BL BLUE BLEU BR BROWN BRUN G GREEN VERT BLOWER PWM SPEED CONTROL VENTILATEUR CONTR LE DE VITESSE 1 __ TOUCHSCREEN DISPLAY CRAN TACTILE RS 485 MODBUS SIGNAL CONNECTI
27. hot water and water used for space heating e Storage Tank Vessel refers to a tank used to store hot water that is heated indirectly by a water heater external to the tank or a container provided for storage of hot water under pressure Combination Space Heating A boiler with indirect fired water heater 1s the preferred method for combination space heating therefore the building owner assumes all risk and responsibility with respect to installation maintenance and operation of this water heater in a combination space heating application Failure to follow instructions may result in possible illness or death 39 Liberty US Installation and Operation Instructions US WH Series Safe Temperatures for Potable Water Two factors used to determine safe hot water temperatures are Legionella and scalding Potable water needs to be stored at temperatures hot enough to limit the growth of Legionella yet be cool enough to prevent scalding Since both hazards present a potential risk to the user they must be monitored and controlled Table 10 1 indicates how water temperature affects Legionella bacteria and contributes to scald injury Use of a thermostatic mixing valve in the water heater plumbing system can help protect against both of these hazards By storing potable water at higher temperatures bacteria growth is controlled while still providing high temperature water for dishwasher applications and low temperature water for
28. in Chapter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 as adopted by the Board and 2 Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling building or structure used in whole or in part for residential purposes MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM PROVIDED When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment the instructions provided by the manufacturer for installation of the equipment and the venting system shall include 1 Detailed instructions for installation of the venting system design or the venting system components and 2 Acomplete parts list for the venting system design or venting system MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfied by the manufacturer 1 The referenced special venting system instructions shall be included with the water heater or equipment installation instructions and 2 The special venting system shall be Product Approved by the Board and the instructions for that system shall in
29. is present between the Blue and Red wires if not trace wiring back to 24VAC transformer correct wiring and or replace transformer see applicable Figure 13 1 a or 10 2 a 4 Remove the display assembly from the control panel and check the 24V AC wiring connection on the back of the display Blue to terminal 7 24V AC COM Red to terminal 8 24V AC System Disconnected If the Touch screen Display is not blank but is displaying System Disconnected in the middle of the screen ensure the 4 by 1 Molex connector located behind the display at the top is connected and that the wires are fully inserted see Figure 17 2 If the connector appears to be fine check the wiring connections on the back of the touch screen display Green Red and Black go to terminals 1 2 and 3 respectfully Figure 17 2 Touch screen Display Electrical Disconnects Power Supply Connector 2 by 2 Communication Connector 4 by 1 Blue White on bottom Blue DO NOT drop the plastic housing or allow it to swing down freely it may be damaged CAUTION by forceful impact 18 US WH Series Installation and Operation Instructions Liberty US Summary and Diagnostics Display The Liberty US controller and Touchscreen display provides detailed operational and diagnostic information for aid in troubleshooting When power is applied to the water heater the initial page displayed is the Summary page Information presented on the Summary page incl
30. mating connector on the blower Blown fuse Check Fuse A using the procedure described above Fuse A protects the blower as well as the ignition spark generator and water heater pump Faulty blower Measure voltage across pins 1 amp 2 black and white wires of 3 position connector on wiring harness If 120VAC detected replace power connector and remove 5 position signal connector Blower should rotate at high speed If blower does not rotate replace blower Table 17 2 Thermistor Resistance vs Temperature Temp F C 360 2986 2488 1 752 imas 44 1 Table 17 3 Hold and Lockout Codes D None 1 15 Hold Nolockout 5 Imtemalfau Unstable power DCDC output _ 5 6 _ Internal fault Invalid processor clock JL Ho 84 US WH Series Installation and Operation Instructions Liberty US Table 17 3 Hold and Lockout Codes 8 Lem fault Zero crossing not detected Dol m Internal fault Flame bias out of range Hold 12 Hold 19 Lockout 22 Hold Hold 28 Internal fault A D linearity test fails Hold 29 Internal fault Flame bias cannot be set in range Hold 32 Lockout 35 Lockout 38 Lockout 41 Lockout 44 Lockout Hold Hold Hold Hold 56 57 RESERVED 85 Liberty US Installation and Operation Instructions US WH Series Table 17 3 Hold and Lockout Codes 59 Lockout 60 Intrnalfaul HFS sh
31. oOo ooo o oo ACE84388 Nipple 3 4 x 5 Black Iron US500 ACE84061 700 800 Nipple 1 x 6 Black Iron US700 800 ACE84389 Elbow 1 90 deg Street Black Iron US600 800 Manual Shutoff Valve 3 4 NPT US500 Manual Shutoff Valve 1 NPT US600 800 89 ACE84390 500 Nipple 3 4 x 2 1 2 Black Iron US500 Z O Z o ACE84351 em Nipple 1 x Close Black Iron US600 89 ACE84062 700 800 Nipple 1 x 3 1 2 Black Iron US700 800 Elbow 1 90 deg Black Iron US700 800 Bushing 2 x 1 Brass US Commercial Tee 2 x 2 x 2 Brass US Commercial 94 ACESA381 600 Gas Valve Regulator Sensing Tube Ugen Plug 7 8 Black Dome US Commercial ACE84069 600 800 Clamp U bolt 1 IPS US600 800 ACE84072 500 800 Leg Leveler 3 8 16 x 1 5 US Commercial o ACE84073 Leg Leveler Hex Base Cap US Commercial 99 ACES4ISO 500 800 LPon Switch Wiring Conduit US Commercial 101 ACES401 600 800 Gasket Air inlet 3 16 gea 00 01 101 Relay Omron US Commercial 103 04 103 ACE84043 500 800 Rocker Switch Black US Commercial 104 ACE84130 500 800 Flow Switch Wiring Conduit Fitting US Commercial 1 ACE83016 Gas Valve Harness US400 ACE843 19 Gas Valve Harness Dungs US500 ACE84392 400 800 Thermal Fuse Heat Exchanger Exterior US400 800 ACE84993 400 800 M5 Reset Safety Switch US400 800 US WH Series Installation and Operation Instruc
32. space vents or other area where condensate of vapor could create a nuisance or hazard or cause property damage or where condensate or vapor could cause damage or could be detrimental to the operation of regulators relief valves or other equipment 23 Liberty US Installation and Operation Instructions US WH Series Figure 4 11 Venting Below Grade For installations that exit the wall below grade Exhaust 1 Excavate site to a point below where the pipes are to exit as shown 2 Ensure the wall is fully sealed where the pipes penetrate 3 The Vent Air inlet piping MUST be secured to the side of the building above grade as shown to provide rigidity 4 Optional mounting bracket P N ACE82075 for securing the exhaust pipes only applicable for 3 in PVC CPVC venting 5 Ensure that the Vent Air inlet clearances are maintained see Section 5 0 for details Air inlet Figure 4 12 Outdoor Venting Vent piping outside the building is permitted under the following conditions o Gas Vent Directly Below o 1 The maximum length outside the building is 20 ft Note that outdoor length must be included in the overall vent length calculation 2 All normal termination clearances are maintained i Urs 0 mm The pipe is supported every 24 in 4 The exhaust and inlet are sloped back to the water Exhaust heater 2 in elevation for every linear foot Keep Free of Obstructions e Maximum of 20 ft 6
33. supply of gas to the water heater off 2 Open the bleed screw of the line pressure test port approximately 1 1 2 turns US400WH USSOOWH models This port is directly connected to the gas line feeding the water heater For US600WH US800WH models replace 1 8 NPT plug in the inlet flange of the gas valve with a hose barb fitting suitable for manometer tubing used See Figures 9 1 through 9 4 3 Force 1 4 ID tubing over the housing of the line pressure test port install the other end of the tubing to an appropriate line pressure test gauge or manometer Ensure both ends of the tubing make a tight connection 4 Open the supply of gas to the water heater and check for gas leaks 5 Observe the line pressure under static conditions and compare it to Table 9 1 The pressure will be greatest under static conditions 6 With all other gas appliances in the applications running operate the burner to the maximum firing rate see Table 9 2 and compare the observed line pressure with Table 9 1 The pressure will be lowest during the maximum flow of gas 7 Adjust the gas line pressure to ensure the parameters in Table 9 1 are attained under all conditions If possible adjust the line pressure to the Nominal Desired value listed in Table 9 1 while the unit is operating at the maximum modulation rate see Table 9 2 8 Continue observing the gas line pressure until the completion of the combustion analyses incase adjustments need to be made 9 Upon
34. using the vent materials and rules outlined in these instructions Failure to follow these instructions will result in serious injury or death O US WH Series Installation and Operation Instructions Liberty US a b c d e IN THE STATE OF MASSACHUSETTS ONLY For all horizontally vented gas fueled equipment installed in every dwelling building or structure used in whole or in part for residential purposes including those owned and 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 but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall horizontal vented gas fueled equipment the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back up is installed on the floor level where the gas equipment is to be installed and on each additional level of the dwelling building or structure served by the equipment It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors a In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic the hard wired carbon monoxide dete
35. 16 2 J31 FUSE FUSIBLE A 3AG 7A 250V Gel AGING IAGTION SPARK GENERATOR G N RATEUR D TINCELLE sol J12 J13 P HONEYWELL R7S10A SOLA 120VAC PRI AAS I Lk IGNITOR ALLUMEUR 24VAG SEC HIGH VENT PR SW INTERRUPTEUR DE HAUTE PRESSION DANS L VENT R R s a 5 l an mE e a ls BLOWER PWM SPEED B SS J15 4 CONTROL VENTILATEUR T2 2 o L 315 5 CONTR LE DE VITESSE MOSTAT 1 MOSTAT 2 a BL o e N 0 pe i TE J3 MB1 W TOUCHSCREEN DISPLAY CRAN TACTILE i T2 17 RS 485 MODBUS SIGNAL T2 18 CONNECTIONS T2 19 CONNECTIONS RS 485 OUTLET SENSOR SONDE SORTIE J3 MB2 A EL J3 MB2 B STACK SENSOR SONDE TUYAU D EVACUATION T2 20 SN I ALARM DRY CONT TP e a G JB 7 PR 912 22 24VAC 0 63A MAX DHW ECD AQUASTAT T2 11 FLAME SENSOR SONDE DE SIGNAL DE FLAMME EQ J1 2 OD SYSTEM SENSOR DE EXTERIEURE SYSTEME rem m 6 E AIR SWITCH COMMUTATEUR D AR LLA LH w FLOW SWITCH COMMUTATEUR K ee i B ECOULEMENT EXTERNAL CONTROL CONTROLE T2 18 amp BR HAUTE PR EXTERIEURE 4 20 mA T2 15e B e e OPT INT DE u 2 s GAS Hi PR SW OPT INT DE GAZ OPL 4 d WIRE COLOR CODE CODE COULEUR DE FILS GAZ OFT BK BLACK NOIR BL BLUE BLEU PR PURPLE VIOLET PUMP POMPE OD OUTDOOR T
36. 500WH USS00WH 120VAC Hot Location for connecting line voltage of the power supply Note most L1 120VAC 1 installation codes require the installation of a service switch to break line voltage to the appliance CUm 120VAC Common Location for connecting neutral of the power supply and circulator Gm o3 120VAC Ground Location for connecting ground of the power supply and circulator LEN m DHW Demand Dry Contact for Water Heater circulator Coil B powered during tank demands Non Powered Dry Contacts Not used 53 Liberty US Installation and Operation Instructions US WH Series Low Voltage Connections On model US400WH the low voltage junction box is located at the top of the water heater cabinet on the left hand side and can be accessed by removing the top front cover of the water heater On USSOOWH US800WH models the low voltage junction box is located at the back of the water heater cabinet and can be accessed by removing the top back cover of the water heater Each water heater is provided with one hole and two knockouts for routing field wiring into the low voltage junction box Low voltage field connections identified in Tables 12 2 a and 12 2 b are to be read in conjunction with Figure 12 2 Table 12 2 a Low Voltage Field Connections US400WH COM T 1 24VAC Common Neutral for the 24V AC power supply within the water heater 24V AC gt 24VA ly for i 1 and CH2 24VAC 3 VAC H
37. 7 400 P Gas Valve Orifice 6 2mm LP US400 O 9 ACE82989 400 Gas Valve VR8615VB 1044B US400 Z O O O ACE84318 9 ACE84012 600 800 Gas Valve V8730C 1023B US600 800 71 Liberty US Installation and Operation Instructions US WH Series Flame Probe Gasket US Series Gas Valve Adapter 1 NPT US600 800 Outlet Sensor Dual US Series 1 4 x 1 8 Bushing Brass US Series ACE82539 All Models Automatic Air Vent 1 8 US Series ACE83608 Flue Sensor Dual US400 ACE84039 500 800 Flue Sensor Dual US Commercial ACE83605 All Models Inlet Sensor Single US Series ACE83706 Plug Brass 1 4 NPT US400 ACE84075 Plug Brass 1 2 NPT US Commercial Heat Exchanger ASME US400 26 ACE84312 600 Heat Exchanger ASME US600 Heat Exchanger ASME US700 800 Elbow Street PVC 1 2 Sch 40 White US Series ACE83907 Condensate Drain Tube US400 ACE84313 500 600 Condensate Drain Tube US500 600 Bumer Door Ceramic Dise USSO0 Burner Door Ceramic Disc US500 Burner Door Ceramic Disc US400 Cast Alum Burner Door US400 Flame Rod US400 500 Lu jacens so Five Owlet Adar us OOOO 41 ACE84387 Lama Live Outlet Adapter c w Tabs USS00 600 000 Coupling Rubber 4 Fernco US400 Exhaust Test Plug US400 800 OS ACE84054 400 800 Exhaust Test Plug US400 800 ACE83953 Wall Mounting Clip US400 ACE83923 Grommet Vinyl 3 4 IPS US400 ACE83506 600 800 Grom
38. Flow Switch must be installed on the water heater outlet fitting see Figure NOTICE 10 1 in accordance with the instructions provided with the flow switch Install the flow switch in a 1 1 4 diameter line for models US400WH NOTICE Models USSOOWH US800WH come equipped with a factory installed flow switch installed in a 2 diameter line The flow switch is pre plumbed with a Nema 4 rated enclosure and prewired via liquid tight conduit The Safety Flow Switch must be wired as per the instructions provided in this manual Refer to Section 12 0 for wiring instructions NOTICE Water Heater System Plumbing The Liberty US water heater uses a low mass heat exchanger that requires a minimum rate of forced water circulation any time the burner is operating See Table 10 5 for minimum flow rates To ensure the minimum flow rate is attained the water heater must be installed with a safety flow switch see Figure 10 2 for suggested plumbing diagram A properly installed system will as a minimum include the major components in Table 10 4 Table 10 4 System Major Component Checklist Factory Supplied Components Field Supplied Components O Pressure Relief Valve LJ Bronze Stainless Steel Water Heater Circulator Pump B in Figure 10 2 C Pressure Gauge 160PSI O System Backflow Preventer check if required by local codes L Flow Switch US500 800 only O DHW Potable Water Expansion Tank check if required by local codes O DHW Storage Tank
39. Liberty AS Model Numbers US400WH US800WH Version Date 7 27 2015 INSTALLATION AND OPERATION INSTRUCTIONS FOR Liberty US WATER HEATER TABLE OF CONTENTS LO INTRODUCTION Peer ee ee ee 3 20 INTRODUCTION C 6 20 WATER HEATER LOCA THON Pam rT tn ere Tete a arr eer rT 7 S MEE CIS HOPES NL es 11 5 0 VENT AND AIR INTAKE TERMINATION CLEARANCES eeeeeeeeeeeerr 25 DO CONDENSATE RTE lr BE 28 FUMER LS EYE NG S lg 29 8 0 LIGHTING REENEN RE 3 90 GAS VALVE AND BURNER SET UP EE 33 100 WATER HEATER PIPING cica eer nr reer enn EE dnd ere ee eee 39 11 0 LEAD LAG INSTRUCTIONS EE 48 iP NE oo BOS A LE 51 DO Mea AION Cae Solo VUNG rere ett werent ttt met Te ere mer ere 57 14 0 INSTALLATION TE EE 61 15 0 ANNUAL MAINTENANCE AND INSPECTION e eeeeeee eene 62 WG PARTS LCIS e 64 70 RO Te EAR NEE 76 HAZARD SYMBOLS AND DEFINITIONS A DANGER Danger Sign Indicates a hazardous situation which if not avoided will result in serious injury or death WARNING Warning Sign Indicates a hazardous situation which if not avoided could result in serious injury or death CAUTION Caution Sign plus Safety Alert Symbol Indicates a hazardous situation which if not avoided could result in minor or moderate injury CAUTION Caution Sign without Safety Alert Symbol Indicates a hazardous situa
40. NSATE DRAIN This unit produces liquid condensate in the heat exchanger and venting system as a product of combustion Steps must be taken to ensure that condensate does not collect in the venting system therefore all exhaust piping must slope back to the water heater a minimum 1 4 per linear foot of vent Condensate must be drained from the unit into a household drain NOTICE Check with your municipality or local gas company to determine if the disposal of combustion condensate is permitted in your area e g in the State of Massachusetts the condensate must be neutralized prior to entering a drain The following are important notes that must be taken into consideration when constructing the condensate drain system See Figure 6 1 for further details e DO NOT install condensate lines outside A frozen or blocked drain will cause the condensate to fill the combustion chamber This will result in a no heat condition as the unit will shut down and damage to the flame sensor and components can occur e NEVER use copper steel or galvanized piping in the construction of the condensate disposal system as condensate is very corrosive and will corrode most metallic drains and sewer pipes e When a condensate pump is used or required select a pump that is designed for residential furnaces AA WARNING If the combustion chamber has been flooded due to the condensate drain backing up or for any other reason the combustion chamber door must b
