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Liberty US400WH Installation And Operation Instructions Manual

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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
130 Klug Circle., Corona CA 92880 · 951-738-2230 tel · 951-281-4959 fax · www.aceheatingllc.com
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

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Summary of Contents for Liberty US400WH

  • Page 1: Table Of Contents

    Model Numbers: US400WH - US800WH Version Date: 7-27-2015 INSTALLATION AND OPERATION INSTRUCTIONS FOR Liberty US WATER HEATER TABLE OF CONTENTS INTRODUCTION ........................ 3 INTRODUCTION ........................ 6 WATER HEATER LOCATION ..................7 GENERAL VENTING ....................... 11 VENT AND AIR-INTAKE TERMINATION CLEARANCES ........25 CONDENSATE DRAIN ....................
  • Page 2 │Installation and Operation Instructions US – WH Series Liberty US 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.

  • Page 3: Introduction

    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 authority, 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.
  • Page 4 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.
  • Page 5 │ US – WH Series Liberty US Installation and Operation Instructions IN THE STATE OF MASSACHUSETTS ONLY (a) 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...

  • Page 6: Introduction

    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.

  • Page 7: Water Heater Location

    Installation and Operation Instructions 3.0 WATER HEATER LOCATION In all cases, the Liberty US must be installed indoors in a dry location where the ambient 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.
  • Page 8 │Installation and Operation Instructions US – WH Series Liberty US Figure 3-1(b) Closet Installation, Minimum Clearances (US400WH) Piping must be CPVC Top 12” [305 mm] 1” [25 mm] clearance for hot water and vent pipes 6” [152 mm] max. above vent opening...
  • Page 9 │ US – WH Series Liberty US Installation and Operation Instructions Figure 3-1(c) Closet Installation, Minimum Clearances (US500WH-US800WH) Model US800 Ventilation Air Openings - shown Openings are not required if the appliance area meets the Recommended Clearances in Table 3-1.
  • Page 10 │Installation and Operation Instructions US – WH Series Liberty US Figure 3-2(b) Wall Mounting Installations (US400WH)  Failure to follow instructions may While leaving the upper bracket intact (A), result in fire, serious injury, or death. remove the wall mount bracket attached to the bottom-back of the boiler (B).

  • Page 11: General Venting

    Installation and Operation Instructions 4.0 GENERAL VENTING The Liberty US is 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.
  • Page 12 US – WH Series Liberty US 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.
  • Page 13 │ US – WH Series Liberty US Installation and Operation Instructions 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.
  • Page 14 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).
  • Page 15 │ US – WH Series Liberty US Installation and Operation Instructions Figure 4-3(a) Near Water Heater Venting (CPVC) Figure 4-3(b) Near Water Heater Venting (PVC) Model US400WH Model US400WH Swing Joint Mandatory Vent Pipe Swing Joint to attain slope in...
  • Page 16 │Installation and Operation Instructions US – WH Series Liberty US Figure 4-4(a) Near Water Heater Venting (CPVC/PVC) Models US500WH & US600WH Swing Joint to attain slope in horizontal runs Air-Inlet 4” Pipe * Exhaust Vent 4” CPVC Exhaust Vent Air-Inlet Adapter 4”...
  • Page 17 │ US – WH Series Liberty US Installation and Operation Instructions Figure 4-5(a) Near Water Heater Venting (CPVC) Figure 4-5(b) Near Water Heater Venting (PVC) Models US700WH & US800WH Models US700WH & US800WH Mandatory Vent Pipe Transition Piece 6” CPVC (factory supplied). See Table 4-2.
  • Page 18 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.
  • Page 19 Centrotherm Concentric termination kits must use the applicable “Twin pipe to concentric adapter,” part number Models US400WH-US800WH are not approved for use with any of the 3” vent termination kits; only 4” vent termination kits, listed in Table 4-6, are acceptable.
  • Page 20 Figure 4-7(a) Two-Pipe Sidewall Termination Figure 4-7(a) Two-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 terminations. Failure to follow these instructions may result in venting or water heater component failure resulting in flue gas spillage...
  • Page 21 │ US – WH Series Liberty US Installation and Operation Instructions Sidewall Termination Details – Direct Vent Installation Figure 4-9(a) Figure 4-9(b) Two-Pipe Termination (Sidewall) IPEX Concentric Termination (Sidewall) Horizontal 4-12” or greater than 36” Refer to documentation included with termination kit for complete installation instructions.
  • Page 22 │Installation and Operation Instructions US – WH Series Liberty US Roof Termination Details – Direct Vent Installation Figure 4-10(a) Figure 4-10(b) Two-Pipe Termination (Roof) IPEX Concentric Termination (Roof) Exhaust Refer to documentation included with termination kit for Vent Screen complete installation instructions.
  • Page 23 │ US – WH Series Liberty US Installation and Operation Instructions Venting Rules and Guidelines 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.
  • Page 24 Under no circumstances may an existing chimney or chase-way be used to vent or provide combustion intake air to a Liberty US. Failure to follow these instructions will result in fire, property damage, serious injury or death.

