Lifebreath AH40DHW, AH40BHW, AH60DHW, AH80BHW, AH60BHW User Manual

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OPERATION, SIZING AND INSTALLATION MANUAL

For Models:

AH40DHW

AH60DHW

AH40BHW

AH60BHW

AH80BHW

NOW WITH

FIVE YEAR WARRANTY

ON PARTS AND ACCESSORIES

TO BE COMPLETED BY CONTRACTOR AFTER INSTALLATION

Installing Contractor

Telephone / Contact

Serial Number

Installation Date

Model

* LEAVE FOR HOMEOWNER

NOTE: Due to ongoing research and product development, specifications, ratings and dimensions are subject to change without notice.

AH-01

1203

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

2

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.

3

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.

4

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.

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.

COLD WATER INLET

DOMESTIC HOT WATER

 

 

CHECK

 

 

 

 

VALVE

 

 

 

 

VALVE

 

 

 

SCHEMATIC SYSTEM

(shut off)

(WHEN REQUIRED)

SUPPLY AIR

COOLING COIL

 

 

(OPTIONAL)

 

ANTI-SCALD VALVE

 

 

 

EXPANSION TANK

 

VALVE

 

DIAGRAM

(WHEN REQUIRED)

 

 

 

OR OTHER MEANS

 

(shut off)

 

 

 

 

 

RETURN AIR

(Closed Loop System)

 

VALVE

VALVE

 

 

 

(shut off)

(balancing)

 

 

 

 

CHECK

 

 

 

WATER HEATER

VALVE

 

 

 

 

 

 

 

 

HEATING COIL

 

 

 

 

DRAIN

 

 

 

 

VALVE

 

 

 

 

BLOWER

 

 

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

DOMESTIC HOT WATER

 

 

VALVE

 

 

 

(shut off)

ANTI-SCALD VALVE

SUPPLY AIR

COOLING COIL

 

 

(OPTIONAL)

 

(WHEN REQUIRED)

 

 

 

 

 

VALVE

 

 

 

(shut off)

 

 

 

 

 

RETURN AIR

 

VALVE

VALVE

 

 

(shut off)

(balancing)

 

 

 

CHECK

 

 

WATER HEATER

VALVE

 

 

 

 

 

 

HEATING COIL

 

 

 

DRAIN

 

 

 

VALVE

 

 

 

BLOWER

 

 

5

 

 

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.

6

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.

Balance Valve

Ball Valve

Globe Valve

Gate Valve

7

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.

(a)

Supply

 

 

(b)

(c) Return

H C

SHUT OFF VALVES

Drain Valve

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 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

* Check valves should always be installed in a vertical rise with the flow of water shown.

8

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.

cold

hot

 

water

 

air cushion

EXPANSION TANKS

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.

Time to Scald

(1st degree burns)

Temperature

Time

 

 

120˚F

8 min.

 

 

130˚F

20 sec.

 

 

140˚F

3 sec.

 

 

160˚F

<1 sec.

 

 

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.

9

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.

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 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

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).

10

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