41. OD TME OF DAY L HEURE DU JOUR s EPREUVE AUX PROOF OPT g THERMAL FUSE FUSIBLE THERMIQUE ERM TRINITY LX500 800 LADDER DIAGRAM REV 9 DATE 02 02 14 BR BROWN BRUN R RED ROUGE G GREEN YERT W WHITE BLANC TN TAN 60 US WH Series Installation and Operation Instructions Liberty US 14 0 INSTALLATION CHECKLIST Installation c 1 If operating on Propane Gas convert water heater using appropriate Kit number See Table 7 1 2 Locate the water heater in accordance with Section 3 0 of this manual 3 Install the Vent Air inlet piping in accordance with Sections 4 0 and 5 0 of this manual Ensure all joints are secured and cemented properly Perform the Mandatory Pre commissioning Procedure for Plastic Venting in Section 4 0 Connect the condensate drain in accordance with Section 6 0 of this manual Connect the gas supply in accordance with Section 7 0 of this manual Install the plumbing in accordance with the appropriate this Manual Flush cleanse the internals of the piping system 7 Connect field wiring in accordance with Section 12 0 of this manual 8 Advise home building owner of their responsibilities with respect to maintaining the water heater Nuns O RW O O RW i The building owner is responsible for keeping the Vent Air inlet termination free of snow WARNING ice or other potential blockages and for scheduling routine maintenance on the water he
42. ONS CONNECTIONS RS 4B5 MODBUS ALARM DRY CONTACT ALARME CONTACT SEC 24VAC 0 63A MAX w FLAME SENSOR SONDE DE SIGNAL DE FLAMME NOTE REMOVE JUMPER BETWEEN T2 3 AND T2 4 IF EXTERNAL LIMIT CONNECTED ENLEVEZ LA LIMITE EXTERNE EST RELI E TRINITY LX LADDER DIAGRAM REV 10 DATE 09 27 13 US WH Series Installation and Operation Instructions Liberty US Figure 13 2 a Connection Diagram US500WH USS00WH uS Eps CEA d E D pn sae k e II Wr SE teen k n RE BE TE RS tf D mee hER GER HHR HAE D zs E E T __ GD SYSTEM SENSOR Kali Lu 1 SONDE EXT SYSTEME X I I J24 R2 zn aln 1l e I 4 4 aK V dein K EE ams im Eau p D Che DNA DATA4 m Dsg gn DATA E H AO d 8 gt t ALARM DRY CONTACT Lm Am d po ee ng BLOWER VENTILATEUR A ti zmn SSH II A A RTN B A RTN B NC R STACK TUYAU TOD L HEURE DU JOU D EVACLIATION ROBINET DE PILOT ROBINET PRINCIPALE 7 CEET z T 2 B ERR g i it zz t 1 A RE GAS HIGH PR SW INT DE HAUTE PR r l l Le m D COULEMENT PRESSION DANS L VENT HIGH VENT PRESS MUTATEUR INTERRUPTEUR DE FLOW SWITCH COM 59 Liberty US Installation and Operation Instructions US WH Series Figure 13 2 b Ladder Logic Diagram US500WH US800WH 120VAC 6OHZ 1PH LOCAL DISCONNECT SW J16 1 J
43. TICS Figure 13 1 a Connection Diagram US400WH 5 zu eer 3 gt lt Jovi 30 RE XI ALINIHL LOB B ON 1uvd TINAA M LEIS ZL T amp lox 7 9 Bil Eu A 1dSi0 XI INW LOCO ger NH ee ae ee Cl EL 8 N 3W3ISAS N3LSAS st NnNNv 1 AER T d 3A3ISAS WalsAS S I 1 NANNY z f o Tid vos SES ON Si e pug VIOS HOLG M TI3MA NOH ES JOIN 3d JaNiGo KE AWdloNhid L3NIGO A EC 3 GOAGISAS Adans oz w edu ISL 1 OSH Bi Biro E 2 Eri Rees WAL 3MIN3 L3TINI 3MIN3 LTINI ON e NLY OVAFZ OZI ol Le SN ailmno3s 3d MWGLWNZIN IN3YGHONGTON3 RU HOLIMS ASS Sen 5 BIORUYN SOVHOLAYIAVISK un 1090 y TI Met AYISI NIRASH NOL 68878 C BRNVM IN3KGHONVTON32H LL Den fiv 812 TINY OL vn E Uds OVAPS Rid DEL W Z JI Leem MaivRO JSNYeLL H3NHOJSNYHL Z Jd 30 3WMO4J N3 Qinv SNL 154 IAAL 57 Liberty US Installation and Operation Instructions 58 Figure 13 1 b Ladder Logic Diagram US400WH J30 FUSE FUSIBLE A JAG 7A 250V FAST ACTING ACTION RAPIDE J35 J52 FUSE FUSIBLE B JAG 7A 250V FAST ACTING ACTION RAPIDE VOS BHOLGZH TI3MA3NOH Tt 4 120VAC BOHZ 1PH BLOWER VENTILATEUR US WH Series YNAANNTT HOUND 120VAC PRI B Ww FUSE E WV WV A is R L 31 Y BK 9 12 1 J14 J28 24VAC SEC cs
44. Table 10 5 Communication Wiring using 3 wire cable daisy chain terminals LL DATA LL DATA and SENSOR COM of each water heater in parallel see Field Wiring Tables 12 2 a and 12 2 b and Figure 12 2 System Sensor a system sensor is NOT used in a water heater application at the Master boiler set the applicable sensor input to Unconfigured as follows Configure Sensor Configuration S10 J10 7 sensor S5 J8 11 sensor for USSOOWH US800WH models UNCONFIGURED Modbus Address assign a unique MB2 Modbus Address to each water heater in the cascade Access the MB2 Modbus Address setting via the System Identification amp Access menu as follows Configure System Identification amp Access MB2 Modbus Address Master Enable choose one and only one water heater in the cascade to be the Master this water heater will receive all control wiring and will be used for setting control parameters see steps below On this one water heater set Master enable equal to Enabled via the Lead Lag Master Configuration menu accessed as follows Configure Lead Lag Master Configuration Master enable Tank Thermostat connect to SENSOR COM and DHW of the Master water heater see Field Wiring Tables 12 2 a and 12 2 b and Figure 12 2 Switch must be an isolated end switch dry contact DHW Setpoint at the Master water heater only set the DHW setpoint via the Lead Lag Master Configuration menu accessed as f
45. Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this water heater if any part has been under water Immediately call a qualified service technician to inspect the water heater and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information above very carefully Set the thermostat to lowest setting Turn off all electric power to the water heater This water heater does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Turn the manual gas valve to the OFF position Remove front access panel Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Turn the manual gas valve ON Wait an additional five 5 minutes smelling for gas Replace the front access panel Set thermostat to highest setting Turn on all electric power to the water heater 9 Ignition sequence is automatic Combustion will occur after a brief fan purge 10 If ignition does not occur follow the instructions To Turn Off Gas To Water heater and call y
46. Vent Air inlet Pipe Material Table 4 4 Acceptable Vent and Air inlet Pipe Material Figure 4 5 b Near Water Heater Venting PVC Models US700WH amp US800WH Swing Joint to attain slope in horizontal runs 2 Air Inlet Adapter 4 stainless steel factory supplied Air Inlet 4 6 Pipe Exhaust Vent 6 PVC check local codes and Table 4 3 Coupling 6 PVC length 4 Transition 6 CPVC Flue Outlet 6 stainless steel elbow factory supplied 90 elbow typical or tee and drain cap option for easy cleanouts end Materials Installation Standards United States PVC DWV ANSI ASTM D2265 All Vent and Airinlet PVC Schedule 40 ANSI ASTM D1785 o CPVC Schedule 40 ANSI ASTM F441 ue enne male Canada must be AL29 4C UL 1738 ULC S636 approved ANSI ASTM D2564 appropriate temperature fire serious injury or death applications ANSI ASTM F493 PVC CPVC ANSI ASTM F656 Vent Piping and Fittings Primers Notes materials installed on gas fired appliances in CAN US must meet the Standards listed in Table 4 4 Failure See Note 4 below for to comply could result in Refer to Table 4 5 for Allowable Vent and Air inlet Pipe Sizes and Lengths PVC venting exhaust and air intake is not permitted within the Closet alcove of a Closet alcove installation 3 The Air Intake does not require high temperature pipe material Check applicable local codes for acceptable materials
47. a Line Voltage Field Wiring US400WH 120VAC SUPPLY PUMP B Line Neutral Gnd p SERVICE SWITCH field supplied re s LIBRE beu G PART han Wu Kal Table 12 1 Line Voltage Field Connections Connection Location Description Li 120VAC Hot Location for connecting line voltage of the power supply Note most 1 installation codes require the installation of a service switch to break line voltage to the 120VAC appliance PUMP A Not used PUMP B DHW Demand Output to the Water Heater Circulator powered during tank demand PUMPC Not used EFE N S 120VAC Common Location for connecting neutral of the power supply and circulator Ground a 120VAC Ground Location for connecting ground of the power supply and circulator Factory Wiring This terminal is used only for factory wiring Do not add or remove wires No Conn from this location 52 US WH Series Installation and Operation Instructions Liberty US Figure 12 1 b Line Voltage Wiring US500WH USS00WH Service Switch LINE L1 a EXT NEUTRE hana y GROUND MISE A LA XL TERRE aan aN M NEUTRAL 120VAC Supply GROUND 4 X IM M DN Pump Contact A Normally Open Dry Contacts Pump Contact B 1 5HP 120V 3HP 230V Maximum SOAmps 93S 19VINOO SIOVINOO AMQ Pump Contact C VOC vw AO Z dH AOZL dHS l Table 12 1 b Line Voltage Field Connections US
48. and prewired in series with EXT LIMIT jumper Gas Low Pressure Switch Optional Comes factory equipped with a jumper For applications requiring a Low Gas Pressure Switch remove jumper and connect normally open isolated contacts of the Gas Low Pressure Switch Switch must be installed external to unit 24V AC circuit For preapproved High Gas Pressure Switch see Note 1 below Auxiliary Proof Comes factory equipped with a jumper For applications using Indoor AUX PROOF EN Combustion Air US500 800 only remove jumper and replace with field supplied end GAS LO PR switch incorporated with motorized damper louver control Local Central Heat Demand Not applicable for Water Heater Applications CH2 LL 10 Lead Lag Central Heat Demand Not applicable for Water Heater Applications DHW Tank Demand Input requiring closure of terminals 11 and 14 to initiate a demand DHW 11 for DHW Switch made via isolated end switch dry contact from the storage tank thermostat Aquastat Or optional Tank Sensor P N ACE84632 see Appendix A OD SYS 12 Outdoor Temperature Sensor Not applicable for Water Heater Applications SENSOR System Water Temperature Not applicable for Water Heater Applications C A Time of Day Night Time Setback Input requiring closure of terminals 13 and 14 to TOD 13 initiate TOD setback setting Switch is made using an isolated end switch dry contact using
49. ater see Section 15 0 Failure to properly maintain the water heater may result in serious injury or death Start up Allow primers cements to cure for 8 hours prior to Start up If curing time is less than 8 hours first perform Steps 2 through 6 of Mandatory Pre commissioning Procedure for Plastic Venting in Section 4 0 Failure to follow these instructions can result in explosion serious injury or death Turn gas shut off valve to the ON position Turn Power on to water heater Set Controller to the desired settings Turn thermostat up Ignition will occur Operational Checklist System is free of gas leaks System is free of water leaks Water pressure is maintained above 15 PSI All air is purged from the heating system piping Ensure proper water flow rate unit must not kettle bang hiss or flash the water to steam Ensure gas line pressure is in accordance with Section 9 0 System is free of combustion leaks Unit must operate smoothly Ensure the flue gas combustion readings are within the tolerances listed in Table 9 1 Each ignition must be smooth Verify that all condensate lines are clean and drain freely OOOO a i LILIEIEIETJEIETEIETEI pense Sese Ds O Before Leaving 1 Remove line pressure gauge from gas valve tighten bleed screw test screw for leaks See Section 9 0 2 Install plug into the flue gas test port and test for leaks see Section 9 0 3 Allow the water heate
50. ations Ensure the wall mount bracket is mounted level and flush to the wall with mounting holes on the bottom flange pointed upward and angled away from the wall Mount the boiler to the wall by aligning the upper bracket A with the wall mount bracket B Slide the upper bracket down over the wall mount bracket until it hooks Once the boiler is resting securely on the upper bracket secure the bottom bracket to the underside of the boiler using the mounting hardware removed in Step 1 then anchor the bottom bracket to the wall as shown Ensure that the upper bracket on the back of the appliance A slides down over the wall mount bracket B and rests securely on it zd Bottom Bracket is in US Installation Kit Box Code requires all wall mounted instantaneous water heaters to be installed with suitable wall protection extending the full length and width of the water heater Check with local authorities regarding acceptable protection materials US WH Series Installation and Operation Instructions Liberty US 4 0 GENERAL VENTING The Liberty US 1s certified as a Category IV water heater requiring a Special Venting System designed for pressurized venting The Exhaust Vent must be piped to the outdoors using the vent materials and rules outlined in this section Under no conditions may this unit vent gases into a masonry chimney unless it is vacant and utilizes the approved vent
51. ations in excess of 175ppm Failure to comply may result in injury of death AN Manifold Pressure DO NOT adjust or measure the Manifold Pressure of the water A WARNING de heater Correct manifold pressure is factory set Field adjustment could result in improper burner operation resulting in fire explosion property damage or death 33 Liberty US Installation and Operation Instructions US WH Series Figure 9 2 Gas Valve and Venturi Assembly US400WH Manifold Pressure Test Port Throttle Input Adjustment Screw Line Pressure Test Port Orifice Location See Kit 83017 1 Venturi 4 Gas In Gas Valve Air Inlet Figure 9 3 Gas Valve and Venturi Assembly US500WH Gas Valve Line Pressure Test Port Gas In B D Throttle Input Adjustment Screw E Manifold Pressure Test Port e x 34 US WH Series Installation and Operation Instructions Liberty US Figure 9 4 Gas Valve and Venturi Assembly US600WH US800WH Gas Valve M v Throttle Input Adjustment Screw E Manifold Pressure Test Port outlet flange Manual Gas Shutoff Valve Gas In vai Line Pressure Test Port inlet flange Remove cover to 70 0m make adjustments to the throttle input screw Gas Valve L Sensing M Tube D Venturi Air inlet Adjustment Input Screw Adjustments The water heater is equipped with a Throttle Input Adjustment Screw
52. aust center Min 12 above grade or snow level gt Air inlet aN perimeter d Figure 4 10 d Exhaust only Termination Roof A WARNING Figure illustrates two options for exhaust termination only neither vent pipe illustrated is for combustion air inlet S Exhaust Vent pipe piece to UN retain vent screen Q D Option 1 N am 1 M BN Vent Screen gt n aa S gt eR Hi gt Nw Min 12 above grade or snow level Flashing N US WH Series Installation and Operation Instructions Liberty US Venting Rules and Guidelines 1 2 10 11 12 13 14 15 16 17 18 Prevailing Winds Ensure the vent is located where it will not be exposed to normal prevailing winds Combustion Air inlet Contamination Air for combustion must be drawn from an area free of dust and contaminants Combustion air containing chemicals such as chloride fluoride bromine or iodine or dust and debris will cause corrosion damage of the heat exchanger voiding your ACE warranty Refer to Table 4 1 for a list of corrosive products and contaminants sources to avoid Vertical Separation The exhaust must be a minimum of 18 in above the air inlet and the air inlet must always be a minimum of 12 in plus snow allowance above any surface that will support snow Two feet plus snow allowance is highly recommended Consult your weather office for the maximum typical snowfall for your region Exampl
53. backflow prevention device used to control system thermal expansion See example in Figure 10 2 Ensure the expansion tank cannot become isolated from the water heater anytime the system is operating Failure to follow these instructions may result in discharge of the Pressure Relief Valve may result in property damage or personal injury DHW Storage Tank Storage vessels shall be equipped with a drain valve to facilitate emptying the tank for cleaning or flushing debris or foreign deposits Drain valves on counter type water heaters shall be accessible from the front of the heater In Canada glass lined storage tanks for household hot water service must comply with the current performance requirements in CAN CSA C309 8 The DHW storage tank should be located in an area where leakage or connections will NOTICE not result in damage to the area adjacent to the appliance or to lower floors of the structure When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance This manufacturer is not responsible for any water damage that may occur in connection with the storage tank or any of its components 45 Liberty US Installation and Operation Instructions US WH Series Tank Temperature and Pressure Relief Valve The storage tank will require a temperature and pressure relief valve sized to ASME specifications and that complies with the Standard for Relief Va
54. bers in high temperature applications above 1000 C can result in the formation of Crystalline Silica cristobalite a respirable silica dust Repeated airborne exposure to crystalline silica dust may result in chronic lung infections acute respiratory illness or death Crystalline silica is listed as a potential occupational carcinogen by the following regulatory organizations International Agency for Research on Cancer IARC Canadian Centre for Occupational Health and Safety CCOHS Occupational Safety and Health Administration OSHA and National Institute for Occupational Safety and Health NIOSH Failure to comply with handling instructions in Table 15 1 may result in serious injury or death IN WARNING Crystalline Silica Certain components confined in the combustion chamber may contain this potential carcinogen Improper installation adjustment alteration service or maintenance can cause property damage serious injury exposure to hazardous materials or death Refer to Table 15 1 for handling instruction and recommended personal protective equipment Installation and service must be performed by a qualified installer service agency or the gas supplier who must read and follow the supplied instructions before installing servicing or removing this water heater This water heater contains materials that have been identified as carcinogenic or possibly carcinogenic to humans Table 15 1 Handling Instructions for Refrac
