OPERATION, SIZING AND INSTALLATION MANUAL For Models: NOW WITH FIVE YEAR WARRANTY 40DHW(T) ON PARTS AND ACCESSORIES & Up Flow Model LIFETIME WARRANTY 60DHW(T) ON HRV CORE Up Flow Model 40DHWDF(T) Down Flow Model 60DHWDF(T) Down Flow Model 40DHWH(T) Horizontal Model 60DHWH(T) Horizontal Model 4TONDHW(T) High CFM Lower BTUH Output 40VENTAC No Heating Coil 60VENTAC No Heating Coil 4TONVENTAC No Heating Coil TO BE COMPLETED BY CONTRACTOR AFTER INSTALLATION Installing Contractor Telephone / Cont
Table of Contents Introduction ............................................................................................................ 3 Description and Purpose ........................................................................................ 4 Combo System Basic Principle ................................................................................ 5 Specifications ................................................................................................. 12 - 21 Installation ........
Introduction Congratulations on your selection of the LIFEBREATH Clean Air Furnace (CAF). This is a very advanced unit that combines the outstanding efficiency and economy of the water heater/airhandler concept, plus the tremendous health benefits of year-round fresh air ventilation in every room of your house. With the addition of LIFEBREATH Turbulent Flow Precipitator (TFP) Air Cleaner (optional) you will have the ultimate in comfort and healthy indoor air quality.
Description and Purpose IMPORTANT NOTE The purpose of this manual is to act as an installation guide only for the LIFEBREATH Clean Air Furnace. Manufacturers' instructions for other components, such as the water heater/boiler, must be followed. All national and local code requirements must be met when installing a LIFEBREATH Clean Air Furnace. Be sure to consult the proper authorities.
Combo System Basic Principles Closed/Open Combo System From the aspect of delivery of domestic hot water and space heating, the Open and Closed systems operate the same. A system becomes closed when a backflow prevention valve or check valve is installed in the cold water piping upstream of the water heater. A backflow prevention valve will prevent the pressure created when water is heated in the water heater, from being relieved into the cold water system.
Call for Space Heating Only Operation Air System When the thermostat calls for heat, the circulation pump is activated and hot water is drawn from the top of the water heater through the air handler, and then returned to the water heater. There should be at least a 20˚F (11˚C) temperature drop between the hot water supplied to the air handler and the returning water temperature. If the temperature drop is less then 20˚F (11˚C) two things may happen: A circulation fan draws cool house air at approx.
Manual Valves There are a number of manual valves required for the system to operate properly and safely. These valves are used as shut off valves, drain valves and throttling valves. They can be globe, gate, ball or balancing type valves. malfunction with age. Gate valves tend to be less expensive than the other type of valves. The globe valve can be used as a shut off, drain or throttling valve. Even in the open position, the valve is fairly restrictive to flow.
Shut Off Valves There are 3 shut off valves required for an integrated combo system as follows: • system. The drain valve should be near the low point of the return piping system upstream of the shut off valve and is preferred to be near the water heater. One valve (a) on the cold water side of the water heater upstream of the heating loop connection. This valve has the ability to isolate the hot water (domestic and space heating) from the household cold water supply.
Expansion Tanks Note: There are a number of pressure balancing valves and mixing valves on the market which are not certified as a anti-scalding device. Expansion tanks are only required for “Closed Systems”. The expansion tank has an air bladder, which will contract to relieve pressure in the system. Pressure is created in the closed system when water is heated in the water heater.
Water Heater Thermostat The water heater thermostat is set by the installing contractor to provide the required temperature at the hot water outlet of the water heater. It is important that a warning label be place near the water heater thermostat telling the homeowner not to change the thermostat setting. The label is included with the furnace. The hot water inlet temperature is typically 140˚F (60˚C).
With an Integrated Combo System, the hot water temperature is approx. 130˚F (54˚C) which is 60˚F (15.5˚C) above the return air temperature. These units typically have a temperature rise of 35˚F (2˚C) to 40˚F (4˚C) and therefore would deliver air at the diffuser at approximately 105˚F (40.5˚C) to 110˚F (43˚C).