  • Page 25: Vent And Air-Intake Termination Clearances

    Figures 5-1 through 5-6, and the Venting Rules and Guidelines in Section 4.0. The instructions detailed in this section are a 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.
  • Page 26 │Installation and Operation Instructions US – WH Series Liberty US Figure 5-1 Termination Clearances Quick Reference Diagram...
  • Page 27 │ US – WH Series Liberty US Installation and Operation Instructions 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] Two-Pipe Termination Clearance “Q”...

  • Page 28: Condensate Drain

    │Installation and Operation Instructions US – WH Series Liberty US 6.0 CONDENSATE 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”...

  • Page 29: Installing Gas Piping

    Installation and Operation Instructions 7.0 INSTALLING GAS PIPING 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.
  • Page 30 │Installation and Operation Instructions US – WH Series Liberty US 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 used within the water heater cabinet and cannot pass through the cabinet wall, use rigid piping as shown in Figure 7-1.

  • Page 31: Lighting The Water Heater

    │ US – WH Series Liberty US Installation and Operation Instructions 8.0 LIGHTING THE WATER HEATER Before Start-up refer to Mandatory Pre-commissioning Procedure for Plastic Venting in Section 4.0. Failure to follow these instructions can result in explosions, injury or death.
  • Page 32 Initial Start-Up 1. 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.)

  • Page 33: Gas Valve And Burner Set-Up

    1. Turn the 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-US500WH models). This port is directly connected to the gas line feeding the water heater. For US600WH- US800WH models, replace 1/8”...
  • Page 34 │Installation and Operation Instructions US – WH Series Liberty US Figure 9-2 Gas Valve and Venturi Assembly (US400WH) Manifold Pressure Throttle/Input Test Port Adjustment Screw Line Pressure Orifice Location Test Port (See Kit 83017-1) Venturi Gas In Gas Valve Air Inlet...
  • Page 35 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.
  • Page 36 Failure to follow these instructions may result in serious injury or death. Analysis - Liberty US flue gas test ports 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-US800WH; Figures 9-7 and 9-8).
  • Page 37 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.
  • Page 38 │Installation and Operation Instructions US – WH Series Liberty US Figure 9-8 Flue Gas Sampling Using Test Port (US500WH & US600WH) Combustion Analyzer FLUE GAS TEST PORT PLUG Remove test port plug to perform flue gas analysis. Re-install plug once sampling completed to prevent...

  • Page 39: Water Heater Piping

    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.
  • Page 40 │Installation and Operation Instructions US – WH Series Liberty US 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.
  • Page 41 │ US – WH Series Liberty US Installation and Operation Instructions Thermostatic Mixing Valve - When the system requires water at temperatures higher than required for other uses, such as high temperature applications typically greater than 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.
  • Page 42 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 US500WH-US800WH models come with a 150 psi relief valve. The maximum allowable working pressure (MAWP) varies with water heater model, see Table 10-2;...
  • Page 43 │ US – WH Series Liberty US Installation and Operation Instructions Figure 10-1(a) Near Water Heater Piping (US400WH) Pressure Relief Valve discharge Inlet to floor drain Safety Flow Switch Trim-able paddle Outlet Pressure Gauge Pressure Relief Valve Near Water Heater tees...
  • Page 44 ACE models US500WH-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.
  • Page 45 │ US – WH Series Liberty US Installation and Operation Instructions 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.
  • Page 46 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.
  • Page 47 │ US – WH Series Liberty US Installation and Operation Instructions Figure 10-2 All Models Stand Alone Water Heater Plumbing Configuration...