55. blockage restriction leakage corrosion or other deficiencies which could cause an unsafe condition 3 Insofar as is practical close fireplace dampers all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan 4 Place in operation the water heater being inspected Follow the lighting instructions Adjust thermostat so water heater will operate continuously 5 Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe 6 After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use 7 Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code When resizing any portion of the common venting system the common venting system s
56. cle stack limit Abnormal Recycle delta T limit 355 Abnormal Recycle fault outlet sensor 356 Abnormal Recycle outlet high limit 96 US WH Series Installation and Operation Instructions Liberty US Table 17 4 Alert Codes 359 Abnormal Recycle fault inlet sensor Abnormal Recycle fault inlet sensor o 362 365 Internal error DHW PID P scaler was invalid S Internal error DHW PID P scaler was invalid Internal error DHW PID I scaler was invalid Internal error DHW PID T scaler was ins Abnormal Recycle Hardware flame bias high 375 Abnormal Recycle Hardware flame bias low Abnormal Recycle Hardware flame biaslow 378 Abnormal Recycle Hardware flame bias dynamic high Abnormal Recycle Fan Speed Range Low S o 381 Abnormal Recycle Fan Speed Range Low 2 Abnormal Recycle Fan Speed Range High 382 Abnormal Recycle Fan Speed Range High S 383 448 452 invali 5 4 4 4 4 4 Circulator outlet temperature was invalid 4 4 4 4 458 Circulator sensor choice was invalid 461 4 LCI lost in Combustion Pressure Stabilizing Period 65 RESERVED 97 Liberty US Installation and Operation Instructions US WH Series Table 17 4 Alert Codes Internal error EEPROM cycle count address was invalid Internal error Safety key bit 0 was incorrect S 478 Internal error Safety key bit O was incorrect 479 480 481 482 Internal error Safety key bi
57. clude a parts list and detailed installation instructions A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment all venting instructions all parts list for venting instructions and or all venting design instructions shall remain with the water heater or equipment at the completion of the installation Liberty US Installation and Operation Instructions US 2 0 INTRODUCTION WH Series Table 2 1 General Specifications US700WH Gas Connection 25 m Water Connections inches NPT m 1 1 4 Female 2 Female Exhaust Vent 4 Connection inches Air inlet Connection 4 inches Cabinet Width 7 inches Cabinet Depth 24 32 5 47 5 63 5 inches Approximate Weight Water Content 24 33 4 5 2 gallons Electrical Rating 120V 1 Phase 60 Hz 12A Table 2 2 a Water Heater Performance Specifications DESCRIPTION US400WH USS00WH US600WH US700WH USSOOWH ecd MBHy 75 399 100 500 120 600 160 700 160 800 BEEN Recovery Rating at orrea 4 Xe e jJ we Jom o Cabinet Height 36 43 37 inches Thermal Efficiency P Notes Listed Input and Output ratings are at minimum vent lengths at Sea Level Numbers will be lower with longer venting and or altitudes greater than 2000 feet 610 m Based on standard test procedures prescribed by the U S Department of Energy Ratings have been confirmed by AHRI
58. completion of the line pressure testing return the bleed screw of the Line Pressure Test Port to the closed position For the US600 800 models replace the installed hose barb fitting with the factory 1 8 NPT plug use NG LP approved thread sealant The line pressure is a function of the gas supply and is affected solely by field provided parameters such as line size and regulator settings Under no circumstances can the water heater gas valve influence or be used to adjust the gas line pressure Failure to close the bleed screw of the Line Pressure Test Port will cause a severe leakage DANGEH of litine l ee gas resulting in a fire or explosion causing property damage serious injury or death Table 9 1 Line Pressure and Combustion Parameters Line Pressure inches wc CO 96 CO ppm Nominal Desired vm Max Min Ma Ma e EE ER HR ro Propane i 8 Ip am 1s Us Notes tis permissible to have higher CO values with the burner operating at the minimum modulation rate The minimum permissible line pressure when operating with Natural Gas is 5 5 inches wc for model USSOOWH Table 9 2 Minimum and Maximum Modulation Rates Modulation US400WH US500WH US600WH US700WH USS00WH Rates rpm Minimum 1550 149 105 020 150 Maximum 7 0 6400 on 4x so JN WARNING Carbon Monoxide Never leave the water heater operating if emitting Carbon Monoxide CO concentr
59. conductor Refer to warning regarding Spark Igniter Cable 4 Turn power on to the water heater and apply a heat demand 5 Allow for 3 complete trials for ignition consisting of pre and post purge of the combustion blower until an ignition lockout occurs Repeat the process two more times i e 9 complete ignition sequences in total 6 Turn power off and reconnect the electrical leads to the Igniter 13 Liberty US Installation and Operation Instructions US WH Series Near Water Heater Vent Air inlet Piping Each Liberty US is equipped with a short piece of approved CPVC vent pipe see Table 4 2 CPVC Vent Pipe Transition Piece Insert one end into the water heater flue outlet adapter and cement the other to field venting see Table 4 4 for approved venting material The CPVC vent pipe should extend fully into the water heater flue outlet adapter see Table 4 2 Ensure that the venting system does not apply a load or strain on the water heater flue outlet adapter The manufacturer recommends using two elbows to create a swing joint to reduce potential strain on vent piping and cemented joints see Figures 4 2 through 4 5 AN Gasket Seating Improper seating can cause leakage and eventual failure of the sealin 4 WARNING proper scaung ce oe gasket Failure to follow these instructions may result in serious injury or death PVC Exhaust Venting DO NOT insert PVC pipe directly into the water heater exhaust adapt
60. ctor with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirements of this subdivision cannot be met at the time of completion of installation the owner shall have a period of 30 days to comply with the above requirements provided however that during said 30 day period a battery operated carbon monoxide detector with an alarm shall be installed 2 APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI UL 2034 listed and IAS certified 3 SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating water heater or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS plate included with water heater 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5 08 2 a 1 through 4 EXEMPTIONS The following equipment is exempt from 248 CMR 5 08 2 a 1 through 4 1 The equipment listed
61. d 50 Maximum hours count was reached Illegal Modbus write was attempted Modbus write attempt was rejected NOT ALLOWED Illegal Modbus read was attempted 54 Safety processor brown out reset occurred Application processor watchdog reset occurred 56 Application processor brown out reset occurred 57 Safety processor watchdog reset occurred Safety processor watchdog reset occurred S 60 Burner control firing rate was lt absolute min rate O 64 66 Burner control rate non firing was invalid vs RPM 68 _ Set point was over ridden due to sensor bh 69 Modulation was over ridden due to sensor nt Flame strength step rate was invalid S 73 Flame strength step rate was invalid 74 76 Fan gain down was invalid Fan gain up was invalid Fan minimum duty cycle was invalid Fan pulses per revolution was invalid 82 83 85 86 Lo Lead Lag add stage detection time was configured o O 87 No Lead Lag drop stage error threshold was configured 89 Lead Lag all water heater off threshold was mal 90 Modulation output type was nal 96 Slow start was ended due to outlet sensor Dt 98 CH max modulation rate was invalid vs REM 91 Liberty US Installation and Operation Instructions US WH Series Table 17 4 Alert Codes 99 CH max modulation rate was gt absolute max rate S O 101 104 TAS open rate differential was invalid S IAS open rate differ
62. e New Brunswick Canada typical maximum snowfall is 19 in thus the inlet must be 12 19 3 in above grade and exhaust must be 31 18 49 above grade Horizontal Separation The horizontal distance between the inlet and exhaust must be a minimum of 4 102 mm center to center Wall Flashing Under normal operating conditions this water heater will produce a plume of white gases and should be taken into consideration when selecting an adequate location A 36 in diameter stainless plastic or vinyl shield can be used to flash the exterior of the residence Flue Gas Hazard Position the vent termination where vapors cannot make accidental contact with people and pets or damage nearby shrubs and plants Elbow Extensions Elbows on outside of wall must be no more than 12 in away from the wall Vent Sloping All indoor exhaust piping must be on a slope back to the water heater a minimum of in per linear foot of vent For applications where excessive condensation is possible in per linear foot is recommended Vent Supports Where required Vent and Air inlet piping shall be secured to the wall for more rigidity All interior vent pipe shall be supported a minimum of every 36 in Roof Exhaust In all roof applications the discharge must point away from the pitch of the roof Roof Flashing Install adequate flashing where the pipe enters the roof to prevent water leakage Rain Cap Install and seal a rain cap over existing
63. e i e a large motor or multiple pieces of equipment starting at the same time Lockout 174 Safety relay i Failing Limit Switch in ILK circuit Check operation of internal LWCO and or feedback incorrect external limit 1 e devise connected between R and LIM replace as necessary Hardware failure of Sola controller Reset power If problem persists replace Sola controller Alert 206 Lead Lag header System Sensor not connected If desired install System Sensor and wire to temperature was invalid sensor input connections SYSTEM and SENSOR COM Otherwise ignore Alert 206 Alert 233 Lead Lag outdoor See Alert 248 temperature was invalid Alert 248 CH outdoor Outdoor sensor not connected The Liberty US is factory set with Outdoor Reset temperature was invalid enabled Connect outdoor sensor or disable Outdoor Reset Outdoor sensor wiring Check wiring of outdoor sensor Wires should connect to Low Voltage barrier terminals 11 amp 12 Faulty sensor Check sensor Should be free of ice and snow Check resistance of sensor and compare to thermistor resistance chart see Table 17 2 Alert 311 Run was Blocked venting Check for blockage of the exhaust vent terminated due to interrupted Blocked air inlet Check for blockage of the air inlet EES Disconnected damaged or blocked Inspect the clear vinyl tubing connecting the air tubing switch and ports to the air metering elbow Condensati
64. e removed and the inside of the water heater must be inspected for component damage e g the internal insulation at the front and back of the chamber Failure to follow these instructions may result in fire property damage serious injury or death Figure 6 1 All Models Condensate Drain Piping Drain Vent Do not block or install piping into the top branch of the condensate drain tee Drain Pipe Connection to the bottom of the condensate drain tee must be made using 1 2 Schedule 40 PVC pipe Secure using appropriate PVC cement All piping must be below the level where the condensate leaves the boiler Floor Drain Check with your local authorities regarding disposal of condensate regulation may require the use of a neutralizer 28 US WH Series Installation and Operation Instructions Liberty US 7 0 INSTALLING GAS PIPING IN WARNING The Liberty US is factory equipped to operate with Natural Gas the installation of a conversion kit is required prior to operating with Propane Gas The Natural to LP Conversion Kit see Table 7 1 must be installed prior to installing the gas piping to the water heater Failure to properly convert the unit to operate with Propane may result in property damage serious injury or death AN Liquefied Petroleum LP propane gas is heavier than air Do not install the water heater WARNING i l l l in a pit or similar location that will permit heavier than air gas to collect Chec
65. efer to Section 12 0 for field wiring instructions The Water Heater Circulator Pump B must be sized according to Table 10 5 to provide NOTICE S adequate circulation through the water heater Figure 10 2 illustrates a typical piping system The Water Heater Plumbing Schematic NOTICE does not illustrate all of the required concepts and components required to have a proper installation Concepts not shown include prevention of thermal siphoning e heat traps isolation valves drain and purge valves etc It is the responsibility of the installing contractor and system designer to consider all aspects of a proper system design including compliance with local codes Contractor modifications to these instructions may be required based upon existing piping and system design Energy Efficiency Although the Liberty US Water Heater is an energy efficient appliance insulating long pipe runs can improve the overall system efficiency by conserving energy and reducing standby losses 46 US WH Series Installation and Operation Instructions Liberty US Figure 10 2 All Models Stand Alone Water Heater Plumbing Configuration aeneae ra LOW TEMPERATURE SUPPLY lt b gt J p HIGH TEMPERATURE SUPPLY STORAGE TANK TRIN amp STOR lt 4 Al 928 FRONT LEGEND DHW LOW TEMPERATURE THERMOSTATIC MIXING DHW LOW TEMPERATURE TEMPERATURE AND RETURN PRESSURE RELIEF VALVE oA Jess or e
66. ential was invalid 111 IAS open step rate was invalid TAS open step rate was invalid 00000000 117 127 _ Fan Speed outofrangeinRUN S O 128 _ Modulation rate was limited due to IAS was open 129 _ Slow start ramp setting of zero will result in no modulation rate change 130 No forced rate was configured for slow start ramp 2 2 2 133 3 3 3 3 127 128 129 131 132 136 CH remote control parameter was invalid 140 146 l 148 9 139 CH remote control parameter was invalid 92 US WH Series Installation and Operation Instructions Liberty US Table 17 4 Alert Codes DHW demand source was invalid 158 DHW P gain was invalid DHW I gain was invalid DHWEgaiwasinvlid 000 164 Inlet sensor type was invalid for DHW Outlet sensor type was invalid for DHW DHW storage OFF hysteresis was invalid DHW storage ON hysteresis was invalid 169 170 171 172 DHW temperature was invalid _DHW temperature was nal DHW priority source setting was invalid DHW priority source setting was invalid 178 DHW priority method setting was invalid CH 55 J8 11 sensor was invalid CH Inlet temperature was invalid CH 510 J10 7 sensor was invalid 182 183 184 Lead Lag ON hysteresis was invalid 0 Lead Lag ON hysteresis was invalid 188 189 191 Lead Lag base load common setting was invalid 194 197 Lead Lag add stage method setting was invalid 204 Lead Lag master was suspended d
67. er as it can deform from the clamping force of the gear clamp Failure to follow these instructions may result in gasket failure and or the dislodging of the exhaust pipe from the water heater adapter resulting in property damage serious injury or death A WARNING Table 4 2 CPVC Vent Pipe Transition Piece used when venting with PVC Model No CPVC Vent Pipe Size CPVC Transition Vent Pipe Length Full Insertion Depth US400WH US600WH 4 Minimum 4 100 mm 1 7 8 48 mm US700WH amp US800NH 60 Minimum 6 152 mm 2 1 2 63 mm TN D Polypropylene or Stainless Steel Venting When using Polypropylene or Stainless Steel A WARNING be 7 piping the appropriate water heater adapters must be used to transition the water heater vent connections to accept the respective Polypropylene or Stainless Steel venting See Table 4 3 for a list of approved adapters Failure to use the correct adapter will result in flue gas leakage resulting in property damage serious injury or death Table 4 3 Water heater Adapters for Polypropylene and Stainless Steel Venting Model No Vent Material Venting Brand T Part No DE DuraVent PolyPro 3005 Polypropylene Centrotherm InnoFlue ISAA0404 Stainless Steel DuraVent FasNSeal 303631 DuraVent PolyPro 810004281 Polypropylene Centrotherm InnoFlue ISAA0606 Stainless Steel DuraVent FasNSeal 810005231 Notes Listed water heater adapters are only approved for
68. esistance of stack sensor and compare to thermistor resistance chart see Table 17 2 Pump flowing in the wrong Ensure water circulation is flowing into the water direction heater at the fitting closest to the wall Incorrect factory sensor wiring Disconnect flue sensor cable screen should Insufficient water flow Dirty heat exchanger Incorrect Stack limit setpoint display Hold 95 Stack sensor fault if not contact Ace Heating Solutions Lockout or Hold 88 Outlet Insufficient water flow See Lockout or Hold 81 T Rise limit 81 Liberty US Installation and Operation Instructions US WH Series Table 17 1 Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Sensor disconnected e Verify that 2 position Molex connector on wiring harness is securely attached to mating Hold 91 Inlet sensor fault connector on inlet sensor e Inspect sensor wiring Faulty sensor Check resistance of sensor and compare to thermistor resistance chart see Table 17 2 Sensor disconnected e Verify that 4 position Molex connector on wiring harness is securely attached to mating connector on outlet sensor e Inspect sensor wiring Faulty sensor Check resistance of sensor and compare to thermistor resistance chart see Table 17 2 Sensor disconnected e Verify that 4 position Molex connector on wiring harness is securely attached to mating connector on stack sensor e Inspect sensor wiring
