OPERATION, SIZING AND INSTALLATION MANUAL CLEAN AIR FURNACE NOW MANUFACTURED WITH AIRCOM ELECTRONICS NOTE: ALTHOUGH SOME MODELS DIFFER IN OPERATION, THE BASIC STEPS ARE SIMILAR. CAUTION It is always important to assess how the operation of any HRV/ERV may interact with vented combustion equipment (ie. Gas Furnaces, Oil Furnaces, Wood Stoves, etc.).
Table of Contents Introduction ............................................................................................................ 3 Description and Purpose ........................................................................................ 4 Combo System Basic Principle ................................................................................ 5 Model Number Nomenclature Breakdown ...................................................................... 12 Specifications .................
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 Combining two or more end uses such as space heating and the heating of domestic hot water in a single system has the potential to increase efficiency and reduce overall capital costs. However, the proper design, installation, and commissioning of these systems are critical if these advantages are to be realized. The purpose of this manual is to act as an installation guide only for the LIFEBREATH Clean Air Furnace.
Combo System Basic Principles Closed/Open Combo System Therefore, an expansion tank (or equivalent device) may be installed as part of any closed system. The operations of the valve and expansion tank are discussed later in this section of this manual. 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.
Call for Space Heating Only Operation Air System A circulation fan draws cool house air at approx. 70˚F (21˚C) from the return ductwork, forces it through the water coil where it is heated, and then distributes it to the various rooms of the house through the supply ductwork. 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.
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 required for “Closed Systems”(most municipal water systems are 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 hot water inlet temperature is typically 140˚F (60˚C). If this temperature must be increased to achieve higher outputs from the furnace an anti-scald valve must be used to prevent domestic hot water temperatures above 140˚F (60˚C). The manufacturer of the Hot Water Tank should be consulted for temperatures higher than 140˚F. The water heater ther mostat is set by the installing contractor to provide the required temperature at the hot water outlet of the water heater.
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). Note: The vertical height of the heating loop does not impact on the head pressure as the pressure required to push the water up the vertical height is offset by the weight of the water in the vertical drop on the other side of the heating loop.
Model Number Nomenclature Breakdown Example Model Number CAF - U - S2A - 24 - P16 Model Configuration CAF - Clean Air Furnace (Built-in HRV) AH - Air Handler (No HRV) Configuration U - Upflow D - Downflow H - Horizontal Hydronic Coil Size S2A - Small Coil - 2 Row (output chart A) S4A - Small Coil - 4 Row (output chart A) L2A - Large Coil - 2 Row (output chart A) L4A - Large Coil - 4 Row (output chart A) L2B - Large Coil - 2 Row (output chart B) 00 - No Hydronics (No Heating Coil, No Pump) * CFM (High
Specifications Core Filters Case Model CAF-U-S4A-24-P16 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). Washable air filters in exhaust and supply air streams of ventilation section, 1" pleated in return plenum side. Prepainted galvanized steel for superior corrosion resistance.
Specifications Model CAF-U-L4A-36-P16 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 CAF-D-S4A-24-P16 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 CAF-D-L4A-36-P16 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 CAF-H-S4A-24-P16 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 CAF-H-L4A-36-P16 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 CAF-U-L2A-48-P16 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 CAF-U-00-36-P16 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 CAF-U-00-48-P16 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 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. 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.
Option 2 - Ventilation Ports Off Right Side Downflow Models Upflow Models Remove circular metal knockout Remove styrofoam knockout Remove styrofoam knockout Remove styrofoam knockout Horizontal Models 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. This is to avoid contact and damage of the heating/air conditioning coils and internal wiring.
Locating Intake Weatherhood Outside Ducting the Weatherhoods 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.
Placement of the Pitot Tube Pitot Tube and Gauge Pitot Tube Note: For best results keep Pitot tube well away from dampers. Figure B Figure A The accuracy of the airflow reading will be affected by how close to any elbows or bends the readings are taken. Accuracy can be increased by taking an average of multiple readings as outlined in the literature supplied with the Pitot tube. This is an example for determining the airflow in a 6" duct. The Pitot tube reading was 0.025 inches of water.
