Liberty US400WH Скачать руководство пользователя страница 1

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Model Numbers: US400WH - US800WH
Version Date: 7-27-2015

INSTALLATION AND OPERATION INSTRUCTIONS FOR
Liberty US

WATER HEATER

TABLE OF CONTENTS

1.0

INTRODUCTION ................................................................................................................ 3

2.0

INTRODUCTION ................................................................................................................ 6

3.0

WATER HEATER LOCATION .......................................................................................... 7

4.0

GENERAL VENTING ....................................................................................................... 11

5.0

VENT AND AIR-INTAKE TERMINATION CLEARANCES ........................................ 25

6.0

CONDENSATE DRAIN .................................................................................................... 28

7.0

INSTALLING GAS PIPING ............................................................................................. 29

8.0

LIGHTING THE WATER HEATER ................................................................................ 31

9.0

GAS VALVE AND BURNER SET-UP ............................................................................ 33

10.0

WATER HEATER PIPING ............................................................................................... 39

11.0

LEAD LAG INSTRUCTIONS .......................................................................................... 48

12.0

FIELD WIRING ................................................................................................................. 51

13.0

WIRING SCHEMATICS ................................................................................................... 57

14.0

INSTALLATION CHECKLIST ........................................................................................ 61

15.0

ANNUAL MAINTENANCE AND INSPECTION ........................................................... 62

16.0

PARTS LIST ...................................................................................................................... 64

17.0

TROUBLESHOOTING ..................................................................................................... 76

HAZARD SYMBOLS AND DEFINITIONS

Danger Sign: Indicates a hazardous situation which, if not avoided, will
result in serious injury or death.

Warning Sign: Indicates a hazardous situation which, if not avoided, could
result in serious injury or death.

Caution Sign plus Safety Alert Symbol: Indicates a hazardous situation
which, if not avoided, could result in minor or moderate injury.

Caution Sign without Safety Alert Symbol: Indicates a hazardous situation

which, if not avoided, could result in property damage.

Notice Sign: Indicates a hazardous situation which, if not avoided, could
result in property damage.

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

Содержание US400WH

Страница 1: ...hazardous situation which if not avoided will result in serious injury or death Warning Sign Indicates a hazardous situation which if not avoided could result in serious injury or death Caution Sign...

Страница 2: ...burner Do not try to light the burner by hand 4 Turn the manual gas valve to the OFF position Remove front access panel 5 Wait five 5 minutes to clear out any gas Then smell for gas including near the...

Страница 3: ...d serviced by a qualified installer or service technician This water heater must be serviced and inspected annually when operating in normal residential applications Demanding applications or extreme...

Страница 4: ...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 fr...

Страница 5: ...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 o...

Страница 6: ...gs have been confirmed by AHRI 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 t...

Страница 7: ...ed 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...

Страница 8: ...able Surface or Closet Door Ventilation Air Openings are not required if the appliance area meets the listed Recommended Clearances in Table 3 1 Top 12 305 mm 6 152 mm max above vent opening Front 6 1...

Страница 9: ...of unit is accessible for wiring and flue gas testing 4 Code requires all wall mounted instantaneous water heaters to be installed with suitable wall protection extending the full length and width of...

Страница 10: ...pointed upward and angled away from the wall This unit requires two people to lift it or damage and injury may result Mount the boiler to the wall by aligning the upper bracket A with the wall mount b...

Страница 11: ...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 bl...

Страница 12: ...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 Controller...

Страница 13: ...tics 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...

Страница 14: ...Insertion Depth US400WH US600WH 4 Minimum 4 100 mm 1 7 8 48 mm US700WH US800WH 6 Minimum 6 152 mm 2 1 2 63 mm Polypropylene or Stainless Steel Venting When using Polypropylene or Stainless Steel pipin...

Страница 15: ...nless Steel Adapter factory supplied Coupling 4 Removable factory supplied supplied 90o elbow typical or tee and drain cap option for easy cleanouts Air Inlet 4 Pipe Swing Joint to attain slope in hor...