69. he ACE warranty and may result in property damage fire serious injury or death Water Heater System Preparation Prior to connecting plumbing to the water heater flush the entire system to ensure it is free of sediment flux solder scale debris or other impurities that may be harmful to the system and water heater During the assembly of the piping system it is important to keep the inside of the piping free of any debris including construction and copper dust sand and dirt Toxic chemicals such as used for boiler treatment shall not be introduced into the potable water system Water Chemistry The installer of the Liberty US water heater must consider the condition of the potable water Ensure the water condition falls within the following recommended parameters to avoid scale build up and aggressive PH levels that can result in corrosive reactions and damage to the heat exchanger and system components e Conductivity 170 to 400 uS cm at 25 C TDS 80 to 200 ppm or Total Hardness 5 to 12 grains USgal Water heater water that falls outside of the parameters listed above must only be NOTICE conditioned or treated with products approved for potable hot water systems Toxic chemicals such as used for boiler treatment must not be introduced into the potable water system Potable Water Systems This water heater is suitable for water potable heating and space heating The water heater can be configured for water potab
70. he following basic precautions are common sense Young children and elderly adults burn more quickly and should use cooler water Never leave a child alone while drawing water in a bathtub Test the water temperature before bathing or showering Turn cold water on first then add hot water until the temperature 1s comfortable 40 US WH Series Installation and Operation Instructions Liberty US Thermostatic Mixing Valve When the system requires water at temperatures higher than required for other uses such as high temperature applications typically greater than 46 C 115 F a means such as a thermostatic mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential Anit scald devices such as a thermostatic mixing valve allows potable water to be stored at a higher temperature to limit bacteria growth and allows water at the tap to be delivered at a lower temperature to prevent scalds Failure to follow these instructions may result in serious injury or death Water stored at temperatures between 68 113 F is ideal for bacteria growth see Table D CAUTION 10 1 therefore consuming water from a Water Heater is not recommended Consuming water from a Water Heater may cause illness or death Legislation and Guidelines At the time this document was written standards and IMPOREFANT guidelines regulating the prevention of Legionella in the United States and Canada were m
71. he pipe assembly Freshly assembled piping assembly should be allowed to cure for a minimum of 8 hours before applying power to the gas fired appliance Refer to Mandatory Pre commissioning Procedure for Plastic Venting in this section D Flammable Cements and Primers It is the installers responsibility to familiarize geri lez themselves with the hazards associated with explosive solvents and to take all precautions to reduce these risks Failure to follow these instructions can cause explosions property damage injury or death Mandatory Pre commissioning Procedure for Plastic Venting PVC or CPVC 4 WARNING Do not apply power to the water heater prior to Step 4 in the Mandatory Pre commissioning Procedure for Plastic Venting E Spark Igniter Cable Maintain a minimum 2 separation between spark igniter circuit gen fille and conductors Failure to follow instructions may result in component failure injury or death 1 Working with the power turned off to the water heater completely install the vent and air inlet system securely cementing joints together If possible allow primers cements to cure for 8 hours before firing the burner If curing time is less than 8 hours proceed with Steps 2 through 6 2 Maintain the water heater gas supply shut off valve in the off position 3 Disconnect electrical leads to the Hot Surface or Spark Igniter Ensure the cables are placed in a fashion where they will not arc to ground or other
72. hority and the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Codes Where required by the Authority the installation must conform to the standard for Controls and Safety Devices for Automatically Fired Water heaters ANSI ASME CSD 1 This document pertains to the correct installation and operation of Ace Liberty US water heater models US400WH USSOOWH US600WH US700WH and USSOOWH The instructions detailed in this document supersede any and all previous instructions provided by Ace Heating Solutions LLC written or otherwise Each unit is provided with the following 1 Installation and Operating Instructions 2 Appendix A Controller and Touchscreen Display Instructions 3 Liberty User s Manual and 4 Natural Gas to LP Conversion Kit The conversion kit is required to convert the water heater so it will safely operate with Propane Gas D Models US600WH US800WH are not approved for operation with Propane LP Gas DANGER Operating these models with Propane will result in property damage serious injury or death A DANGER Read and understand this entire document prior to proceeding with the installation of the Liberty US Failure to follow the instructions outlined in this document will result in property damage serious injury or death User Responsibilities This water heater must be installed and serviced by a qualified installer or service technician This water heater must be serviced and inspected ann
73. hould be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code 11 Liberty US Installation and Operation Instructions US WH Series Direct Vent Installation Mandatory for model US400WH When installed as a Direct Vent water heater the combustion air inlet must also be piped directly to the outdoors using the methods described in this section and in accordance with the National Fuel Gas Code ANSI Z223 1 U S or CSA B149 1 Canada and local requirements Indoor Combustion Air Optional for models US5500WH US800WH When the installation uses Indoor Combustion Air i e piping is not directly connecting the water heater air inlet fitting to the outdoors provisions for combustion and ventilation air in accordance with section Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 I NFPA 54 U S or Clause 8 2 8 3 or 8 4 of Natural Gas and Propane Installation Code CAN CSA B149 1 Canada or applicable provisions of the local building codes must be adhered to Gen The water heater shall be located so as not to interfere with proper circulation of NOTICE T tir combustion ventilation and dilution air A Make up air requirements for the operation of exhaust fans kitchen ventilation systems WARNING DA e clothes dryers and fireplaces shall
74. ing material and rules described in this section A DANGER Vent and Air inlet are to be piped separately The Liberty US cannot share a common vent or air inlet with multiple appliances Failure to comply will result in serious injury or death Removing an Existing Water heater from Common Venting System D Do not install the Liberty US into a common venting system with any other appliances Erie Failure to comply with this warning will cause flue gas spillage and leech carbon monoxide emissions into the surrounding air resulting in serious injury or death YN WARNING When an existing water heater is removed from a common venting system the common venting system is likely to be too large for proper venting of the remaining appliances connected to it Instructions have been provided on how to remove the existing water heater and how to resize the remaining venting system Failure to follow these instructions may result in property damage serious injury or death At the time of removal of an existing water heater the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation Steps to Removing an Existing Water Heater 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch Verify that there is no
75. ion and Operation Instructions US WH Series AN WARNING The initial lighting of the water heater must be performed by a licensed Gas Technician Failure to follow instructions may result in property damage serious injury or death Ensure the water heater is wired in accordance with this manual Ensure the gas shut off valve is turned on and that the gas system has been fully tested for leaks Ensure the system is completely filled with water and that ALL the air is purged out Allow primers cements to cure for 8 hours prior to Start up If curing time is less than 8 hours first perform Steps 2 through 6 of Mandatory Pre commissioning Procedure for Plastic Venting in Section 4 0 Failure to follow these instructions can result in explosion serious injury or death Initial Start Up l Turn on power to the Liberty US and turn up the Thermostat s The water heater should run through a purge and combustion should occur The control system has a built in ignition retry allowing the system to try at least three times before locking out With the unit operating at full capacity verify that the gas line pressure is 5 5 10 5 inches w c for Natural gas and 9 13 inches w c for Propane See Section 9 0 for details Using an appropriate Oxygen or Carbon Dioxide analyzer take a sample of the flue gas The sample must fall within the acceptable ranges for Carbon Dioxide which is 8 8 9 8 for Natural gas and 9 8 10 8 fo
76. ions of the gas valve wiring With an AC voltmeter measure the voltage from controller terminals J5 2 to J4 10 There should be 24VAC present during trial for ignition Faulty Gas Valve The gas valve emits an audible click when it switches on or off If the controller is providing 24V AC to the gas valve and the wiring is intact it should be possible to detect if the valve is responding Lockout 113 Flame circuit A flame circuit shorted to ground Check to ensure condensate drain is not blocked timeout may show up as a flame circuit Check to ensure no voltage applied to R amp CH timeout High resistance shorts can terminals If using 4 20mA input check to ensure display as Lockout 113 current is not greater than 21mA 82 US WH Series Installation and Operation Instructions Liberty US Table 17 1 Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Lockout 122 Lightoff rate See Blower not operating below proving failed Missing or incorrect blower See Hold 62 above feedback signal Blower is always on See Blower operating at high speed while burner is off below Alert 128 Modulation rate Blocked venting Check for blockage of the exhaust vent was limited due to IAS was Blocked air inlet Check for blockage of the air inlet open Air switch open while burner firing Lockout 173 Pilot relay feedback incorrect External Electrical Noise Look for sources of electrical nois
77. k with Local Codes as they may require appliances fueled with LP gas to be provided with an approved means of removing unburned gases from the room Failure to follow these instructions may result in serious injury or death Table 7 1 Natural Gas to LP Propane Conversion Kit Model Number LP Conversion Kit Number LP Orifice US400WH 83017 1 62 6 2 mm USSOOWH 84386 1 Notes No LP orifice is used with model US500WH see conversion kit instructions for information on adjusting the throttle screw convert water heater to LP Models US600WH US800WH cannot be operated with LP Propane Use Natural Gas only Installation Refer to the current National Fuel Gas Code ANSI Z223 1 NFPA 54 or CAN CGA B149 1 installation codes and local codes for gas piping requirements and sizing Pipe size running to the unit depends on e Length of pipe e Number of fittings e Type of gas e Maximum input requirement of all gas appliances in the residence Ensure that e The gas line connection to the water heater does not apply any weight to the gas valve ACE recommends using approved flexible gas piping if acceptable by local codes to connect the water heater to the gas supply See Figure 7 1 for details e You plan the installation so that the piping does not interfere with the vent pipe or the removal of the valve burner and serviceable components e The water heater shall be installed such that the gas ignition system components are p
78. ks where water temperature is coolest and piping runs where water can stagnate e Abandoned water lines should be capped off at the distribution main not at the most convenient place e Avoid dead ends in piping system If unavoidable provide a drainage port in these areas at the lowest point to flush out stagnant water regularity e Insulate DHW recirculation lines and keep pipe runs as short as possible e Recommend annual water testing of water in your tank and piping system s to monitor water conditions e Keep a maintenance record of when your water heater and storage tank were cleaned piping systems flushed and who did the service work Table 10 1 How Water Temperature relates to Legionella and Scald Hazard S seconds 24 or 3 degree bum Notes Published by Chartered Institute of Plumbing and Heating Engineering Databyte series Safe Hot Water Temperatures The elderly and small children are susceptible to bad burns at shorter exposure times than listed in this table 3 A thermostatic mixing valve should be installed on DHW storage tanks when outlet temperatures exceed 115 F 46 C Typical water temperature for bathing or showering range between 98 113 F 37 45 C Temperature Time Burn Chart published by John Hopkins University excluding notes 41 Liberty US Installation and Operation Instructions US WH Series Near Water Heater Plumbing Pressure Relief Valve A Pressure Relief Valve is fact
79. l 3 M6 Internal fault Flame bias out of range 4 M Internal fault Flame bias out of range 5 13 13 14 147 i 14 15 15 15 15 15 15 Internal fault Flame bias out of range 3 5 6 9 Flame detected Hold Lockout 0 Flame not detected Hold 2 5 H 4 155 Purge fan switch OFF Hold Lockou 160 Lockout 162 Lockout 163 Lockout 166168 RESERVED G 87 151 High fire switch ON old Lockout Liberty US Installation and Operation Instructions US WH Series Table 17 3 Hold and Lockout Codes Lockout l 15 Lockout 176 Lockout 177 178 Lockout 179 180 RESERVED EE Invalid J7 1 configuration both LFS and Blocked condensate Disabled 186 Lockout 189 Invalid Flame sensor type setting Lockout l 92 Lockout 193 Lockout 195 Lockout 196 Invalid Ignition source setting Lockout Invalid Interlock open response setting Invalid Interlock start check setting Lockout 199 Invalid LCI enable setting Lockout Invalid PII enable setting 208 Lockout 210 212 Invalid Pre ignition time setting Lockout 215 Lockout 218 Lockout 88 US WH Series Installation and Operation Instructions Liberty US Table 17 3 Hold and Lockout Codes 225 Lockout 2 28 Invalid Stack limit set point setting Lockout 229 Invalid Modulation output setting Lockout 232 Lockout 235 Lockout 238 Invalid Stack connector
80. le heating only or combination space heating and is subject to the following requirements 1 Piping and components connected to the water heater for use with water potable heating or combination space heating applications shall be suitable for use with potable water 2 Toxic chemicals such as used for boiler treatment shall not be introduced into the potable water system 3 This water heater which will be used to supply potable water shall not be connected to any heating system or component s previously used with a non potable water heating appliance 4 When the system requires water for space heating at temperatures higher than required for other uses a means such as a mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential These instructions shall include a piping diagram s for a typical installation Definitions of Potable Water Systems Each potable water system described below is meant to be used with a storage tank refer to Table 10 1 e Water Potable Heating Only refers to an open potable water system dedicated to providing domestic hot water and is not intended for space heating e Combination Space Heating refers to an open potable water system where the domestic hot water and heating system water are drawn from the same storage tank Heat exchange typically takes place in the water heater and there is no separation or differentiation between water used for domestic
81. ll ll yY O E BG BE BE BS eee Minimum 36 10 e m2 J 0 J Recommended 36 a ein 9 soweesw Mamm xr om foe opa ou o Recommended 36 24 3 23 1 Notes 6 if surface is removable allowing 36 clearance i e closet installation See Ventilation Air Opening dimensions in Figure 3 1 Clearances can be as low as 12 if the right side has a clearance of 24 3 For models USSOOWH US800WH ensure rear of unit is accessible for wiring and flue gas testing Code requires all wall mounted instantaneous water heaters to be installed with suitable wall protection extending the full length and width of the water heater Check with local authorities regarding acceptable protection materials Liberty US Installation and Operation Instructions US WH Series Figure 3 2 b Wall Mounting Installations US400WH Q While leaving the upper bracket intact A 4 WARNING Failure to follow instructions may remove the wall mount bracket attached to the result in fire serious injury or death bottom back of the boiler B Save the N CAUTION This unit requires two people to lift it mounting hardware for Step 4 or damage and injury may result Secure the wall mount bracket removed from the bottom of the boiler in Step 1 to a solid o wall using field supplied lag screws anchors when mounting to a concrete wall that are adequate to support the weight of the boiler refer to Table 2 1 Specific