  • Page 48: Lead Lag Instructions

    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;...
  • Page 49 │ US – WH Series Liberty US Installation and Operation Instructions 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.
  • Page 50 │Installation and Operation Instructions US – WH Series Liberty US Figure 11-1 All Models Multiple Water Heater Lead-Lag Plumbing Configuration...

  • Page 51: Field Wiring

    Line Voltage Connections Electrical 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.
  • Page 52 │Installation and Operation Instructions US – WH Series Liberty US Figure 12-1(a) Line Voltage Field Wiring (US400WH) PUMP B 120VAC SUPPLY_ Line Neutral Gnd__ SERVICE SWITCH (field supplied) Table 12-1 Line Voltage Field Connections Connection Location Description 120VAC Hot - Location for connecting line voltage of the power supply. Note most...
  • Page 53 │ US – WH Series Liberty US Installation and Operation Instructions Figure 12-1(b) Line Voltage Wiring (US500WH-US800WH) Table 12-1(b) Line Voltage Field Connections (US500WH-US800WH) Connection Location Description 120VAC Hot - Location for connecting line voltage of the power supply. Note most...
  • Page 54 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 US500WH-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.
  • Page 55 │ US – WH Series Liberty US Installation and Operation Instructions Table 12-2(b) Low Voltage Field Connections (US500WH-US800WH) Connection Location Description 24VAC Common – Neutral for the 24VAC power supply within the water heater. COM (24VAC) R1/R2 (24VAC) 24VAC Hot - Power supply for inputs EXT. LIM, CH1, and CH2 (LL).
  • Page 56 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 with a “blade style” 2 Amp fuse to protect the internal transformer located within the slide-out control panel box.

  • Page 57: Wiring Schematics

    │ US – WH Series Liberty US Installation and Operation Instructions 13.0 WIRING SCHEMATICS Figure 13-1(a) Connection Diagram (US400WH)
  • Page 58 │Installation and Operation Instructions US – WH Series Liberty US Figure 13-1(b) Ladder/Logic Diagram (US400WH)
  • Page 59 │ US – WH Series Liberty US Installation and Operation Instructions Figure 13-2(a) Connection Diagram (US500WH-US800WH)
  • Page 60 │Installation and Operation Instructions US – WH Series Liberty US Figure 13-2(b) Ladder/Logic Diagram (US500WH-US800WH)

  • Page 61: Installation Checklist

    │ US – WH Series Liberty US Installation and Operation Instructions 14.0 INSTALLATION CHECKLIST Installation  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.

  • Page 62: Annual Maintenance And Inspection

     11. Re-install the burner door, gas-supply 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.
  • Page 63 │ US – WH Series Liberty US Installation and Operation Instructions Refractory Ceramic Fibers (RFC) Personal Protective Equipment Recommended - Read the following warnings and 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.