Страница 16: ...4 CPVC Swing Joint to attain slope in horizontal runs Flue Outlet 4 stainless steel factory supplied Air Inlet Adapter 4 stainless steel factory supplied 90o elbow typical or tee and drain cap option...

Страница 17: ...alcove of a Closet alcove installation 3 The Air Intake does not require high temperature pipe material Check applicable local codes for acceptable materials 4 ULC S636 PVC is approved for flue gas te...

Страница 18: ...ter Kit venting restrictions Models US500WH 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...

Страница 19: ...ing installation 5 IPEX Concentric Terminal MUST be cemented together and to the vent pipes during installation 6 Vent Screens provided with water heater may be used with the IPEX Concentric Vent Kits...

Страница 20: ...o Pipe Sidewall Termination US800WH Illustrated US400WH Illustrated Extra precaution must be taken to adequately support the weight of the Vent Air inlet piping in applications using roof top terminat...

Страница 21: ...Min 12 above grade or snow level Exhaust Air inlet Exhaust Air inlet around perimeter Min 12 above grade or snow level Exhaust center Air inlet bottom Exhaust Air inlet Gas Vent Directly Below Keep Fr...

Страница 22: ...than 36 Flashing Min 12 above grade or snow level Vent Screen Vent pipe piece to retain vent screen Exhaust center Air inlet around perimeter Flashing Refer to documentation included with termination...

Страница 23: ...ent 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 10 Roof Exhaust In all roof appl...

Страница 24: ...the water heater in elevation for every linear foot 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 1 Th...

Страница 25: ...ic property if adjacent 12 7 ft 2 13 m 7 ft 2 13 m R Above a public walkway X X X X S Above a sidewalk or paved driveway that is located between two single family dwellings and services both dwellings...

Страница 26: ...Liberty US Installation and Operation Instructions US WH Series 26 Figure 5 1 Termination Clearances Quick Reference Diagram...

Страница 27: ...le 5 1 G Letter represents a specific Termination Position Refer to Table 5 1 for corresponding termination clearances Concentric Vent Termination Q Two Pipe Termination F Clearance Q Adjacent to Publ...

Страница 28: ...own and damage to the flame sensor and components can occur NEVER use copper steel or galvanized piping in the construction of the condensate disposal system as condensate is very corrosive and will c...

Страница 29: ...ds on Length of pipe Number of fittings Type of gas Maximum input requirement of all gas appliances in the residence Ensure that The gas line connection to the water heater does not apply any weight t...

Страница 30: ...t 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...

Страница 31: ...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 If you cannot reach your gas supplier call the fire depa...

Страница 32: ...ety system replace the wire on the flame sensor and reconfirm proper lighting If the unit fails to light consistently and smoothly contact ACE for technical assistance at 951 738 2230 Never allow the...

Страница 33: ...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 combustio...

Страница 34: ...S400WH Figure 9 3 Gas Valve and Venturi Assembly US500WH Throttle Input Adjustment Screw Venturi Air Inlet Line Pressure Test Port Gas In Gas Valve Orifice Location See Kit 83017 1 Manifold Pressure T...

Страница 35: ...e 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 US50...

Страница 36: ...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 Model US400WH...

Страница 37: ...alysis 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 Analyz...

Страница 38: ...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 Combu...

Страница 39: ...able heating and space heating The water heater can be configured for water potable heating only or combination space heating and is subject to the following requirements 1 Piping and components conne...

Страница 40: ...ring 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 pra...

Страница 41: ...C 115o 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 b...

Страница 42: ...d meet the requirements for the respective water heater If installed with the incorrect orientation horizontally with drain pipe out the bottom the relief valve may not function properly resulting in...

Страница 43: ...H US800WH Pressure Relief Valve discharge to floor drain Outlet To Boiler and system plumbing Refer to piping diagrams Mandatory Safety Flow Switch Pressure Gauge Pressure Relief Valve Inlet Pressure...