82. located on the Gas Valve and Venturi Assembly The Throttle screw is used to adjust the flow of gas leaving the gas valve entering the Venturi and hence entering the combustion air stream By turning the adjustment screw in clockwise the flow of gas is reduced and the combustion becomes leaner thus reducing the concentration of CO in the flue gases To increase the CO the Throttle screw must be adjusted out counterclockwise thus increasing the flow of gas from the gas valve to the combustion air stream See Figure 9 5 for screw direction US400WH Adjustments The throttle screw for the US400WH is a geared valve with a 4 1 ratio Adjusting the throttle screw 4 complete turns will return the valve to the original location 2 turns from fully open will completely close the valve Typical adjustment required is 0 1 4 turn in or out from the factory setting See Figure 9 2 for throttle screw location USS00WH Adjustments The throttle screw for the USSOOWH is a multiple turn valve Typical adjustment required for Natural Gas is 0 1 full turns in or out from the factory setting To adjust combustion for Propane Gas turn the throttle screw all the way in clockwise until it stops then turn the throttle screw out counterclockwise 4 1 2 turns and set with a combustion analyzer See Figure 9 3 for throttle screw location US600WH US800WH Adjustments Remove the cap and adjust the input screw by turning it clockwise to decrease gas flow and counte
83. lves for Hot Water Supply Systems ANSI Z21 22 CSA 4 4 The relief valve is to be installed on the storage tank in accordance with Figure 10 2 and must be accessible for servicing or replacement No valve is to be place between the T amp P Relief Valve and the storage tank Check if local codes require storage tanks to have any additional valves Ensure the discharge of the temperature and pressure relief valve is piped to a drain or a location where steam or water will not cause property damage serious injury or death Tank Thermostat Aquastat The aquastat is intended to allow the water heater to monitor and control tank temperature improve response time and prevent short cycles of operation Check that the aquastat will mate with the tapping on the storage tank prior to commencing installation Install the aquastat in the storage tank as per the manufactures instructions Refer to Section 12 0 Field Wiring for details Tank Sensor In lieu of a Tank Thermostat the US water heater control can monitor a tank sensor installed in the storage tank When a tank sensor is used the tank temperature is set via the US control burner demands are generated directly by the US controller based on controller settings Tank sensor MUST be used in conjunction with a DHW temperature safety shutoff switch ACE recommends using P N ACE84632 Tank Sensor w integrated safety switch Failure to provide such a switch may result in property damage seriou
84. m clearances as closet installations except the front must be completely open to the room at a distance no greater than 18 457 mm from the front of the water heater and the room is at least three 3 times the size of the alcove Provided these conditions are met the water heater requires no extra ventilation air openings to the space See Table 3 1for minimum recommended clearances Residential Garage Installations When installed in a residential garage mount the water heater a minimum of 18 457 mm above the floor Locate or protect the water heater so it cannot be damaged by a moving vehicle Check with your local authorities for other possible regulations pertaining to the installation of a water heater in a garage Wall Mounting Installations Optional Model US400WH is shipped with wall mounting brackets to provide installers with the option of wall mounting the water heater USSOOWH US800WH models are not available as a wall mountable unit Refer to Figures 3 3 a and 3 3 b for instructions and illustrations on wall mounting applicable models Liberty US Installation and Operation Instructions US WH Series Figure 3 1 b Closet Installation Minimum Clearances US400WH Piping must be CPVC Top 12 305 mm 6 152 mm max above vent opening 1 25 mm clearance for hot water and vent pipes ad LI K X Front 6 152 mm lt lt Left Side 12 305 mm AA WARNING Closet
85. mbient temperature must be maintained above freezing and below 100 F 38 C Gas components must be protected from dripping spraying water or rain during operation and servicing Consider the proximity of system piping gas and electrical supply condensate disposal drain and proximity to vent termination when determining the best water heater location YN Water or flood damaged components must be replaced immediately with new factory WARNING ae NDA approved components as failure to do so may result in fire serious injury or death Floor Mounting The Liberty US can be mounted directly on combustible flooring with the exception of carpeting Installing the water heater on carpeting is not permissible Ensure the water heater is mounted above any anticipated flood level Model US400WH come equipped with stationary low profile legs Models USSOOWH US800WH include factory supplied field installed leveling legs Once the unit is removed from the pallet thread the leveling legs into the allocated threaded inserts in the bottom of the unit Water heater Area Ventilation Air Openings Direct Vent If water heater area clearances are less than the recommended clearances specified in Table 3 1 the water heater area must be ventilated Exception if the water heater area room has a volume of 150 ft or greater ventilation of the water heater room is not required Each ventilation air opening must meet the minimum requirements of 1 in pe
86. met Vinyl 1 IPS 1030 US600 800 ACE83924 Grommet Vinyl 2 OD US400 72 US WH Series Installation and Operation Instructions Liberty US Grommet Vinyl 2 1 2 IPS 3125 US Commercial Air Switch Bracket US400 Air Switch Huba 604 E021180 set 15 w c US Series Wall Mounting Support Bottom US400 Display Molding Display 7999D Black spark Igniter Wire 12 US Series SNAP BUSHING 1 US Series Power Supply Touch Screen US Series Transformer 24V 40V A US400 ACE84047 Transformer 24V 75VA US Commercial Control Panel Cover US Commercial Drawer US400 Control Panel US Commercial ACE83871 Barrier Strip Low Voltage US150 400 ACE84065 500 800 Barrier Strip Low Voltage US Commercial ACE83517 Fuse Matrix US 2 Amp US150 400 68 ACES4I92 AIl Models JL Fuse Holder 20 Amp at 250VAC Max US Series Fuse Littlefuse 7A 250VAC Fast Blow US Series Touch Screen Display Support US Series Outdoor Sensor 10K US Series Front Cover US600 800 Right Side R1 US400 Right Side US500 73 ACES4374 600 Right Side US600 LefSide USS00 S ACE84375 Left Side US500 74 ACE84376 600 JjLleftSide US60 S O ACES4377 Top US500 Testen 75 ACES4378 600 Top US000 S ACE84147 13 Liberty US Installation and Operation Instructions US WH Series Coupling 2 Brass US Commercial Nipple 3 4 x 5 Black Iron US500 O
87. o 400 20 at 32 GPM 5 Aor 2 Shp PL 55B UPS 26 150 E24B 2400 458 500 17 at40 GPM PDB 35 UPS43 100 EI4B 2400 5084 23 at 48 GPM 2 1 2 PDB 37 TP 32 160 E 22B5 700 19 at 56 GPM 2 1 2 PDB 37 TP 32 160 33B 2400 70S 800 25 at 64 GPM 2 1 2 PDB 38 TP40 160 J Notes Pump models listed are for bronze or stainless steel circulators only cast iron pumps are not permitted Maximum Current Load 1 1 2hp 120V AC or3hp 240VAC Armstrong pumps E10B E13B and Taco pump 2400 408 are not recommended Armstrong pumps E15B 17B and Taco pump 2400 608 are not recommended Armstrong pump E23B E33B not recommended Armstrong pumps E22B and E24B also recommended System Backflow Preventer Check if a backflow preventer is required by local codes This manufacturer and most plumbing codes require a thermal expansion control device be installed if a backflow preventer pressure reducing valve or check valve is installed on a domestic supply line Installing an expansion tank approved for use with potable water is mandatory in applications using a System Backflow Preventer device DHW Potable Water Expansion Tank Check if an expansion tank is required by local codes If required the expansion tank must be suitable for use with potable water and be sized in accordance with the water volume of the system as well as the firing rate of the appliance The expansion tank must be installed downstream of any
88. o keep it from rotating while loosening the compression fitting nut with a 9 16 wrench Remove tubing assembly from blower 3 Access the combustion chamber by removing the aluminum burner door assembly of the water heater 4 Remove or cover the insulation disc located in the back of the combustion chamber to avoid damaging it during the cleaning process The disc is held in place with a 2 5mm Allen head screw 5 Use a vacuum with a high efficiency filter to remove any loose debris or dust 6 Wet the inside of the combustion chamber with water Use a garden hose with a trigger nozzle to direct pressurized water through the gaps between the heat exchanger tubes The water should pass in between the heat exchanger tubes and exit via the condensate drain This process may require the use of some dry rags or plastic to protect electrical components from being damaged by dripping or spraying water 7 Use a nylon or other non metallic brush to loosen the incrustations and any other contaminates that have remained stuck on and in between the tubes 8 Repeat steps 6 and 7 until the heat exchanger is clean and water from the condensate drain runs clear 9 Re install the insulation disc to the back of the combustion chamber see Table 16 1 Item 31 for part 10 Inspect the insulation disc located on the back side of the burner door Replace if damaged see Table 16 1 Item 33 for part by applicable model 11 Re install the burner door gas su
89. ollows Configure Lead Lag Master Configuration DHW setpoint DHW switch Lead Lag at the Master water heater only set DHW switch equal to DHW S6 sensor shorted via the Lead Lag Master Configuration menu accessed as follows Configure Lead Lag Master Configuration Advanced Settings Domestic Hot Water DHW switch DHW enable Local at the Master water heater only set DHW enable equal to Disabled via the Domestic Hot Water Configuration menu accessed as follows Configure Domestic Hot Water Configuration DHW enable 48 Table 11 1 Minimum Pipe Sizes for Multiple Water Heater Applications US400WH USSOOWH US600WH US700WH USS800WH ti 2 3 3 aa BEE MEM MN MEM NM MN MM MN BEER RE NEN NNNM NEMINEM EN NEN NENENMNMMNMN US WH Series Installation and Operation Instructions Liberty US Tank Sensor when operating in a cascade system the water heater controls do not NOTICE support the use of a tank sensor a tank thermostat switch must be used NOTICE All Water Heater piping in Multiple Water Heater Applications must be sized based on Table 11 1 in accordance with the number of units the piping supports NOTICE All water heater circulators Pump B must be sized according to Table 10 5 49 US WH Series Liberty US Installation and Operation Instructions 1 All Models Multiple Water Heater Lead Lag Plumbing Configuration Figure 11
90. on or other foreign matter may be obstructing the tubing preventing the switch from sensing differential pressure caused by air flow through the metering elbow Incorrect air switch setting Contact Ace technical support Blown fuse Check Fuse A EE Faulty controller If Fuse B not blown and controller is operating navigate to pump diagnostic on display Manually switch pump on check for 120VAC at pump connection terminal on line voltage barrier strip If 120V AC not detected replace controller Faulty pump If 120VAC supplied to pump and pump does not operate replace pump 83 Liberty US Installation and Operation Instructions US WH Series Table 17 1 Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Blower operating at high Blower signal cable disconnected Verify that the 5 position Molex connector on speed while burner off the wiring harness is securely connected to its mating connector on the blower Check that the 4 position Molex connector on wiring harness is securely connected to its mating connector on the controller Blower operating at high No 24V AC to controller Check Power LED on controller speed while burner off Check Fuse C With an AC voltmeter measure voltage at terminals J8 1 amp 2 24VAC should be present Blower not operating Blower power disconnected Verify that the 3 position Molex connector on the wiring harness is securely connected to its
91. on space heating system may result in illness or death Contributing Factors to Legionella Experts acknowledge that Legionella is an identified risk in most water systems Although eradicating Legionella is improbable pre cautions can be taken to control and monitor conditions that promote bacteria growth According to the World Health Organization WHO American Society of Heating Refrigeration and Air conditioning Engineers ASHRAE Canada Safety Council CSC and Centers for Disease Control CDC contributing factors to the growth of Legionella in potable water systems include Minerals and nutrients present in the source water and systems materials Stagnation or low flow characteristic of dead ends in distribution piping systems and storage tanks Scale corrosion and bio film Tepid water in cold water lines Water storage temperatures optimal for bacteria growth Chlorine concentration Scald Hazard Hotter water increases the risk of scald injury There is a hot water scald potential if the storage tank thermostat is set too high Before changing the temperature setting on the tank thermostat refer to the thermostat manufacturers recommended settings Failure to follow these instructions may result in serious injury or death A scald injury can occur when hot steam or liquid makes contact with one or more layers of skin Scald severity degree of burn is directly impacted by exposure time and temperature Refer to Table 10 1 T
92. orted to LES Lockot Hold 65 Interrupted Airflow Switch OFF Hold Hold 6 68 IKON J NA 69 Piottsthold Hold TT RESERVED o 00 0 00 0 0 0 Outlet high limit 80 DHWhighlimt o Disabled 8 3 Delta T exchanger outlet limit Disabled 84 Delta T inlet exchanger limit Disabled Inlet Outlet inversion limit See Table 17 1 86 Exchanger outlet inversion limit Disabled Inlet exchanger inversion limit Disabled Outlet T Rise limit See Table 17 1 Exchanger T rise limit Disabled Heat exchanger high limit Disabled o 90 Hold Outdoor sensor fault Hold 98 Tnteral fault Exceeded VSNSR voltage tolerance Lockout 99 Internal fault Exceeded 28V voltage tolerance JL Lockout 102 104 RESERVED el 5 Flame lost in run Lockout Flame current lower than WEAK threshold Hold 86 9 9 10 10 10 10 10 10 0 US WH Series Installation and Operation Instructions Liberty US Table 17 3 Hold and Lockout Codes 114115 RESERVED _ o Controller interaction communications fault Hold 120 Disabled 121 122 Lockout 123 Lockout 126 Hold 131 Fan movement detected during standby Hold 132 Fan speed failed during run Hold 133 135 RESERVED po Interrupted Airflow Switch failed to close 7 ILK failed to close Hold 138 Flame too low Lockout 139 142 RESERVED Se 3 Internal fault Flame bias out of range 1 8
93. ory supplied with each unit and must be field installed at the water heater outlet in the vertical position as shown in Figures 10 1 a and b with the drain pipe outlet exiting the side of the pressure relief valve horizontally and elbowing down US400WH model come with a 125 psi relief valve while USSOOWH US800WH models come with a 150 psi relief valve The maximum allowable working pressure MAWP varies with water heater model see Table 10 2 alternate relief valves may be used so long as they are ASME certified and meet the requirements for the respective water heater If installed with the incorrect orientation horizontally with drain pipe out the bottom the N CAUTION mE W relief valve may not function properly resulting in property damage or personal injury NX WARNING Ensure the discharge of the pressure relief 1s piped to a location where the steam or water inca will not cause property damage or serious injury Pressure Gauge Liberty US units come with a factory supplied Pressure Gauge The pressure gauge must be installed at the water heater outlet prior to any circulators and in the vicinity of the pressure relief valve See Figures 10 1 a and b Table 10 2 Pressure Relief Valve SSES Model Water heater MAWP psi Valve MBH US40WH 4S emm 160 00 oan wwo 80 US700WH USS00WH 42 US WH Series Installation and Operation Instructions Liberty US Figure 10 1 a Near Water Heater Pi
94. osition and then remove the front cover Wait five 5 minutes to clear out any gas Then check for gas including near the floor If you smell gas Stop and follow B above If you don t detect any gas proceed to the next step Turn the gas shut off valve to the on position wait an addition five 5 minutes and check for gas Replace the front cover Set the thermostat to the highest setting and then turn on all power to the water heater Ignition sequence is automatic combustion will occur after a brief fan purge Ignition will retry 3 times If ignition does not occur Turn off the gas and electricity to the water heater and contact a professional service technician or gas supplier Turning Off The Water heater l 2 32 Set the thermostat to the lowest setting and then turn off all power to the water heater Turn the gas shut off valve to the off position US WH Series Installation and Operation Instructions Liberty US 9 0 GAS VALVE AND BURNER SET UP C The Liberty US gas valve must be set up by a licensed Gas Technician Improper set up may result in incorrect operation damage to components or property injury or death Gas Line Pressure The water heater gas valve is equipped with a line pressure test port see Figures 9 1 through 9 3 Use the following procedure to measure the gas line pressure to the water heater to ensure if falls within the range given in Table 9 1 Turn the