  • Page 64: Parts List

    │Installation and Operation Instructions US – WH Series Liberty US 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.
  • Page 65 │ US – WH Series Liberty US Installation and Operation Instructions Figure 16-1 Electrical Housing, Controller, and Display Module (US400WH)
  • Page 66 │Installation and Operation Instructions US – WH Series Liberty US Figure 16-2 Cabinet, Vent and Air-Intake Parts (US400WH)
  • Page 67 │ US – WH Series Liberty US Installation and Operation Instructions Figure 16-3 Heat Exchanger, Gas Valve, Blower and Burner Assembly (US400WH)
  • Page 68 │Installation and Operation Instructions US – WH Series Liberty US Commercial Models (US500WH-US800WH) Figure 16-4 Cabinet, Vent and Air-inlet Parts (US500WH-US800WH)
  • Page 69 │ US – WH Series Liberty US Installation and Operation Instructions Figure 16-5 Heat Exchanger, Gas Valve, Blower and Burner Assembly (US500WH)
  • Page 70 │Installation and Operation Instructions US – WH Series Liberty US Figure 16-6 Heat Exchanger, Gas Valve, Blower and Burner Assembly (US600WH-US800WH)
  • Page 71 │ US – WH Series Liberty US Installation and Operation Instructions Figure 16-7 Electrical Housing, Controller, and Display Module (US500WH-US800WH) 58 wal Liberty US Table 16-1 Parts List: Item Part # Models Description ACE83338 400, 500 Premix burner (US400-500) ACE84383...
  • Page 72 │Installation and Operation Instructions US – WH Series Liberty US Item Part # Models Description ACE84154 600–800 Ignition Electrode, Dual (US600-800) ACE82774 All Models Flame Probe Gasket (US Series) ACE83194 Gas Valve Connector O-ring, Large (US400) ACE84138 600–800 Gas Valve Inlet O-ring (US600-800) ACE82991 Gas Valve Adapter 45900400-138B, 3/4"...
  • Page 73 │ US – WH Series Liberty US Installation and Operation Instructions Item Part # Models Description ACE84097 500–800 Grommet, Vinyl, 2 1/2" IPS (3125) (US Commercial) ACE83954 Air Switch Bracket (US400) ACE84139 600–800 Air Switch Bracket (US600-800) ACE82662 All Models Air Switch Huba 604.E021180 set @ .15"...
  • Page 74 │Installation and Operation Instructions US – WH Series Liberty US Item Part # Models Description ACE83962 Gas Valve Orifice O-ring, Large (US400) Coupling, 2”, Brass (US Commercial) ACE84057 500–800 ACE84010 All Models System Sensor, Pipe Sensor TSA00A4 (US Series) ACE84087 600–800...
  • Page 75 │ US – WH Series Liberty US Installation and Operation Instructions Item Part # Models Description...