Страница 44: ...ctory 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 pe...

Страница 45: ...recommended 6 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 the...

Страница 46: ...nt 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...

Страница 47: ...US WH Series Installation and Operation Instructions Liberty US 47 Figure 10 2 All Models Stand Alone Water Heater Plumbing Configuration...

Страница 48: ...s 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 Se...

Страница 49: ...11 1 Minimum Pipe Sizes for Multiple Water Heater Applications of Units US400WH US500WH US600WH US700WH US800WH 2 3 3 4 4 4 3 4 4 4 4 4 4 4 4 4 5 5 5 4 4 5 5 5 6 4 5 5 5 5 7 5 5 5 6 6 8 5 5 5 6 6 All...

Страница 50: ...Liberty US Installation and Operation Instructions US WH Series 50 Figure 11 1 All Models Multiple Water Heater Lead Lag Plumbing Configuration...

Страница 51: ...ted on the front of the control panel box and can be easily accessed from the outside of the control panel US400WH Control Panel Fuse A Protects the blower spark generator and PUMP B output circuits F...

Страница 52: ...eak line voltage to the appliance PUMP A 2 Not used PUMP B 3 DHW Demand Output to the Water Heater Circulator powered during tank demand PUMP C 4 Not used L2 Neutral 5 120VAC Common Location for conne...

Страница 53: ...he power supply Note most installation codes require the installation of a service switch to break line voltage to the appliance L2 Neutral 2 120VAC Common Location for connecting neutral of the power...

Страница 54: ...ations Sensor DHW 7 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 thermostat Aquastat...

Страница 55: ...r optional Tank Sensor P N ACE84632 see Appendix A OD SYS SENSOR 12 Outdoor Temperature Sensor Not applicable for Water Heater Applications System Water Temperature Not applicable for Water Heater App...

Страница 56: ...er from these terminals to any other terminal other than terminals 4 5 and 6 LIM CH1 and CH2 LL Failure to follow these instructions may damage the unit Fuse 24VAC Liberty US400WH model is equipped wi...

Страница 57: ...US WH Series Installation and Operation Instructions Liberty US 57 13 0 WIRING SCHEMATICS Figure 13 1 a Connection Diagram US400WH...

Страница 58: ...Liberty US Installation and Operation Instructions US WH Series 58 Figure 13 1 b Ladder Logic Diagram US400WH...

Страница 59: ...US WH Series Installation and Operation Instructions Liberty US 59 Figure 13 2 a Connection Diagram US500WH US800WH...

Страница 60: ...Liberty US Installation and Operation Instructions US WH Series 60 Figure 13 2 b Ladder Logic Diagram US500WH US800WH...

Страница 61: ...valve to the ON position 2 Turn Power on to water heater 3 Set Controller to the desired settings 4 Turn thermostat up Ignition will occur Operational Checklist 1 System is free of gas leaks 2 System...

Страница 62: ...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 dis...

Страница 63: ...r 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 Refractory Ceramic F...

Страница 64: ...e 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 yo...

Страница 65: ...WH Series Installation and Operation Instructions Liberty US 65 Figure 16 1 Electrical Housing Controller and Display Module US400WH 56 58 57 52 70 59 62 71 61 63 69 58 60 67 81 68 51 54 65 58 10 11...

Страница 66: ...Liberty US Installation and Operation Instructions US WH Series 66 Figure 16 2 Cabinet Vent and Air Intake Parts US400WH 44 42 39 50 49 46 47 72 73 75 48 37 76 78 77 45 41...

Страница 67: ...on Instructions Liberty US 67 Figure 16 3 Heat Exchanger Gas Valve Blower and Burner Assembly US400WH 10 2 36 3 5 6 11 34 33 31 28 24 25 19 18 17 15 4 35 13 13 14 4 1 20 26 32 30 29 79 8 7 9 105 Rever...