95. ostly voluntary The American Society of Heating Refrigerating and Air Conditioning Engineers Inc ASHRAE is currently in the process of converting its guideline entitled Minimizing the Risk of Legionellosis Associated with Building Water Systems ASHRAE Guideline 12 2000 into an official standard Consult with your local authorities as to recommended guidelines for controlling Legionella in potable water systems A WARNING General Guidelines In the absence of a National standard or local codes the following are general guidelines for good practice on maintaining monitoring and operating your potable water system Store hot water at temperatures gt 60 C 140 F for water potable heating only applications Store hot water at temperatures gt 80 C 176 F for combined space heating applications Store and distribute cold water at temperatures below 20 C 68 F System supply for uses other than high temperature applications typically greater than 46 C 115 F shall be equipped with a thermostatic mixing valve on the hot water outlet to reduce potential scald hazards Clean aerators and nozzles on water fixtures on a regular basis to reduce scale build up e Clean storage tanks and remove sediment Flush storage tanks and piping systems regularly for 10 30 minutes at high water temperatures depending on guidelines used to rid the system of sediment and scale that develops typically in the bottom of storage tan
96. ot Power supply for inputs LIM CH1 and CH2 LL 3 External Limit Input requiring 24VAC from terminal R to permit the burner to LIM 4 operate Comes factory equipped with a jumper to the R terminal Remove the factory installed jumper and install the normally open isolated contacts of the field supplied Safety Flow Switch Local Central Heat Demand Not applicable for Water Heater Applications CH2 LL 6 Lead Lag Central Heat Demand Not applicable for Water Heater Applications DHW Tank Demand Input requiring closure of terminals 7 and 10 to initiate a demand for DHW Switch made via isolated end switch dry contact from the storage tank DHW 7 thermostat Aquastat Or optional Tank Sensor P N ACE84632 see Appendix A NOTICE Tank Sensor when operating in a cascade system the water heater controls do not support the use of a tank sensor a tank thermostat switch must be used O GA el OD E O SENSOR E Outdoor Temperature Sensor Not applicable for Water Heater Applications SYSTEM 09 System Water Temperature Not applicable for Water Heater Applications SENSOR TM COM 10 System Common Common port for field inputs DHW OD Sensor and System Sensor External Modulation Control Using a 4 20mA signal an external control can be used 4 20mA to directly modulate the burner firing rate or adjust the active set point This can be useful for applications using external staging controls or Building A
97. our service technician or gas supplier TO TURN OFF GAS TO THE WATER HEATER STOP Read the safety information above very carefully Turn off all electric power to the water heater 3 Turn the manual gas valve to the OFF position pape p CS aS NO N WARNING Crystalline Silica Certain components confined in the combustion chamber may contain this potential carcinogen Improper installation adjustment alteration service or maintenance can cause property damage serious injury exposure to hazardous materials or death Refer to Section 15 0 for information on handling instructions and recommended personal protective equipment Installation and service must be performed by a qualified installer service agency or the gas supplier who must read and follow the supplied instructions before installing servicing or removing this water heater This water heater contains materials that have been identified as carcinogenic or possibly carcinogenic to humans A Void Warranty This Water heater must have water flowing through it whenever the en ELE burner is on or it will damage the unit and void the warranty Failure to follow these instructions may result in serious injury or death US WH Series Installation and Operation Instructions Liberty US 1 0 INTRODUCTION General Installation Requirements The installation of your Ace Liberty US water heater must conform to the requirements of this manual your local aut
98. perature setting was invalid 271 272 273 276 Abnormal Recycle LCI off during Measured Purge Time oo 276 277 283 287 _ Abnormal Recycle Flame was on during Safe Start check 288 Abnormal Recycle Flame was on during Drive to Purge Rate S O 289 Abnormal Recycle Flame was on during Measured PurgeTime 291 Abnormal Recycle Flame was not on at end of Ignition period 2 2 2 D 2 Abnormal Recycle Flame was lost during Main Flame Establishing Period 2 2 2 2 293 Abnormal Recycle Flame was lost early in Run 87 88 89 9 92 Abnormal Recycle ILK off during Pre Ignition test 307 Abnormal Recycle ILK off during Pre Ignition time 95 Liberty US Installation and Operation Instructions US WH Series Table 17 4 Alert Codes Abnormal Recycle ILK off during Ignition period 310 Run was terminated due to ILK was off Run was terminated due to ILK wasoff S O 319 Abnormal Recycle Fan failed during Ignition period Abnormal Recycle Hardware invalid power Abnormal Recycle Hardware invalid power Abnormal Recycle Hardware invalid AC line Abnormal Recycle Hardware SLO flame ripple Abnormal Recycle Hardware SLO flame sample 332 Abnormal Recycle Hardware SLO flame bias range Abnormal Recycle Hardware SLO spark stuck 342 Abnormal Recycle Hardware HFS LES shorted 351 Abnormal Recycle Invalid zero crossing Abnormal Recycle fault stack sensor Abnormal Recy
99. ping US400WH A Te s 1 A Pressure Relief Valve discharge to floor drain Safety Flow Switch Trim able paddle d N Outlet Pressure Gauge M e Pressure Relief Valve A Near Water Heater tees and fittings Figure 10 1 b Near Water heater Piping US500WH USS00WH To Boiler and system plumbing Refer to piping diagrams Outlet Inlet Mandatory Safety Flow Switch Pressure Relief Valve Pressure Gauge Pressure Relief Valve discharge to floor drain 43 Liberty US Installation and Operation Instructions US WH Series Safety Flow Switch A safety flow switch is required by code to ensure a sufficient rate of water supply is available for proper operation of the water heater ACE models USSOOWH US800WH come factory equipped with a safety flow switch installed for model US400WH a safety flow switch must be field supplied and installed Locate the flow switch in series with the water heater and in accordance with the instructions provided with the safety flow switch ACE recommends a safety flow switch with an activation point no lower than the flow rate specified in Table 10 3 Table 10 3 Flow Switch Installation Requirements pase keane sae SC ps ia IMPORTANT After the flow switch no lower than 2y MC increase pipe diameter to the size US400WH 12 gpm 1 1 4 specified in Table 10 5 Refer to Section ll 1 12 0 for instructions on wiring the safety rr The Safety
100. pply and Air inlet pipe check for gas leaks 12 US400WH US800WH Reconnect the fuel air metallic tubing between the blower and the high vent pressure switch Ensure the brass fitting body at the blower remains stationary and does not rotate during reconnection 13 Perform the Operational Check List detailed in Section 14 0 Explosion Hazard US400WH US800WH The fuel air metallic tubing connecting the DANGER blower and the high vent pressure switch contains a mixture of fuel and air Refer to Combustion Chamber Cleaning Procedure for instructions on connecting and disconnecting the metallic tubing Failure to follow these instructions will result in serious injury or death OO OU OO OOO LI Da Replace any gaskets or insulation discs that show any signs of damage and do not re use A WARNING l t Failure to follow these instructions may result in fire property damage or death US WH Series Installation and Operation Instructions Liberty US Refractory Ceramic Fibers RFC Personal Protective Equipment Recommended Read the following warnings and IMPORTANT handling instructions carefully before commencing any service work in the combustion chamber The insulating material on the inside of the burner door and at the back of the combustion chamber contains Refractory Ceramic Fibers and should not be handled without personal protective equipment YN WARNING Potential Carcinogen Use of Refractory Ceramic Fi
101. px 4 Wel JOVYOLS WNOLLdO asss 3ATVA NOLNY10SI NANLIY xenivN3dW3l MOT NOLLO3MIQ MOTA XNYL NOISNYdX3 KZ wem we EE 39nw9 3Wnivea3dW3iL Han MH AlddNS 3univH3dWa3l HOLIMS ACL JAWA 33H NANLIY AMAA D o MM OY Monae ie ATddNS 2024 HOH e NEU ONS ELE ONIXIA OLLWISOMYSHL wv MOT MHC W 3ATVA BEIEN lt D4 ganay 3HnSS3Nd q100 ous3Wod AlddNS 33nivsa3dWiL MOTT 2 SATWA AlddNS 3YyNLVHAdWAL NOldiOS30 e Lucr ors Oe 50 US WH Series Installation and Operation Instructions Liberty US 12 0 FIELD WIRING All wiring must be in accordance with the Canadian Electrical code CSA C22 2 and any applicable local codes Ensure that the wiring complies with this manual The water heater must be electrically grounded in accordance with the National Electrical Code ANSI NFPA 70 local codes and or the Canadian Electrical Code CSA C22 1 X Avoid Shocks To Avoid Electrical Shock turn off electrical power to the water heater WARNING prior to opening any electrical box within the unit Ensure the power remains off while any wiring connections are being made Failure to follow these instructions may result in component failure serious injury or death CAUTION Field Wiring Wire grommets must be used to secure wiring and prevent chafing when ake passing wiring through the cabinet wall Failure to follow instructions may damage unit Line Voltage Connections Elect
102. r 1000 Btu hr but not less than 100 in The lower ventilation opening must be located within 6 of the floor while the upper opening must be located 6 from the top of the space If the Water heater Area does not meet the recommended clearances listed in Table 3 NOTICE 1 and if the water heater area has a volume less than 150 ft it is considered a Closet or Alcove PVC vent pipe and fittings shall not be used within the closet or alcove only approved CPVC Polypropylene or Stainless Steel vent pipe and fittings can be used See Table 4 3 for a list of approved materials Indoor Combustion Air When using Indoor Combustion Air in lieu of Direct Vent air inlet piping an option for models USSOOWH US800WH provisions for combustion and ventilation air in accordance with section Air for Combustion and Ventilation of the National Fuel Gas Code ANSI Z223 I1 NFPA 54 U S or Clause 8 2 8 3 or 8 4 of Natural Gas and Propane Installation Code CAN CSA B149 1 Canada or applicable provisions of the local building codes must be adhered to Closet Installations For closet installations it is necessary to provide two ventilation air openings as shown in Figure 3 1 a b and c each providing a minimum area equal to 1 in per 1000 Btu hr but not less than 100 in and within 6 of the top and bottom of the closet door See Table 3 1for minimum recommended clearances Alcove Installations Alcove installations have the same minimu
103. r clockwise to increase gas flow Typical adjustment required is 0 1 8 turns in or out See Figure 9 4 for throttle screw location 35 Liberty US Installation and Operation Instructions US WH Series Figure 9 5 Throttle Input Adjustment Screw All Models Decrease Gas Turn Clockwise Increase Gas Turn Counter Clockwise IF FOR ANY REASON THE INPUT SCREW IS ADJUSTED A COMBUSTION ANALYZER MUST BE USED TO ENSURE SAFE AND PROPER OPERATION OF THE GAS VALVE Adjustments to the Throttle screw may only be made by a qualified gas technician while INS ftl Le using a calibrated combustion analyzer capable of measuring CO and CO Failure to follow these instructions may result in serious injury or death X Adjustments to the Throttle screw may only be performed if the gas line pressure is Le maintained above minimum levels throughout the duration of the test see Table 9 1 Failure to follow these instructions may result in serious injury or death Combustion Calibration To calibrate burner operation perform the following procedure using a calibrated combustion analyzer capable of measuring CO and CO from Natural and Propane Gas burning appliances Operate the unit at the maximum modulation rate see Table 9 2 Ensure the gas line pressure is maintained within tolerance see Table 9 1 3 While at the maximum modulation rate measure the CO and CO adjust as necessary using the Throttle Screw to be within the limits lis
104. r propane See Section 9 0 for details Perform at least three lights in succession to ensure proper operation After the three successive lights unplug the flame probe and allow the unit to cycle again Ensure that it tries to light and locks out on safety reset Once you have successfully activated the flame safety system replace the wire on the flame sensor and reconfirm proper lighting ge WARNING If the unit fails to light consistently and smoothly contact ACE for technical assistance at 951 738 2230 Never allow the water heater to operate if the ignition or operation of the burner is rough or erratic Failure to follow these instructions may result in serious injury or death AA WARNING The flame probe uses a single electrode located in the burner door at the 6 O clock Re 1 Zi 3 A Lm position DO NOT remove the wire from the dual electrode located in the burner door at the 3 O clock position this device is used for spark igniting and delivers a high voltage potential which would result in an EXTREME ELECTRICAL SHOCK possibly causing serious injury or death lighting Unit Stop and read these instructions very carefully Set the thermostat to the lowest setting and then turn off all power to the water heater This water heater does not have a pilot It is equipped with an ignition device that automatically lights the burner Do not try to light the burner by hand Turn the gas shut off valve to the off p
105. r to complete at least one heating cycle or to operate for at least 15 minutes 4 Always verify proper operation after servicing Instructions to Installing Contractor 1 Ensure that the customer receives the Warranty Documentation included with the installation manual 2 Leave the manual with the customer so they know when to call for annual maintenance and inspection This water heater must have water flowing through it whenever the burner is firing Tea Pelr Lea Failure to comply may damage the unit void the warranty and cause serious injury or death Allowing the water heater to operate with a dirty combustion chamber will adversely affect its operation and void the warranty Failure to clean the heat exchanger on a frequency that matches the need of the application may result in fire property damage or death A WARNING 61 Liberty US Installation and Operation Instructions US WH Series 15 0 ANNUAL MAINTENANCE AND INSPECTION This unit must be inspected at the beginning of every heating season by a Qualified Technician Annual Inspection Checklist Lighting is smooth and consistent and the combustion fan is noise amp vibration free The condensate freely flows from the unit and is cleaned of sediment Relief Valve and air vents are not weeping Low water cut off is flushed if applicable Examine all venting for evidence of leaks Ensure vent screens are cleaned and clear of debris
106. ressure switch will trip when the US500 800 only combustion chamber is blocked or venting is too restrictive Check venting and clean combustion chamber CH or DHW settings Check if CH and or DHW setpoint temperature plus off hysteresis exceed High limit setpoint factory setting 210 F 99 C CH or DHW pump problem See Inoperative CH or DHW pump below Incorrect Outlet high limit setting Increase Outlet high limit setting maximum setting 210 F 99 C Incorrect Outlet high limit Unless deemed unacceptable by local installation response setting US400 water codes the Outlet high limit response should be heater applications only set to recycle and hold to prevent lockout Check Fuse A Check water heater pump Ensure plumbing is correct Refer to Supplementary Documentation section 2 0 System Piping Check that water pressure is at least ISPSI Water heaters Only Water heater heat transfer surfaces may be fouled with scale or magnetite Clean with Fernox DS 40 Descaler and Cleanser See Table 10 1 Inspect and if required clean the combustion chamber and or heat exchanger Refer to 14 0 Annual Maintenance and Inspection and Supplementary Documentation section 2 0 System Piping Unless installed in Canada with PVC exhaust venting set Stack limit setpoint to maximum setting of 220 F 104 C In Canada PVC exhaust venting is limited to 149 F 65 C Faulty sensor Check r
107. rical rating for the Liberty US is 120V 1 Phase 60 Hz 12A The Liberty US line voltage junction box is located at the top of the water heater cabinet on the right hand side and can be accessed by removing the top front cover of the water heater for model US400WH On USSOOWH US800WH models the line voltage junction box is located at the back of the water heater cabinet on the power switch side Remove the top back cover of the water heater to access the three holes knockouts needed for routing field wiring into the line voltage junction box Line voltage field connections are to be installed in accordance with Figures and Tables 12 1 a and 12 1 b Fuses 120VA C The Liberty US is equipped with either one or two 7 Amp fuses to protect 120V AC system components The fast acting fuses are located on the front of the control panel box and can be easily accessed from the outside of the control panel US400WH Control Panel e Fuse A Protects the blower spark generator and PUMP B output circuits e Fuse B Protects PUMP A and PUMP C output circuits USSOOWH US800WH Control Panel e Fuse A Protects the 120VAC circuits within the water heater Pump Relays USSOOWH US800WH In lieu of the 120VAC pump outputs the USSOOWH US800WH incorporates three non powered isolation relay contacts for switching high capacity pumps Contact Secondary Maximum rating is 1 5HP 120V 3 0HP 240V or 30A Refer to Figure 12 2 b for Field Wiring requirements