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 This will allow for ease of service to remove any installation debris or service required due to extended hard water conditions. 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. Note: Take care during soldering to avoid debris or solder from lodging in the check valve. The check valve should be installed in a vertical run of pipe with the flow of water in an upward direction.
Function & Controls Automatic Self Test Selecting Different Heat & Cool Speeds Approximate duration - 1.5 minutes. To select medium speed for heating or cooling, switch the appropriate DIP switch to the ON position. Unit will perform a self test each time power is first applied. Unit will cycle blower through all speeds, holding each for 15 seconds. Remainder of test is for circuit board tests, after which normal operation will resume.
ECM MOTOR SETTINGS Switch Setting Fan Speeds Cool Switches Cool Both OFF High 1 0N - 2 OFF Med High 1 OFF - 2 ON Med Low 1 ON - 2 ON Low Switch Setting Fan Speeds Heat Switches Heat Both OFF High 3 0N - 4 OFF Med High 3 OFF - 4 ON Med Low 3 ON - 4 ON Low Switch Setting Fan Speeds Adjust Switches Heat Cool Both OFF Normal Normal 5 0N - 6 OFF Increase 15% Increase 15% 5 OFF - 6 ON Decrease 15% Decrease 15% 5 ON - 6 ON Normal Normal Delay Switches are for future use -
Operation Heating/Cooling Ventilation 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. The heat recovery ventilation (HRV) portion of the Clean Air Furnace, is automatic.
Start-Up Procedure Once all of the necessary connections have been made, the Clean Air Furnace Start-Up Procedure is as follows: In order for any appliance to work properly it must be set up and tested by a knowledgeable technician. 1. Close shut-off valves separating the Clean Air Furnace from the water heater. The following conditions must be met prior to start-up 2. Set up water heater according to manufacturer's instructions. 1. Ensure that connecting water lines are purged and free of debris.
Troubleshooting Lack of heat HRV core freezes up 1. Check that the room thermostat is set to the desired temperature. 1. Make sure that the supply and exhaust lines are balanced according to the "Balancing Procedure" in this manual. 2. Confirm the units have power and the shut-off valves are open. 2. If out of balance, ensure that the balancing dampers have not been moved and that there are no obstructions in the outside hoods. 3. Ensure there is power to the unit and that the pump is working.
Humidity levels are too low Humidity levels are too high 1. If you have installed a dehumidistat ensure that its setting is correct. (Summer - OFF) (Winter 30% RH to 45% RH). 1. If you have installed a dehumidistat ensure its setting is correct. (Summer - OFF)(Winter 30% RH to 45% RH). 2. Install a dehumidistat if necessary. (Winter use only. Not for hot southern climates). 2. Check humidifier settings. (Summer - OFF) (Winter - 30% RH to 45% RH).
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.
Normally closed N.C. Plug Relay Fuse Switch P# K# F# SW# 42 12/24Vac MAX 1 amp F1 T2 T25 T5 Line T4 T6 C Pressure Sensor C T7 R off W Y on G SW1 T8 Thermostat DFR2 cool heat DD FD POOL Dehumidistat T21 T22 T23 T24 T3 T26 T27 12Vac Com T1 YEL GRN DET Neutral RED T10 T11 T12 T13 T14 T15 T16 THERMISTOR O T9 BLACK K6 K3 N.O. T28 T29 T30 K4 K5 Defrost Damper COM T43 SPARE T20 Vent Damper N.O.
Normally closed T25 N.C. Terminal Plug Relay Fuse Switch T# P# K# F# SW# COM Common T1 MAX 1 amp F1 T2 T5 Line T4 T6 C C R Pressure Sensor C W T7 R off W2 W Y Y on O T9 Y1 G SW1 T8 Thermostat DFR2 cool heat DD FD POOL Dehumidistat T21 T22 T23 T24 T3 T26 T27 12Vac Com Normally open RED WHITE BLACK BLACK BLACK WHITE N.O.