Страница 68: ...ries 68 Commercial Models US500WH US800WH Figure 16 4 Cabinet Vent and Air inlet Parts US500WH US800WH 76 77 73 72 95 95 95 95 78 101 101 42 98 49 48 96 96 47 46 47 74 100 99 104 75 104 97 41 41 US700...

Страница 69: ...n Instructions Liberty US 69 Figure 16 5 Heat Exchanger Gas Valve Blower and Burner Assembly US500WH 5 36 11 10 11 32 34 31 33 14 87 89 86 88 20 19 25 15 24 26 93 29 28 4 2 1 80 Reverse Angle View e A...

Страница 70: ...Valve Blower and Burner Assembly US600WH US800WH 80 1 6 2 4 5 7 9 36 11 10 11 32 34 31 33 14 14 89 90 86 89 20 19 25 15 24 30 85 26 93 13 13 92 91 83 29 14 18 84 87 3 88 94 86 82 94 86 90 89 9 14 13 1...

Страница 71: ...sket US400 500 4 ACE84026 600 800 Blower Gasket US600 800 5 ACE82994 400 EBM Blower RG148 Enhanced US400 5 ACE84322 500 EBM Blower NRG137 US500 5 ACE84006 600 800 EBM Blower G1G170 US600 800 6 ACE8310...

Страница 72: ...h 40 White US Series 29 ACE83720 All Models Elbow Street PVC 1 2 Sch 40 White US Series 30 ACE83907 400 Condensate Drain Tube US400 30 ACE84313 500 600 Condensate Drain Tube US500 600 30 ACE83996 700...

Страница 73: ...ACE83871 400 Barrier Strip Low Voltage US150 400 65 ACE84065 500 800 Barrier Strip Low Voltage US Commercial 67 ACE83517 400 Fuse Matrix US 2 Amp US150 400 68 ACE84192 All Models Fuse Holder 20 Amp at...

Страница 74: ...64 700 800 Elbow 1 90 deg Black Iron US700 800 91 ACE84102 500 800 Flow switch FS8 W Paddles 2 1 2 US Commercial 92 ACE84099 500 800 Bushing 2 x 1 Brass US Commercial 93 ACE84058 500 800 Tee 2 x 2 x 2...

Страница 75: ...US WH Series Installation and Operation Instructions Liberty US 75 Item Part Models Description...

Страница 76: ...in the electrical panel supplying power to the water heater is not tripped o The service switch if applicable is in the ON position There is a heat call from the thermostat o Verify 24VAC to thermost...

Страница 77: ...aded knurled knob of their respective holders Push the knob toward the panel and twist approximately 1 4 turn counter clockwise To access Fuse C remove the two 10 pan head Phillips screws and lift the...

Страница 78: ...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...

Страница 79: ...creen Check thermostat and DHW aquastat if applicable setting Water heater outlet temperature exceeds Setpoint On Hysteresis Check outlet temperature setpoint and hysteresis settings via Touchscreen H...

Страница 80: ...y replace air switch If the unit fails to light or lights but runs rough or abruptly shuts down check water heater internals for blockage WARNING Only jumper the air switch for diagnosing purposes Tri...

Страница 81: ...ons only Unless deemed unacceptable by local installation codes the Outlet high limit response should be set to recycle and hold to prevent lockout Lockout or Hold 81 Delta T limit OR Water heater mak...

Страница 82: ...r electrode Insufficient gas line pressure Ensure the manual gas shutoff valve is open Refer to manual section 9 0 GAS VALVE AND BURNER SETUP Flame rod disconnected Verify that the flame rod signal wi...

Страница 83: ...06 Alert 233 Lead Lag outdoor temperature was invalid See Alert 248 Alert 248 CH outdoor temperature was invalid Outdoor sensor not connected The Liberty US is factory set with Outdoor Reset enabled C...

Страница 84: ...l as the ignition spark generator and water heater pump Faulty blower Measure voltage across pins 1 2 black and white wires of 3 position connector on wiring harness If 120VAC detected replace power c...