108. rofile Termination Sidewall PolyPro InnoFlue Termination Sidewall A WARNING Refer to documentation included with termination kit for Refer to documentation included with termination kit for complete installation instructions complete installation instructions Sy A Mu d Air inl d S irinlet ir inlet aroun EN ir inle perimeter Q NW y o Gas Vent Directly Below o Z Exhaust Keep Free of Obstructions e Pl QDy NS Air inlet bottom Exhaust center Min 12 td above grade or snow level Min 12 above grade or snow level 21 Liberty US Installation and Operation Instructions US WH Series Roof Termination Details Direct Vent Installation Figure 4 10 a Two Pipe Termination Roof Exhaust 7 SE Vent Screen Vent pipe piece to V vent screen Vertical Min 18 lt Min 12 Flashing Si o NS ET i MB than 36 Ba Figure 4 10 c PolyPro InnoFlue Termination Roof A WARNING Hefer to documentation included with termination kit for complete installation instructions Exhaust N d N ey be Air inlet N Si gt N Min 12 above grade or snow level NP EN Flashing N 22 Figure 4 10 b IPEX Concentric Termination Roof A WARNING Refer to documentation included with termination kit for complete installation instructions Pa S lt Vent pipe piece to retain vent screen Exh
109. rotected from water dripping spraying rain etc during installation and servicing e The gas piping is large enough for all the appliances in the home No appreciable drop in line pressure should occur when any unit or combination of units lights or runs Use common gas line sizing practices e Always use a pipe threading compound that is resistant to propane LP gas solvent action Apply sparingly to all male threads starting at two threads from the end Over doping or applying dope to the female end can result in a blocked gas line e DO NOT TIGHTEN FITTINGS WITHOUT SUPPORTING THE GAS VALVE as damage to the gas valve or combustion blower can occur e Install a manual Equipment Shut Off Valve as shown in Figure 7 1 Valve must be listed by a nationally recognized testing lab e The gas line piping can safely be removed from the water heater for servicing by strategically placing the gas line shutoff and union see example in Figure 7 1 e All gas piping including gas components in the water heater are checked for leaks using a Bubble Test prior to operating the water heater 29 Liberty US Installation and Operation Instructions US WH Series CO A WARNING A WARNING A WARNING A WARNING 0 Strain on the gas valve and fittings may result in vibration premature component failure and leakage and may result in a fire explosion property damage serious injury or death Flexible gas piping cannot be u
110. rty US Installation and Operation Instructions US WH Series Sidewall Termination Examples Direct Vent Installation Figure 4 7 a Two Pipe Sidewall Termination Figure 4 7 a Two Pipe Sidewall Termination USS00WH Illustrated US400WH Illustrated AA WARNING Extra precaution must be taken to adequately support the weight of the Vent Air inlet piping in applications using roof top terminations Failure to follow these instructions may result in venting or water heater component failure resulting in flue gas spillage leading to property damage serious injury or death 20 US WH Series Installation and Operation Instructions Liberty US Sidewall Termination Details Direct Vent Installation Figure 4 9 a Figure 4 9 b Two Pipe Termination Sidewall IPEX Concentric Termination Sidewall Horizontal A WARNING 4 12 or greater than 36 Refer to documentation included with termination kit for complete installation instructions Exhaust a d ji ay e Vertical LN d WD N NS Min 18 E ps Air inlet o Gas Vent Directly Below o Keep Free of Obstructions NM p Air inlet around Ve perimeter 1 2 from wall Air inlet Exhaust through center I Vent Screen Min 12 Min 12 Vent Screen above grade above grade X or snow level Vent pipe piece to or snow level Vent pipe piece to retain vent screen retain vent screen Figure 4 9 c Figure 4 9 d Low P
111. s are located in the flue outlet adapter assembly Test port access is either from inside the water heater cabinet or from outside the water heater cabinet US400WH USS00WH Figures 9 7 and 9 8 Remove the test port plug perform flue gas analysis and adjust throttle input screw as required until CO and CO levels are within acceptable limits see Table 9 1 Line Pressure and Combustion Parameters Once flue gas sampling completed re install test port plug For model with a threaded plug seal threads with Teflon tape before reinstalling plug AN le Failure to re install the test port plug will result in damage to the unit property damage DANGER i a fire explosion serious injury or death 36 US WH Series Installation and Operation Instructions Liberty US Figure 9 6 Flue Gas Sampling Using Test Port 2 ly Combustion Analyzer FLUE GAS TEST PORT PLUG Remove test port plug to perform flue gas analysis Re install plug once sampling completed to prevent flue gas leakage during appliance operation Failure to comply with these instructions will result in serious injury or death Figure 9 7 Flue Gas Sampling Using Test Port US400WH FLUE GAS TEST PORT PLUG Remove test port plug to perform flue gas analysis Re install plug once sampling completed to prevent flue gas leakage during appliance operation Failure to comply with these instructions will result in serious injury or death Combustion Analy
112. s injury to occupants or possibly death A WARNING Thermostatic Anti Scald Mixing Valve An anti scald mixing valve is recommended when storing domestic hot water above 46 C 115 F and should be used on branches supplying low temperature water to endpoint plumbing fixtures A mixing valve is optional on high temperature water applications including but not limited to process water clothes washers dishwashers or sanitizers depending on the temperature desired at the appliance and water storage temperature When the system requires water at temperatures higher than required for other uses a means such as a mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential Failure to follow these instructions may result in serious injury or death 4 WARNING Figure 10 2 Stand Alone Water Heater Applications This piping diagram demonstrates an application with both low temperature requirements such as bathing and high temperature requirements such as commercial process water heating or laundry When the system requires water at temperatures higher than required for other uses a thermostatic anti scald mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential see Table 10 1 An optional DHW Recirculation Return may be used on long plumbing runs to prevent wait times for hot water on both low and high temperature water applications R
113. s or more while Faulty Blower the blower is running check Fan speed indicated on display If LOW RPM HIGH RPM 0 or rapidly changing RPM value is displayed try connecting another Sola controller If problem remains replace blower 19 Liberty US Installation and Operation Instructions US WH Series Table 17 1 Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Hold 63 LCI OFF Limit Replacement control incorrectly control input configured LCI must be set to enable on all US models excluding US400 units with a serial number of 48251 or lower See instructions included with replacement controller Lockout or Hold 65 No problem normal operation Hold 65 will normally be displayed momentarily Interrupted Air Switch OFF during the drive to light off Blown fuse Check Fuse A blown fuse prevents blower from operating Faulty blower If Fuse A is good and blower remains off check 120VAC supply to blower if present replace blower If blower is on proceed to next step Blocked venting Check for blockage of the exhaust vent Blocked air inlet Check for blockage of the air inlet Disconnected damaged or blocked Inspect the clear vinyl tubing connecting the air tubing switch and ports to the air metering elbow Condensation or other foreign matter may be obstructing the tubing preventing the switch from sensing differential pressure caused by air
114. screen Hold delay or Lockout Check Summary page on Touchscreen for code Burner switch off Check Summary page if Demand indicates Burner switch off go to diagnostics burner test page and switch on Lockout 2 Waiting for Safety parameter s has been Changing settings that are considered safety safety data verification adjusted parameters require Safety data verification Refer to Appendix A Lockout 9 Flame bias out of 4 20mA input being overdriven If using 4 20mA input check to ensure current is range not greater than 21 mA Control malfunction Cycle power if problem returns replace control Hold 27 Flame rod shorted A flame circuit shorted to ground Check to ensure condensate drain is not blocked to ground detected may show up as a flame circuit Check to ensure no voltage applied to R amp T timeout Zero ohm shorts can terminals If using 4 20mA input check to ensure display as Hold 27 current is not greater than 21mA Hold 61 Anti short cycle Demand off Check demand Delay is to prevent rapid cycling of burner Hold 62 Fan speed not Normal Operation Drive to Hold 62 is momentarily displayed prior to burner proved Lightoff ignition during the Drive to Lightoff Blown fuse Check Fuse A blown fuse prevents blower from operating Wiring defect Inspect blower wiring ensure connectors at Sola controller and blower are securely attached Faulty Sola controller If Hold 62 persists for 15 second
115. screws provided in the filter kit 12 US WH Series Installation and Operation Instructions Liberty US Combustion Air inlet Contamination Be careful not to locate the Air inlet termination in an area where contaminants can be drawn in and used for combustion Combustion air containing dust debris or air borne contaminants will drastically increase the required maintenance and may cause a corrosive reaction in the Heat Exchanger which could result in premature failure fire serious injury or death See Table 4 1 for a list of areas to avoid when terminating air intake piping Table 4 1 Corrosive Products and Contaminant Sources Solvents cutting oils fiberglass cleaning solvents Concrete plant or construction site Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance Failure to follow instructions may result in serious injury or death NOTICE It is BEST PRACTICE to pipe the combustion air inlet directly to the outdoors Direct Vent installation to avoid contamination often contained in indoor air A WARNING Flammable Solvents and Plastic Piping Due to the extremely flammable characteristics of most glues cements solvents and primers used in the process of joining plastic vent and air inlet pipe explosive solvent vapors must be evacuated from the vent and air intake prior to start up Avoid using excess cement or primer that may lead to pooling inside t
116. sed within the water heater cabinet and cannot pass through the cabinet wall use rigid piping as shown in Figure 7 1 Failure to follow these instructions may result in fire property damage serious injury or death Do not use an open flame to test for gas leaks Failure to follow these instructions may result in fire property damage serious injury or death When performing a pressure test on the gas line piping be sure the water heater is disconnected or isolated if the test pressure is expected to exceed 1 2 PSI 14 w c as damage to the valve could occur resulting in fire property damage serious injury or death US WH Series Installation and Operation Instructions Liberty US 8 0 LIGHTING THE WATER HEATER AN DANGER Before Start up refer to Mandatory Pre commissioning Procedure for Plastic Venting Z in Section 4 0 Failure to follow these instructions can result in explosions injury or death AN Bee Prior to turning the gas supply on and lighting the water heater ensure all aspects of the installation are complete and in conformance with the instructions provided in this manual including the Vent Air Intake Condensate Drain and System Water Piping Failure to precisely follow these instructions will cause a fire or explosion resulting in property damage serious injury or death AA WARNING Do not store or use gasoline or other flammable vapors amp liquids in the vicinity of this or any other appliance Failure to
117. ss the R and C terminals terminals 3 and 1 o If2A4VAC is not detected check Fuse C see below 76 US WH Series Installation and Operation Instructions Liberty US Figure 17 1 a US400WH Figure 17 1 b USS00WH USS00WH Control Panel Fuse Locations Control Panel Fuse Location T E y S X SS X SR SE Fuse C ATO 2A 32V Auto Z S Blade Type Fuse B 3AG 7A 250V Wi fi Fast Acting Fuse A 3AG lt 7A 250V Fast Acting Fuses There are three 3 fuses associated with the Liberty US 400WH controller but only one 1 with the USSOOWH US800WH controller Check these fuses before replacing the controller or any other electrical component if the fuse is blown it will prevent the protected device s from functioning To check and if necessary replace the fuses e Remove all 120VAC power from the water heater Be careful to check that the unit is not powered from more than one source e g a UPS uninterruptible power supply Remove the front cover On model US400WH the control panel is located below the heat exchanger Fuses A and B are accessible by removing the spring loaded knurled knob of their respective holders Push the knob toward the panel and twist approximately 1 4 turn counter clockwise e To access Fuse C remove the two 10 pan head Phillips screws and lift the top cover from the panel The auto blade type fuse is installed in an inline style fuse holder
118. supplying power to the water heater is not tripped o Theservice switch if applicable 1s in the ON position e There is a heat call from the thermostat o Verify 24V AC to thermostat o The thermostat is placed at a sufficiently high setting to create a call for heat to the water heater To check for the presence of 120V AC and 24V AC at the water heater follow this procedure e Remove the water heater front cover e 120VAC o Remove the Line Voltage junction box cover First remove the 10 pan head Phillips screw securing the cover to the junction box Lift the cover to release it from the water heater base and withdraw the cover from the water heater cabinet This will expose the Line Voltage barrier strip o With an AC voltmeter set on the appropriate scale measure the voltage across the L1 and L2 terminals terminals 1 and 5 o 1 f I20VAC is not detected check the electrical service as suggested above If the service is verified inspect the circuit wiring from the panel to the water heater for broken or disconnected conductors e 24V AC only check if 120V AC supply is verified o Remove the Low Voltage junction box cover First remove the 10 pan head Phillips screw securing the cover to the junction box Lift the cover to release it from the water heater base and withdraw the cover from the water heater cabinet This will expose the Low Voltage barrier strip o With an AC voltmeter set on the appropriate scale measure the voltage acro
119. t 4 was incorrect Internal error Safety key bit 5 was incorrect Internal error Safety key bit 6 was incorrect 485 Internal error Safety key bit 7 was incorrect Internal error Safety key bit 8 was incorrect Internal error Safety key bit 9 was incorrect 488 Internal error Safety key bit 10 was incorrect Internal error Safety key bit 11 was incorrect Internal error Safety key bit 12 was incorrect 491 Internal error Safety key bit 13 was incorrect 492 493 494 Internal error Safety relay commanded off Internal error Unknown safety error occurred 497 Internal error Safety timer was corrupt 498 Internal error Safety timer was expired 499 Internal error Safety timings 500 Internal error Safety shutdown Internal error Safety shutdown 604 606 _ Lead Lag ODR boost max offpoint temperature was too lun 609 Time to rotate lead water heater to next firing slave 98 US WH Series Installation and Operation Instructions Liberty US Table 17 4 Alert Codes Parameter PCB was switched to backup Range PCB was switched to backup Lead Lag modulation sensor was not valid with setpoint source Lead Lag modulation sensor was not valid with local setpoint source Lead Lag modulation sensor was not valid with local modulation rate source 629 Disagreement on number of interacting controls 99 Liberty US Installation and Operation Instructions US WH Series NOTES 100 US WH Series Ins
120. tallation and Operation Instructions Liberty US Ace Heating Solutions LLC Ace Heating Solutions LLC 130 Klug Circle Corona CA 92880 951 738 2230 tel 951 281 4959 fax www aceheatingllc com AM CERTIFIED HLW H 101
121. tch and check for open circuit between terminals 1 amp 3 If continuity detected replace air switch Hold 66 Interrupted air Blower problem Check low voltage wiring from blower to switch ON and blower is on Faulty controller controller Check VDC signal from red green and black green if not 28 32VDC and 0 VDC respectfully replace controller If signal is correct replace blower 80 US WH Series Installation and Operation Instructions Liberty US Table 17 1 Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Insufficient water pressure US400 Ensure at least I5PSI at water heater outlet Refer only to Supplementary Documentation section 2 0 System Piping Lockout or Hold 67 ILK OFF Lockout or Hold 79 Outlet High Limit Lockout or Hold 81 Delta T limit OR Water heater making banging or hissing sounds Lockout 82 Stack limit Lockout or Hold 85 Inlet Outlet Inversion Limit External Limit Tripped Indication that an external limit wired to LIM is open Not a problem with water heater check external limit Insufficient flow for Flow Switch Check plumbing ensure circulator is operating US500 800 only Tripped Thermal Fuse US500 800 Check Thermal Fuse on the back of the heat only exchanger accessed from the rear of the cabinet If tripped contact Ace Heating Solutions Tripped High Vent Pressure Switch The high vent p
