Lifebreath AH40DHW, AH40BHW, AH60DHW, AH80BHW, AH60BHW User Manual
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NOTE: Due to ongoing research and product development, specifications,
ratings and dimensions are subject to change without notice.
For Models:
AH40DHW
AH60DHW
AH40BHW
AH60BHW
AH80BHW
AH-01
1203
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OPERATION, SIZING AND
INSTALLATION MANUAL
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FIVE YEAR WARRANTY
ON PARTS AND ACCESSORIES
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Table of Contents
Introduction...................................................................................................3
Description and Purpose ............................................................................4
Combo System Basic Principle ...................................................................5
Specifications ......................................................................................12 - 16
Installation .................................................................................................17
Plumbing ....................................................................................................18
Electrical ....................................................................................................19
Optional Dehumidistat .............................................................................. 20
Start Up Procedure ................................................................................... 21
Operation................................................................................................... 22
Troubleshooting .........................................................................................23
System Commissioning .............................................................................24
Work Sheets ........................................................................................25 - 30
Introduction
Congratulations on your selection of the LIFEBREATH Air Handler. This is a very advanced unit that
combines the outstanding efficiency and economy of the water heater/airhandler concept.
With the addition of LIFEBREATH Turbulent Flow Precipitator (TFP) Air Cleaner (optional) you
will have the ultimate in comfort and healthy indoor air quality.
You will notice that the heated air in your home feels more comfortable than air heated by a conventional
furnace. One reason for this is that LIFEBREATH's hydronically heated air is uniform and temperate... no
short blasts of hot air or hot and cold temperature spikes. In this regard, the air flowing from your hot air
vents will not feel as hot to the touch as air from a conventional furnace.
With a high efficiency, adequately sized hot water heater/boiler, you will always have plenty of hot water
for showers and baths, washing dishes and clothes, and all other normal domestic hot water needs. If
there is an unusually high demand for hot water, such as filling a large hot tub, than all you need to do
is allow more time for the task so the water heater/boiler can keep up to its job of providing hot water
for the heating system as well as other household uses.
Once it is correctly installed, safety will never be an issue with your LIFEBREATH Air Handler. No
flames, fumes or flue gases to be concerned about.Your domestic hot water heater/boiler now provides
the heat source for your air handler.
This Operating and Installation Guide will help you learn about your LIFEBREATH
Air Handler quickly
and easily. The table of contents will show you where to find information
on every feature of this unit along
with easy to understand operating instructions. If, however, you do encounter a question that is not covered in this Guide you should call the LIFEBREATH dealer who installed your air handler. Chances are
that he will be able to give you a satisfactory answer but if he is unable to do so then we invite you to
contact us directly.
Nutech Brands Inc.
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Description and Purpose
IMPORTANT NOTE
The purpose of this manual is to act as an installation guide only for the LIFEBREATH Air Handler.
Manufacturers' instructions for other components,
such as the waterheater/boiler, must be followed.
All national and local code requirements must be
met when installing a LIFEBREATH Air Handler.
Be sure to consult the proper authorities.
Note: Temperatures greater than 130 °F (54°C) pose
a serious risk of scalding individuals running
domestic hot water for potable use.
This appliance complies with IAS Canada Inc.
Requirement CR95-003, Additional Requirements
for Fan Coil Units for use with Potable Water
Heaters.
All piping and components connected to this appliance shall be suitable for use with potable water.
Toxic chemicals, such as used for boiler treatment, shall not be introduced into the potable
water heater system.
When using this system, and water for space
heating, is required to be at a higher temperature
than for other uses, an anti-scald valve shall be
used to ensure water for other uses is reduced in
temperature to minimize a scald hazard potential.
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 is critical if these advantages are
to be realized.
This manual provides a guideline of good engineering practice in the design, installation and
commissioning of Integrated Combo Systems.
The guidelines in the manual are designed for residential forced warm air Integrated Combo
Systems which utilize domestic water heaters or
boilers and the LIFEBREATH furnace. Heating
and cooling loads shall be calculated in accordance with recognized Residential Heat Loss and
Heat
Gain Calculation methods
. Duct design shall comply with recognized Residential Air System Design
methods
. This manual
provides worksheets to be
used for the purpose of sizing residential water
heaters and the combo furnace.
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.
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.
Note:
Water systems that incorporate a pressure
tank (well systems) are normally open systems.