CFM @ .25"WG CFM @ .5"WG Specifications Model 40DHW (Up Flow) Core Ventilation system has patented aluminum heat recovery core (standard) or an enthalpic energy recovery core (optional) for energy-efficient ventilation. Enthalpic cores are recommended for regions where the temperature does not drop below 25˚F (-4˚C). Filters Washable air filters in exhaust and supply air streams of ventilation section, 1" pleated in return plenum side.
Specifications Model 60DHW (Up Flow) Ventilation system has patented aluminum heat recovery core (standard) or an enthalpic energy recovery core (optional) for energy-efficient ventilation. Enthalpic cores are recommended for regions where the temperature does not drop below 25˚F (-4˚C). Filters Washable air filters in exhaust and supply air streams of ventilation section, 1" pleated in return plenum side. Case Prepainted galvanized steel for superior corrosion resistance. CFM @ .25"WG CFM @ .
Specifications Model 40DHWDF (Down Flow) Ventilation system has patented aluminum heat recovery core (standard) or an enthalpic energy recovery core (optional) for energy-efficient ventilation. Enthalpic cores are recommended for regions where the temperature does not drop below 25˚F (-4˚C). Filters Washable air filters in exhaust and supply air streams of ventilation section, 1" pleated in return plenum side. Case Prepainted galvanized steel for superior corrosion resistance. CFM @ .25"WG CFM @ .
CFM @ .25"WG CFM @ .5"WG Specifications Model 60DHWDF (Down Flow) Core Ventilation system has patented aluminum heat recovery core (standard) or an enthalpic energy recovery core (optional) for energy-efficient ventilation. Enthalpic cores are recommended for regions where the temperature does not drop below 25˚F (-4˚C). Filters Washable air filters in exhaust and supply air streams of ventilation section, 1" pleated in return plenum side.
CFM @ .25"WG CFM @ .5"WG Specifications Model 40DHWH (Horizontal) Core Ventilation system has patented aluminum heat recovery core (standard) or an enthalpic energy recovery core (optional) for energy-efficient ventilation. Enthalpic cores are recommended for regions where the temperature does not drop below 25˚F (-4˚C). Filters Washable air filters in exhaust and supply air streams of ventilation section, 1" pleated in return plenum side.
CFM @ .25"WG CFM @ .5"WG Specifications Model 60DHWH (Horizontal) Core Ventilation system has patented aluminum heat recovery core (standard) or an enthalpic energy recovery core (optional) for energy-efficient ventilation. Enthalpic cores are recommended for regions where the temperature does not drop below 25˚F (-4˚C). Filters Washable air filters in exhaust and supply air streams of ventilation section, 1" pleated in return plenum side.
Specifications Model 4TONDHW (High CFM Lower BTUH Output) Ventilation system has patented aluminum heat recovery core (standard) or an enthalpic energy recovery core (optional) for energy-efficient ventilation. Enthalpic cores are recommended for regions where the temperature does not drop below 25˚F (-4˚C). Filters Washable air filters in exhaust and supply air streams of ventilation section, 1" pleated in return plenum side. Case Prepainted galvanized steel for superior corrosion resistance.
Specifications Model 40VENTAC (No Heating Coil) Core Ventilation system has patented aluminum heat recovery core (standard) or an enthalpic energy recovery core (optional) for energy-efficient ventilation. Enthalpic cores are recommended for regions where the temperature does not drop below 25˚F (-4˚C). Filters Washable air filters in exhaust and supply air streams of ventilation section, 1" pleated in return plenum side. Case Prepainted galvanized steel for superior corrosion resistance.
Specifications Model 60VENTAC (No Heating Coil) Core Ventilation system has patented aluminum heat recovery core (standard) or an enthalpic energy recovery core (optional) for energy-efficient ventilation. Enthalpic cores are recommended for regions where the temperature does not drop below 25˚F (-4˚C). Filters Washable air filters in exhaust and supply air streams of ventilation section, 1" pleated in return plenum side. Case Prepainted galvanized steel for superior corrosion resistance.
Specifications Model 4TONVENTAC (No Heating Coil) Core Ventilation system has patented aluminum heat recovery core (standard) or an enthalpic energy recovery core (optional) for energy-efficient ventilation. Enthalpic cores are recommended for regions where the temperature does not drop below 25˚F (-4˚C). Filters Washable air filters in exhaust and supply air streams of ventilation section, 1" pleated in return plenum side. Case Prepainted galvanized steel for superior corrosion resistance.