122. ted in Table 9 1 4 Operate the unit at the minimum modulation rate Table 9 2 Ensure the combustion remains smooth and CO and CO remain within the limits Table 9 1 If not do not adjust further contact ACE for assistance NO Flue Gas Analysis and Adjustment Each Liberty US is factory set to operate with Natural Gas for water heaters field converted to operate with Propane Gas a flue gas analysis and adjustment is mandatory See Table 7 1 and propane conversion instructions N Model US400WH require the installation of an LP orifice prior to operating with DANGER p ange ropane Gas see Propane conversion instructions for more details To convert the USSOOWH to operate with Propane Gas requires field calibration of the throttle input screw see USSOOWH Adjustments in Section 9 0 and Propane conversion instructions Models US600WH US800WH only operate with Natural Gas conversion to Propane is not an option Failure to follow these instructions will result in property damage personal injury or death N Failure to perform the flue gas analysis and adjustment detailed in this section may result WARNING E in erratic and unreliable burner operation leading to reduced efficiency increased fuel consumption reduced component life heat exchanger combustion deposits and general unsafe operation Failure to follow these instructions may result in serious injury or death Analysis Liberty US flue gas test port
123. tion which if not avoided could result in property damage NOTICE Notice Sign Indicates a hazardous situation which if not avoided could result in property damage M WARNING This Water Heater must be installed by a licensed and trained Heating Technician or the Warranty is Void Failure to properly install this unit may result in property damage serious injury to occupants or possibly death Ace Heating Solutions LLC 130 Klug Circle Corona CA 92880 951 738 2230 tel 951 281 4959 fax www aceheatingllc com Liberty US Installation and Operation Instructions US WH Series Read Before Proceeding If you do not follow these instructions exactly a fire or explosion may result causing property damage serious injury or death FOR YOUR SAFETY READ BEFORE OPERATING A This water heater does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand B BEFORE OPERATING smell all around the water heater area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch Do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions f you cannot reach your gas supplier call the fire department C
124. tions Liberty US 19 Liberty US Installation and Operation Instructions US WH Series 17 0 TROUBLESHOOTING e Observe the following precautions when servicing the water heater Failure to comply with these may result in fire property damage serious injury or death Servicing the Water heater e Disconnect or shut off all energy sources to the water heater 120V AC power water and gas e Identify and mark wires before disconnecting or removing them e Never bypass electrical fuses or limit devices except temporarily for testing e Use proper personal protective equipment PPE i e eye protection safety footwear These procedures should only be performed by qualified service personnel when abnormal operation of the water heater is suspected The water heater incorporates a sophisticated microprocessor based control which normally responds appropriately to varying conditions If the water heater operation appears to be incorrect or it is not responding at all to a demand for heat the following is suggested to determine and correct the problem Before undertaking any troubleshooting procedures it is highly recommended to have NOTICE available a digital multimeter s capable of measuring AC and DC volts Amperes Resistance ohms and Continuity Check 120VAC and 24VAC at the Water heater First verify the following e There is 120V being supplied to the water heater o Thecircuit breaker in the electrical panel
125. to the vent terminal during installation IPEX Concentric Terminal MUST be cemented together and to the vent pipes during installation Vent Screens provided with water heater may be used with the IPEX Concentric Vent Kits otherwise use IPEX vent screens 3 in vent screen P N 196051 each sold separately 7 PEX Low Profile and Concentric kits excluding P N 197009 are constructed out of ULC S636 approved PVC check with your local authority for the acceptance of PVC as a venting material prior to use 5 PEX Concentric kits can be shortened to fit the requirements of the installation see instructions included with the kit for more details Centrotherm Concentric termination kits must use the applicable Twin pipe to concentric adapter part number AA WARNING Models US400WH US800WH are not approved for use with any of the 3 vent SE 3 termination kits only 4 vent termination kits listed in Table 4 6 are acceptable IMPORTANT PVC In Canada Authorities in some jurisdictions may not allow the use of any PVC venting materials with condensing water heaters check with the local safety inspector to verify compliance prior to installing a PVC Concentric Vent Kit i with a Liberty US PORTANT Sidewall Termination Due to potential moisture loading build up along the exterior wall sidewall venting may not be the preferred venting option Refer to Figures 4 8 and 4 10 for roof top venting options 19 Libe
126. tory Ceramic Fibers RCF Reduce the Risk of Exposure Precautions and Recommended Personal Protective Equipment Avoid contact with skin and eyes e Wear long sleeved clothing gloves and safety goggles or glasses Avoid breathing in silica dust Wear a respirator with a N95 rated filter efficiency or better Use water to reduce airborne dust levels when cleaning the combustion chamber Do not dry sweep silica dust Pre wet or use a vacuum with a high efficiency filter Avoid transferring contamination When installing or removing RFCs place the material in a sealable plastic bag Remove contaminated clothing after use Store in sealable container until cleaned Wash contaminated clothing separately from other laundry First Aid Measures If irritation persists after implementing first aid measures consult a physician Skin Wash with soap and water Eyes Do not rub eyes flush with water immediately Inhalation Breathe in fresh air drink water sneeze or cough to clear irritated passage ways Notes Respirator recommendations based on CCOHS and OSHA requirements at the time this document was written Consult your local regulatory authority regarding current requirements for respirators personal protective equipment handling and disposal of RCFs For more information on Refractory Ceramic Fibers the risks recommended handling procedures and acceptable disposal practices contact the organization s listed below Canada CCOHS
127. type setting Lockout 242 Lockout 248 Lockout 250 254 257 261 Lockout Lockout 89 Liberty US Installation and Operation Instructions US WH Series Table 17 4 Alert Codes 0 None Noale 4 000 0 O 3 Configuration parameters were restored from factory defaults 5 Invalid range PCB record has been dropped Invalid range PCB record has been dropped 8 _ Switched application annunciation data block 12 Annunciation configuration was restored from factory defaults 15 18 e D 22 CRC errors were found in application configuration data blocks Backup Alert PCB was restored from active one RESERVED Lead Lag operation switch was turned OFF 5 26 Lead Lag operation switch was turned ON Safety processor was reset 28 Application processor was reset Burner switch was turned OFF 9 30 34 0 4 4 Range PCB in Program Module was too large for product Alert PCB in Program Module was too large for product IAS start check was forced on due to IAS enabled 44 Low voltage was detected in safety processor 45 High line frequency occurred Low line frequency occurred 47 Invalid subsystem reset request occurred Write large enumerated Modbus register value was not allowed 90 Parameter PCB in Program Module is too large for product US WH Series Installation and Operation Instructions Liberty US Table 17 4 Alert Codes Maximum cycle count was reache
128. ually when operating in normal residential applications Demanding applications or extreme conditions i e commercial may require more frequent service and inspection As the User Owner of this equipment you are responsible for ensuring the maintenance is performed at the required intervals see Section 15 Annual Maintenance and Inspection N WARNING Failure to have the water heater properly serviced and inspected on a regular basis by a l ualified service technician may result in property damage serious injury or death q J property 8 Jury JN WARNING Failure to keep the Vent and Combustion Air inlet clear of ice snow and other debris may result in property damage serious injury or death Installer Responsibilities A qualified installer is a licensed person who has appropriate training and a working knowledge of the applicable codes regulations tools equipment and methods necessary to install a water heater The Installer assumes all responsibility for a safe installation and that it meets the requirements of the water heater instruction manuals as well as National and local installation codes It is also the installer s responsibility to inform the User Owner of their obligation with respect to the description under User Responsibilities Failure to follow this warning could result in fire serious injury or death Failure to use the appropriate Natural to LP Conversion Kit and Orifice when operating Meal the Liberty
129. udes Demand source Burner state status of sensors and pumps and so forth Any current Alert or Lockout condition is also displayed Accessible from the Summary page are the Diagnostics pages Refer to the controller manual for more information Lockout and Alert History The controller maintains a record of the fifteen 15 most recent events for both Lockouts and Alerts To display the logs touch the History button on the Summary page refer to Section 7 0 in Appendix A Controller and Touchscreen Display Instructions In any situation where malfunction is suspected always check the Alerts and Lockouts history Entries recorded in the history provide useful information for determining the cause of the malfunction Table 17 1 Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Display shows System See System Disconnected above Disconnected constantly Faulty Sola controller If 24VAC present at controller terminals J8 1 amp 2 check Power LED on controller Verify that connector J8 is securely plugged into the controller Recycle power to water heater if controller does not operate replace the controller Burner not operating Heat demand satisfied no call for Check Demand and Set points via Touchscreen heat Check thermostat and DHW aquastat if applicable setting Water heater outlet temperature Check outlet temperature setpoint and hysteresis exceeds Setpoint On Hysteresis settings via Touch
130. ue to fault 205 Lead Lag slave was suspended due to fault 93 Liberty US Installation and Operation Instructions US WH Series Table 17 4 Alert Codes Lead Lag header temperature was invalid Lead Lag was suspended due to no enabled Program Module installed 208 Lead Lag slave session has timed out Too many Lead Lag slaves were detected 210 Lead Lag slave was discovered Incompatible Lead Lag slave was discovered Incompatible Lead Lag slave was discovered oo 214 Adding Lead Lag slave aborted due to add requirement change No Lead Lag add stage method was specified S O No Lead Lag add stage method was specified 218 219 220 221 Lead Lag drop stage method setting was invalid 224 233 240 LL water temperature range was too small minimum 12 C 22 F Lead Lag CH demand switch was invalid 244 Lead Lag ODR min water temperature was invalid 8 1 3 2 2 2 4 4 RESERVED 247 2 252 2 S 5 250 3 3 3 3 51 _ CH max outdoor set point was na 5 5 5 5 CH max outdoor set point was invalid CH min water set point was invalid 4 CH outdoor temperature range was too small minimum 12 C 22 F CH water temperature range was too small minimum 12 C 22 F 94 WE Im CH min outdoor setp oint was invalid 5590 1 254 US WH Series Installation and Operation Instructions Liberty US Table 17 4 Alert Codes 260 270 Steam 4mA water tem
131. under water Immediately call a qualified service technician to inspect the water heater and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information above very carefully Set the thermostat to lowest setting Turn off all electric power to the water heater This water heater does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand Turn the manual gas valve to the OFF position Remove front access panel Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Turn the manual gas valve ON Wait an additional five 5 minutes smelling for gas Replace the front access panel Set thermostat to highest setting Turn on all electric power to the water heater 9 Ignition sequence is automatic Combustion will occur after a brief fan purge 10 If ignition does not occur follow the instructions To Turn Off Gas To Water heater and call your service technician or gas supplier TO TURN OFF GAS TO THE WATER HEATER 1 STOP Read the safety information above very carefully 2 Turn off all electric power to the water heater 3 Turn the manual gas valve to the OFF position A Ne AS oS Sen 31 Liberty US Installat
132. use with the respective venting brand i e a PolyPro water heater adapter shall not be used with InnoFlue venting PolyPro and FasNSeal water heater adapters are available from DuraVent 1 800 835 4429 or www duravent com InnoFlue water heater adapters are available from Centrotherm Eco Systems 1 877 434 3432 or www centrotherm us com Exhaust venting must be supported to reduce strain on piping joints Failure to A DANGER dn us follow these instructions may result in result in damage serious injury or death NOTICE In Canada the first 3 ft 915 mm of vent piping must be readily accessible for inspection US400WH US600WH US700WH amp USS00WH 14 US WH Series Installation and Operation Instructions Liberty US Figure 4 3 a Near Water Heater Venting CPVC Model US400WH Swing Joint to attain slope in horizontal runs Exhaust Vent 4 l6 CPVC Flue Outlet Stainless Steel Adapter factory supplied Air Inlet Pipe Coupling 4 Removable factory supplied 90 elbow typical or tee and L drain cap option for easy cleanouts Air Inlet check with applicable local codes for acceptable pipe material Figure 4 3 b Near Water Heater Venting PVC Model US400WH Mandatory Vent Pipe Transition Piece Swing Joint to attain slope in horizontal runs See Table 4 2 Exhaust Vent 4 6 PVC check local codes and Table 4 3 Transition Piece 4
133. used Asterisk indicates connection not used or applicable for Water Heater Applications 55 Liberty US Installation and Operation Instructions US WH Series Low Voltage Terminals Terminals 2 and 3 R have 24V AC potential from the internal CAUTION transformer Do not connect power from these terminals to any other terminal other than terminals 4 5 and 6 LIM CHI and CH2 LL Failure to follow these instructions may damage the unit Fuse 24VAC Liberty US400WH model is equipped with a blade style 2 Amp fuse NOTICE to protect the internal transformer located within the slide out control panel box Figure 12 2 Low Voltage Field Wiring All Models US400WH Illustrated DAW Demand Flow Switch Sensor Switch O O N N O Ke SHA ANEK 24VAC ERE T NIA 4 E ASA S E H SE DRE 3i IS Fra ISS EE CH1 CH2 LL CI SD 7 HOT CES i KED K u SENSOR 114 20mA 2 4 20mA LL DATA m oo HE KS lee DE Ge EE MEGS MISSA ASA LE TRE 5 AD UA a AAA COMMUNICATIONS 6IBMS D el DSi LEA XE GA EN EE Qn T oO B o x gt SS D a Ki Lead Lag Wiring for up BMS to 8 Lx Water Heaters Gateway 56 Installation and Operation Instructions Liberty US US WH Series 13 0 WIRING SCHEMA
134. utomation Systems LL DATA Lead Lag Connects internally to the controllers MB2 Modbus communication port Terminals 13 14 and 10 common can be daisy chained to multiple water heaters up LL DATA to 8 in total for the purpose of staging Communications BMS D Building Management System BMS Connects internally to the display s COM2 Modbus communication port Terminals 15 16 and 10 common can be connected to a BMS D Gateway for communication to a BMS or other device ALARM Normally Open Alarm Contacts Contacts close during a lockout or other alarm condition May be connected to a BMS maximum capacity of 0 63Amps at 24V AC 54 US WH Series Installation and Operation Instructions Liberty US Table 12 2 b Low Voltage Field Connections US500WH USS00WH Connection Location Description COM 24VAC 24VAC Common Neutral for the 24V AC power supply within the water heater 2 RI R2 24VAC 24VAC Hot Power supply for inputs EXT LIM CHI and CH2 LL pp External Limit Input requiring 24V AC from terminals R1 R2 to permit the burner to operate Comes factory equipped with a jumper to the R2 terminal For installations EXT LIM 4 requiring the use of an additional safety switch such as a LWCO or auxiliary temperature limit remove the factory installed jumper and install the normally open isolated contacts of the field supplied additional limit in place of jumper Flow Switch factory installed
135. zer 37 Liberty US Installation and Operation Instructions US WH Series Figure 9 8 Flue Gas Sampling Using Test Port USSOOWH amp US600WH Combustion Analyzer A FLUE GAS TEST PORT PLUG Remove test port plug to perform flue gas analysis Re install plug once sampling completed to prevent flue gas leakage during appliance operation Failure to comply with these instructions will result in serious injury or death Test Port Figure 9 9 Flue Gas Sampling Using Test Port US700WH amp US800WH FLUE GAS TEST PORT PLUG Remove test port plug to perform flue gas analysis Re install plug once sampling completed to prevent flue gas leakage during appliance operation Failure to comply with these instructions will result in serious injury or death Combustion Analyzer Test Port G 38 US WH Series Installation and Operation Instructions Liberty US 10 0 WATER HEATER PIPING The heat exchanger of the Liberty US water heater is designed to attain the highest level of heat transfer in a compact design To accomplish this the heating water flows through a series of fin shaped tubes designed to maximize the heat transfer area To maintain the efficient and reliable operation of the heat exchanger and to avoid heat exchanger failure it 1s critical to ensure the rules and guidelines in this section are followed Failure to follow the instructions provided in this section will void t

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