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Combo System Basic Principles
SCHEMATIC SYSTEM
DIAGRAM
(Closed Loop System)
SCHEMATIC SYSTEM
DIAGRAM
(Open System)
Note:
Plumbing components and system
configuration may vary from diagram
portrayed. Refer to local codes, local
bylaws and installation manuals
supplied with water heater before
starting any installation work.
COLD WATER INLET
EXPANSION TANK
OR OTHER MEANS
(WHEN REQUIRED)
CHECK
VALVE
VALVE
(shut off)
WATER HEATER
DOMESTIC HOT WATER
ANTI-SCALD VALVE
(WHEN REQUIRED)
VALVE
(shut off)
VALVE
(shut off)
VALVE
(balancing)
CHECK
VALVE
HEATING COIL
SUPPLY AIR
COOLING COIL
(OPTIONAL)
RETURN AIR
DRAIN
VALVE
COLD WATER INLET
VALVE
(shut off)
BLOWER
WATER HEATER
DOMESTIC HOT WATER
ANTI-SCALD VALVE
(WHEN REQUIRED)
VALVE
(shut off)
VALVE
(shut off)
VALVE
(balancing)
CHECK
VALVE
HEATING COIL
DRAIN
VALVE
BLOWER
SUPPLY AIR
COOLING COIL
(OPTIONAL)
RETURN AIR
Call for Space Heating Only
Operation
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:
1. Mixing of warm return water with the hot
water within the water heater (no tank
stratification), which will result in a lower hot
water supply temperature.
2. A water heater thermostat temperature
differential (between on and off) is approximately
18˚F (10˚C). Therefore, if the return water is not
cool enough, it may not activate the water heater
thermostat, which causes the burner to operate.
All of the water in the water heater will be cooled
before the burner begins to operate. This may
cause large swings in the delivered hot water
temperature, causing poor space heating
performance, fluctuating domestic water
temperatures and effectively reducing the supply
of domestic hot water.
Call for Domestic Hot Water and
Space Heating Operation
When both return water from the space heating
loop and new cold water (replacing domestic
water being used) enters the water heater, the
mixed entering water is cool enough to activate
the thermostat quickly. In this situation, the water
heater must be capable of satisfying the
combined need for hot water (domestic hot water
and space heating) at the same time.
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.
Water Piping
The Piping and fittings used to connect the water
heater and air handler must be sized to handle
the volume of hot water required by the air
handler within the pressure limitations of the
circulation pump. All piping, fittings solders, and
fluxes must be acceptable for use with domestic
hot water.
Note: Chemicals (such as boiler system additives)
cannot be added to the system because water passing
through the heating loop re-enters the domestic
water systems.
Circulation Pump
The circulation pump is factory installed within
the air handler. The water flow rate will vary
depending on the pumps performance and
the head pressure (resistance) of the complete
heating loop system.
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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.
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. It has a much
greater equivalent length (resistance) than the
other types of valves.
The gate valve can be used as a shut off or drain
valve. When in the open position, there is very
little resistance to flow. Gate valves have a
greater susceptibility to chatter (noise) and
malfunction with age. Gate valves tend to be less
expensive than the other type of valves.
The ball valve can be used as a shut off or drain
valve but not a throttling (balancing) valve. When
in the open position, a full bore ball valve has very
little resistance to flow, and these valves tend to
be both the least expensive and the
least susceptible to seizing over time. Do not
use reduced bore ball valves as they are very
restrictive to water flow.
The balancing valve can be used as a throttling
valve. It can make small flow changes easily and
has lower resistance than a globe valve. This
valve will be considerable more expensive.
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Balance Valve
Ball Valve
Globe Valve
Gate Valve
Shut Off Valves
There are 3 shut off valves required for an
integrated combo system as follows:
• 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. This valve is
required on every waterheater whether or not
the water heater is used for space heating.
• One valve (b) on the hot water supply side of
the heating loop, downstream of its connection
to the domestic water.
• One valve (c) on the return side of the heating
loop upstream of its connection to the domestic cold water.
The two valves in the heating loop allow the
heating loop to be isolated for service or repair.
Drain Valve
A drain valve is required to allow the heating loop
to be drained for service or repair and to remove
air from the heating loop when commissioning a
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.
Throttling Valve
The throttling (balancing) valve is used to reduce
the water flow rate and thereby increase the
water temperature drop. This is done to ensure
proper activation of the water heater thermostat.