INSTALLATION The purpose of this manual is to give the contractor guidelines for installing the LIFEBREATH Clean Air Furnace. All national and local codes relating to this type of equipment must be followed. required for service of the filter, heat recovery core and components. As a rule this unit should be installed adjacent to the hot water heater. If this is not possible, or if the piping layout is complex, the total head pressure on the pump should be calculated.
Option 2 - Ventilation Ports Off Right Side Models 40DHWDF & 60DHWDF Models 40DHW, 60DHW & 4TONDHW Remove circular metal knockout Remove styrofoam knockout Remove styrofoam knockout Remove styrofoam knockout Horizontal Version Models 40DHW, 60DHW & 4TONDHW Remove circular metal knockout Penetrations from sheet metal screws used to fasten the ductwork to the cabinet of the unit should only be placed into the duct flange provided.
Locating Intake Weatherhood Outside Ducting the Weatherhoods The intake weatherhood should be located as follows: The ventilation portion of the Clean Air Furnace can be vented off either side of the unit by removing knockouts provided. Once the knock outs in are removed, a bead of silicone can be placed on the plastic thermo-collars (provided), to form a seal between the collars and the cabinet. The collars can then be fastened into place with screws.
Pitot Tube Air Flow Balancing It is necessary to have balanced air flows in an HRV. The volume of air brought in from the outside must equal the volume of air exhausted by the unit. If the air flows are not properly balanced then: the ductwork. Procedure should be performed with the HRV on high speed. Choose the straightest section of duct between the HRV and the weatherhoods. This will be used for both the supply and return ducts.
Pitot Tube and Gauge Placement of the Pitot Tube DUCT AIR FLOW Pitot tube Pitot Tube Magnehelic gauge Note: For best results keep Pitot tube well away from dampers. IC HEL MAGNE Figure A Figure B This is an example for determining the airflow in a 6" duct. The Pitot tube reading was 0.025 inches of water. From the chart, this is 640 feet per minute. The accuracy of the airflow reading will be affected by how close to any elbows or bends the readings are taken.
Drain Line The ventilation portion of the Clean Air Furnace has two drain pans for removing condensation, which may occur on the heat recovery core during cold weather. Stickers indicating direction of flow, (Supply to furnace, and Return to water heater) are labeled on the outside of the cabinet. Do not reverse these lines, as this will cause the unit to malfunction.
Plumbing In order to improve serviceability of our products, the check valve is included with our manual kit for field installation between the air-handler and hot water source. This will allow for ease of service to remove any installation debris or service required due to extended hard water conditions. The check valve should be installed in a vertical run of pipe with the flow of water in an upward direction. Note: Take care during soldering to avoid debris or solder from lodging in the check valve.
Electrical Caution should be used if installing a setback thermostat to control the system. If the thermostat is set back too far, and, for example, is set to call for a lot of heat when you get out of bed, at which time showering and general water use is at its peak, then the hot water heater may not keep up. The Clean Air Furnace operates at 120V, singles phase and draws anywhere from 2-8.7 amps, depending on fan speed.
Optional Dehumidistat tat Dehumidis e to Relativ Setting s Condition Outside : WINTER at umidist . Set deh 30% to 40% , between is too dry If home setting. er high adjust to too humid, is If home ing. lower sett adjust to An optional dehumidistat can be connected to the furnace to help eliminate excessive moisture during the heating season. When the dehumidistat senses moisture in excess of the control setpoint, the blower will be overridden into high speed.
Start-Up Procedure In order for any appliance to work properly it must be set up and tested by a knowledgeable technician. The following conditions must be met prior to start-up 1. 2. 3. 4. 5. 6. 7. 8. Ensure that connecting water lines are purged and free of debris. Caution: solder or other debris may cause the furnace pump or check valve to malfunction. Blower wheel rotates freely inside its housing. Wiring connections are tight. Water is sitting in the "P" trap below the HRV core.
Operation Heating/Cooling When the room thermostat calls for heat, it activates a circulation pump located inside the Clean Air Furnace. This pump delivers hot water from the water heater, through the furnace coil and back to the water tank. Simultaneously, the furnace blower switches on to high speed and will start circulating air across the coil, which picks up heat and delivers it to the rest of your home.