Страница 85: ...oltage changed too much during flame sensing time Hold 26 Internal fault Static flame ripple Hold 27 Internal fault Flame rod shorted to ground detected Hold 28 Internal fault A D linearity test fails...

Страница 86: ...Inlet Outlet inversion limit See Table 17 1 Hold 86 Exchanger outlet inversion limit Disabled 87 Inlet exchanger inversion limit Disabled 88 Outlet T Rise limit See Table 17 1 Lockout 89 Exchanger T...

Страница 87: ...ed to close Hold 137 ILK failed to close Hold 138 Flame too low Lockout 139 142 RESERVED 143 Internal fault Flame bias out of range 1 Lockout 144 Internal fault Flame bias out of range 2 Lockout 145 I...

Страница 88: ...alid Ignite failure delay setting Lockout 194 Invalid Ignite failure response setting Lockout 195 Invalid Ignite failure retries setting Lockout 196 Invalid Ignition source setting Lockout 197 Invalid...

Страница 89: ...gniter on throughout PFEP Lockout 244 Internal fault Safety relay test invalid state Lockout 245 Invalid Outlet connector type setting for T rise Lockout 246 4 20mA cannot be used for both modulation...

Страница 90: ...be determined 21 Invalid safety group verification table was not accepted 22 CRC errors were found in application configuration data blocks 23 Backup Alert PCB was restored from active one 24 RESERVE...

Страница 91: ...was over ridden due to sensor fault 70 No demand source was set due to demand priority conflicts 71 CH 4 20mA signal was invalid 72 Flame strength rate differential was invalid 73 Flame strength step...

Страница 92: ...s absolute max rate 120 Modulation commanded rate was CH max modulation rate 121 Modulation commanded rate was DHW max modulation rate 122 Modulation commanded rate was min modulation rate 123 Modulat...

Страница 93: ...5 J8 11 sensor was invalid 180 CH Inlet temperature was invalid 181 CH S10 J10 7 sensor was invalid 182 Lead Lag CH setpoint source was invalid 183 Lead Lag P gain was invalid 184 Lead Lag I gain was...

Страница 94: ...t was configured for frost protection 226 RESERVED 227 DHW priority override time was not derated due to invalid outdoor temperature 228 Warm weather shutdown was not checked due to invalid outdoor te...

Страница 95: ...ed Purge Time 284 Abnormal Recycle Demand off during Drive to Light off Rate 285 Abnormal Recycle Demand off during Pre Ignition test 286 Abnormal Recycle Demand off during Pre Ignition time 287 Abnor...

Страница 96: ...alid 327 Abnormal Recycle Hardware flame rod short 328 Abnormal Recycle Hardware invalid power 329 Abnormal Recycle Hardware invalid AC line 330 Abnormal Recycle Hardware SLO flame ripple 331 Abnormal...

Страница 97: ...ame bias high 375 Abnormal Recycle Hardware flame bias low 376 Abnormal Recycle Hardware flame bias delta high 377 Abnormal Recycle Hardware flame bias delta low 378 Abnormal Recycle Hardware flame bi...

Страница 98: ...y key bit 9 was incorrect 488 Internal error Safety key bit 10 was incorrect 489 Internal error Safety key bit 11 was incorrect 490 Internal error Safety key bit 12 was incorrect 491 Internal error Sa...

Страница 99: ...as switched to backup 616 Range PCB was switched to backup 622 Lead Lag modulation sensor was not valid with setpoint source 623 Lead Lag modulation sensor was not valid with local setpoint source 624...

Страница 100: ...Liberty US Installation and Operation Instructions US WH Series 100 NOTES...

Страница 101: ...US WH Series Installation and Operation Instructions Liberty US 101 Ace Heating Solutions LLC 130 Klug Circle Corona CA 92880 951 738 2230 tel 951 281 4959 fax www aceheatingllc com HLW H...

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