  • Page 76: Troubleshooting

    │Installation and Operation Instructions US – WH Series Liberty US 17.0 TROUBLESHOOTING 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 ...
  • Page 77 Fast-Acting Fuses There are three (3) fuses associated with the Liberty US 400WH controller but only one (1) with the US500WH- 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.
  • Page 78 │Installation and Operation Instructions US – WH Series Liberty US 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.
  • Page 79 Liberty US Installation and Operation Instructions 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 includes Demand source, Burner state, status of sensors and pumps, and so forth.
  • Page 80 │Installation and Operation Instructions US – WH Series Liberty US Table 17-1 Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Hold 63 – LCI OFF (Limit LCI must be set to “enable” on all US models, Replacement control incorrectly control input) configured.
  • Page 81 │ US – WH Series Liberty US Installation and Operation Instructions Table 17-1 Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Lockout or Hold 67 – ILK Insufficient water pressure (US400 Ensure at least 15PSI at water heater outlet. Refer only) to Supplementary Documentation section 2.0...
  • Page 82 │Installation and Operation Instructions US – WH Series Liberty US Table 17-1 Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION  Verify that 2-position Molex connector on Hold 91– Inlet sensor fault Sensor disconnected wiring harness is securely attached to mating connector on inlet sensor.
  • Page 83 │ US – WH Series Liberty US Installation and Operation Instructions Table 17-1 Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION Lockout 122 – Lightoff rate See “Blower not operating” below. Blower is not turning on proving failed Missing or incorrect blower See Hold 62 above.
  • Page 84 │Installation and Operation Instructions US – WH Series Liberty US Table 17-1 Troubleshooting Chart PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION  Verify that the 5-position Molex connector on Blower operating at high Blower signal cable disconnected speed while burner off the wiring harness is securely connected to its mating connector on the blower.
  • Page 85 │ US – WH Series Liberty US Installation and Operation Instructions Table 17-3 Hold and Lockout Codes Code Description Note Internal fault: Zero crossing not detected Hold Internal fault: Flame bias out of range Hold Internal fault: Invalid Burner control state...
  • Page 86 │Installation and Operation Instructions US – WH Series Liberty US Table 17-3 Hold and Lockout Codes Code Description Note Internal fault: HFS shorted to IAS Lockout Internal fault: Mux pin shorted Lockout Internal fault: HFS shorted to LFS Lockout Anti short cycle...
  • Page 87 │ US – WH Series Liberty US Installation and Operation Instructions Table 17-3 Hold and Lockout Codes Code Description Note 114-115 RESERVED Wait for OK to Run Disabled Flap valve condensate fault Disabled Controller interaction system fault Hold Controller interaction communications fault...
  • Page 88 │Installation and Operation Instructions US – WH Series Liberty US Table 17-3 Hold and Lockout Codes Code Description Note Safety relay feedback incorrect in run Lockout Main relay feedback incorrect Lockout Pilot relay feedback incorrect Lockout Safety relay feedback incorrect...
  • Page 89 │ US – WH Series Liberty US Installation and Operation Instructions Table 17-3 Hold and Lockout Codes Code Description Note Unconfigured DHW high limit set point setting Lockout Unconfigured Outlet high limit set point setting Lockout Unconfigured Stack limit set point setting...
  • Page 90 │Installation and Operation Instructions US – WH Series Liberty US Table 17-4 Alert Codes Code Description None (No alert) Alert PCB was restored from factory defaults Safety configuration parameters were restored from factory defaults Configuration parameters were restored from factory defaults...
  • Page 91 │ US – WH Series Liberty US Installation and Operation Instructions Table 17-4 Alert Codes Code Description Maximum cycle count was reached Maximum hours count was reached Illegal Modbus write was attempted Modbus write attempt was rejected (NOT ALLOWED) Illegal Modbus read was attempted...
  • Page 92 │Installation and Operation Instructions US – WH Series Liberty US Table 17-4 Alert Codes Code Description CH max modulation rate was > absolute max rate CH modulation range (max minus min) was too small (< 4% or 40 RPM) DHW max modulation rate was invalid, % vs. RPM DHW max modulation rate was >...
  • Page 93 │ US – WH Series Liberty US Installation and Operation Instructions Table 17-4 Alert Codes Code Description DHW demand source was invalid DHW P-gain was invalid DHW I-gain was invalid DHW D-gain was invalid DHW OFF hysteresis was invalid DHW ON hysteresis was invalid...
  • Page 94 │Installation and Operation Instructions US – WH Series Liberty US Table 17-4 Alert Codes Code Description Lead Lag header temperature was invalid Lead Lag was suspended due to no enabled Program Module installed Lead Lag slave session has timed out...
  • Page 95 │ US – WH Series Liberty US Installation and Operation Instructions Table 17-4 Alert Codes Code Description CH ODR min water temperature was invalid RESERVED DHW set point was invalid DHW time of day set point was invalid DHW storage setpoint was invalid...
  • Page 96 │Installation and Operation Instructions US – WH Series Liberty US Table 17-4 Alert Codes Code Description Abnormal Recycle: ILK off during Main Flame Establishing Period Abnormal Recycle: ILK off during Ignition period Run was terminated due to ILK was off...
  • Page 97 │ US – WH Series Liberty US Installation and Operation Instructions Table 17-4 Alert Codes Code Description Abnormal Recycle: fault DHW sensor Abnormal Recycle: DHW high limit Abnormal Recycle: fault inlet sensor Abnormal Recycle: Check Parameters Failed Internal error: No factory parameters were detected in control...
  • Page 98 │Installation and Operation Instructions US – WH Series Liberty US Table 17-4 Alert Codes Code Description Internal error: EEPROM write was attempted before EEPROM was initialized Internal error: EEPROM cycle count address was invalid Internal error: EEPROM days count address was invalid...
  • Page 99 │ US – WH Series Liberty US Installation and Operation Instructions Table 17-4 Alert Codes Code Description 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...
  • Page 100 │Installation and Operation Instructions US – WH Series Liberty US NOTES...
  • Page 101 │ US – WH Series Liberty US Installation and Operation Instructions Ace Heating Solutions, LLC 130 Klug Circle., Corona CA 92880 · 951-738-2230 tel · 951-281-4959 fax www.aceheatingllc.com...

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