This valve should be a globe or balancing valve.
Check Valves
A spring loaded check valve is required in the
heating loop to help minimize thermo-siphoning
of hot water throughout the heating loop when
heating is not called for and cold water back
flowing through the heating loop when domestic
hot water is used. The valve will have a water flow
direction arrow marked on it’s exterior
surface and must be installed with that arrow
pointing downstream.
* Check valves should always be installed in a
vertical rise with the flow of water shown.
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H
(a)
C
Supply
(b)
(c)
Return
SHUT OFF VALVES
CHECK VALVE
Expansion Tanks
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.
Expansion tanks should always be connected to
the cold water piping between the water heater
shut off valve and the cold water inlet to the
water heater. Follow manufacturers instructions
for sizing and installation.
Anti-Scald Valve
An anti-scald valve is required when the water
heater thermostat is set above 140˚F (60˚C).
Also, an anti-scald valve may be required for all
installations by the “authority
having jurisdiction”.
The valve is placed in the hot water supply piping from the water heater downstream of the
heating loop connection and upstream of any
domestic hot water connection.
The purpose of the valve is to limit the maximum
temperature available for domestic hot water by
mixing hot water from the water heater with cold
water from the municipal supply.
The Anti-Scald valve must be thermostatically
controlled and approved to the ASSE standard No.
1016 and 1017 for use as an anti-scald device.
Note: There are a number of pressure balancing
valves and mixing valves on the market which are
not certified as a anti-scalding device.
Off Season Circulation Controls
(Models with a ‘T’ in the model number)
Although the UCG (Unified Canadian Guideline)
does not require these controls, a few building
codes and municipal by-laws do. They are used
to provide periodic circulation of water through
the space heating loop during the summer and
other periods of infrequent use. The concern is
that water which remains stationary in the
heating loop during the summer may be less
than desirable as domestic hot water when it is
returned to the water heater at system startup
in the fall.
Thermostats
There are two thermostats controlling every
combo system, the water heater thermostat
controlling the hot water temperature and the room
thermostat controlling the room air temperature.
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Time to Scald
(1st degree burns)
Temperature Time
120˚F 8 min.
130˚F 20 sec.
140˚F 3 sec.
160˚F <1 sec.
cold
hot
water
air cushion
EXPANSION TANKS
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.
Room Thermostat
The room thermostat controls both the water
circulation pump and the air circulation fan. It
should be on a centrally located, inside wall
away from any source of heat such as diffusers,
appliances and direct sunlight.
Energy Saving Room Thermostat
A set back thermostat or “smart stat” can be
used with a combo system, but care must be
taken in the timing of the temperature changes.
The timing of morning warm up should be early
enough that the desired air temperature has
been reached before the people begin to use
domestic hot water. The highest demand for
space heating is during the morning warm up
and the highest demand for domestic hot water
is during morning showers. Even if the water
heater is properly sized, it may not be able to
meet this combined load. Therefore, large set
backs should be avoided.
Air Handler Output Capacity
There are four factors that will significantly affect
the heating output of the air handler.
They are:
• Hot water supply temperature (EWT)
• Hot water flow rate (GPM)
• Air Handler return air temperature
• Air Handler air flow rate (CFM)
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.
Hot Water Flow Rate
The hot water entering the water coil is the
source of heat to the air handler. The effect of
changing the amount of water entering the coil is
the same as changing the water temperature.
As water flow is reduced, the output of the
air handler and the air temperature rise will
both be lowered.
Air Handler Return Air Temperature
The return air temperature entering the air
handler is approx. 60˚F (33˚C) below the
hot water inlet temperature. If the return air
temperature entering the air handler is reduced,
more heat transfer will occur and the output of
the air handler will increase.
Air Handler Air Flow Rate
The air entering the air handler can only be
warmed by the temperature difference between
the hot water and the cool air. As the volume
(CFM (L/s)) of air is reduced, the amount of heat
which can be transferred is also reduced.
Air Handler Temperature Rise
In a fuel fired furnace, the combustion gases
can be 1000˚F (538˚C) above the return air
temperature. These units typically have a
temperature rise from 50˚F (10˚C) to 90˚F (32˚C)
and therefore delivers air at the diffuser at 120˚F
(49˚C) to 160˚F (71˚C).
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