Troubleshooting Lack of heat 1. 2. 3. 4. 5. 6. 7. 8. 9. Check that the room thermostat is set to the desired temperature. Confirm the units have power and the shut-off valves are open. Ensure there is power to the unit and that the pump is working. If the pump is not working properly it may be stuck. Disconnect power and remove screw in center face of the pump. Using a screwdriver, turn the pump shaft several times to free it from sticking. Replace center-screw and re-connect power.
During cooling cycle, hot water circulates through the coil If the check valve inside the cabinet is stuck in the open position, hot water may infiltrate the heating coil. This occurs when the hot pipes are not capped-off during installation or service and foreign debris enters the piping. This debris can settle under the check valve seat and permit hot water to flow into the coil. The problem can be corrected by repeatedly flushing the heating loop until it is clean. Water sits in drain pipes 1. 2. 3. 4.
System Commissioning This section of the manual is designed to be used with the “Commissioning of Integrated Combo System” worksheet. The worksheet is designed to guide you through the start-up process in a logical, step by step method which should minimize the work and time involved in having the system meet the designed parameters.
WORKSHEET FOR INTEGRATED COMBO SYSTEM DESIGN ¤ Training Courses and Forms are available from HRAI Skill Tech Academy 1-800-267-2231 Designer/Signature: _____________________________________________________________________________ Phone ( ) _______________ Fax ( ) _______________ Date: D ______ M _______ Y _______ Submitted For: (Owner) By: (Contractor) Name _______________________________________ Name _______________________________________ Address _____________________________________ Address __
Part A - DESIGN LOAD SPECIFICATIONS A.1 Total Heat Loss _______________Btu/h A.2 Total Heat Gain _______________Btu/h Part B - EQUIPMENT SELECTION (Air Handler and Cooling) AIR HANDLER: Make: LIFEBREATH Model: ____________ B.1 Heating Output ________________________ Btu/h (110% - 140% of A.1) B.2 Equipment External Static Pressure ________ ins. W.C. (from specs) B.3 Heating Air Flow Rate ________ cfm B.4 Circulation Fan Speed (Heating) ________ speed B.5 Return Air Temperature ________ B.
METHOD A - (domestic hot water usage for C.1) TABLE A 1 (NATURAL GAS AND PROPANE)* No. of Bathrooms 1 to 1.5 2 to 2.5 3 to 3.5 No. of Bedrooms 1** 2 3 2 3 4 5 3 4 5 6 Nominal Tank Size (USG) 30 40 50 50 50 50 60 50 60 60 75 TABLE A 2 (OIL)* No. of Bathrooms 1 to 1.5 2 to 2.5 3 to 3.5 No.
PART D - PROVING REQUIRED WATER FLOW D.1 Effective Length Calculation Fitting # PUMP: EL Total EL D.2 Water Flow Rate ________ US GPM D.3 Max. Head Press. at Water Flow (from specs) ________ ft of head _________ x ________ = ___________ ________________ _________ x ________ = ___________ D.4 Pressure Drop of Water Coil 5 ft of head ________ ________________ _________ x ________ = ___________ D.5 Available Head Press. (D.3 - D.
COMMISSIONING OF INTEGRATED COMBO SYSTEM Training Courses and Forms are available from HRAI Skill Tech Academy 1-800-267-2231 ¤ Designer/Signature: _____________________________________________________________________________ Phone ( ) _______________ Fax ( ) _______________ Date: D ______ M _______ Y _______ Submitted For: (Owner) By: (Contractor) Name _______________________________________ Name _______________________________________ Address _____________________________________ Address ______
Part E - SYSTEM START UP E.1 Fill Water Heater with water ❑ E.5 Start Air Handler ❑ E.2 Set Water Heater at designed temperature ❑ E.6 Check Circulation Pump Operation ❑ E.3 Fill Heating Loop with water ❑ E.7 Check Circulation Fan Operation ❑ E.4 Purge Circulation Pump ❑ E.
511 McCormick Blvd. London, Ontario N5W 4C8 Ph: (519) 457-1904 Fx: (519) 457-1676 Email: nutech@lifebreath.com Website: www.lifebreath.
