Lifebreath CAF-U-L4A-36-P16, CAF-U-L2A-48-P16, CAF-D-L4A-36-P16, CAF-H-L4A-36-P16, CAF-D-S4A-24-P16 Operation, Sizing And Installation Manual

...
Operation, Sizing and Installation Manual
Models
Hydronic Models with Built-in
Heat Recovery Ventilator (HRV)
MANUFACTURED WITH
AIRCOM ELECTRONICS
69-CAF
0912
Never install an HRV/ERV in a situation where its normal operation, lack of operation or partial failure may result in the backdrafting or improper functioning of vented combustion equipment!
CAUTION
Assess how the operation of an HRV/ERV may interact with already installed vented combustion equipment (ie. Gas Furnaces, Oil Furnaces, Wood Stoves, etc.).
CAUTION
Table of Contents
The Clean Air Furnace hydronic coil is not to be used for chilled water applications where condensation is expected.
ATTENTION
Air Condition coil freezing can damage the hydronic coil of the Clean Air Furnace. Install a Freeze Thermostat Kit to your air conditioning coil to prevent coil freeze up. Check with your air conditioner distributor to obtain a Freeze Thermostat Kit.
ATTENTION
Do not apply electrical power to the unit until installation has been fully completed (including low voltage control wiring).
Introduction
Overview of the Clean Air Furnace ..................................3
Description and Purpose
Operation Heating/Cooling...............................................4
The Recovery Core ...........................................................5
Combo System Basic Principles .......................................6
Plumbing......................................................................7-14
Installation .................................................................15-17
Pitot Tube Air Flow Balancing ..................................18-19
Function and Controls ...............................................20-21
Optional Dehumidistat
Optional Timers ..............................................................22
Wiring the Controls.........................................................23
Aircom Relays ................................................................24
Start-up Procedure ..........................................................25
Register for your warranty at www.lifebreath.com
Airia will require the Model and Serial Number to register the unit.
TO BE COMPLETED BY CONTRACTOR AFTER INSTALLATION
Service and Maintenance ................................................26
Troubleshooting ..............................................................27
Controlling your HRV
How the Dehumidistat Works.........................................28
Model Number Nomenclature Breakdown.....................29
Specifications ............................................................30-39
System Commissioning ..................................................40
Work Sheets ...............................................................41-42
Wiring Diagrams .......................................................43-44
Installation Date Model
Installing Contractor
Telephone / Contact
Serial Number
2
Introduction
Hydronic Coil and Pump Compartment
Recovery Core and Ventilation Compartment
Aircom Electronics and Fan Compartment
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. 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 natural gas, propane or oil 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, then 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.
Overview of the Clean Air Furnace
Once it is correctly installed, safety will never be an issue with your LIFEBREATH furnace. No flames, fumes or flue gases to be concerned about. Your domestic hot water heater/boiler now provides the heat source for your furnace.
This Operation and Installation Guide will help you learn about your LIFEBREATH Clean Air Furnace 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 furnace. 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.
Airia Brands Inc.
3
Description and Purpose
IMPORTANT NOTE
The purpose of this manual is to act as an installation guide only for t h e LIFEBRE ATH Cle a n Air F u r n a c e. 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.
Note: Temperatures greater than 130°F (54°C) pose a seri-
ous 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 the hot water for space heating is set to a higher temperature than for other uses, an anti­scald valve shall be used to ensure water for common use is reduced in temperature to minimize a scalding hazard.
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.
This manual provides a guideline of good engineering prac­tice in the desi gn, install atio n and commiss ioni ng 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.
The LIFEBREATH Clean Air Furnace is a volume ventila­tion system. Use the optional Lifebreath Bathroom Exhaust System Kit (Part 99-CAF-BESKIT) if you wish to exhaust from specific locations such as bathrooms.
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.
Once the thermostat's temperature is reached the pump will shut off, and the blower will return to its pre-set speed or off.
Note: When the furnace blower is left running on low speed the air in the home circulates continuously. When the heat is called for the blower will automatically switch to a higher speed. After the required hot air has been delivered the blower will switch back to low speed.
When the thermostat calls for cooling (evaporator coil and condensing unit required), the furnace blower activates to high speed and the outdoor condenser unit is energized. After the thermostat temperature is reached, the condensing unit will shut off and the blower will return to its preset speed or off.
Ventilation
The heat recovery ventilation (HRV) portion of the Clean Air Furnace, is automatic. Once set, a desired amount of fresh air will be drawn into the home while the furnace blower is activated.
To reduce humidity, increased ventilation may be required during heating season. An optional remote dehumidistat can be installed. The dehumidistat will increase the speed of the furnace blower to high and will return to its original setting when humidity levels decrease. Your dehumidistat must be switched off during warmer months. A quality humidifier should be added if you wish to increase winter humidity levels
Typically the air flow for ventilation will be set to 50 ­70cfm, for low sp e ed fu r n a ce op e r at ion, an d 100 - 150cfm at high speed. The pleated furnace filter should be checked regularly and replaced as needed. The HRV filter should be washed twice a year or more often if needed.
Off Season Circulation Timer
All models are equipped with a circulation timer. It is nor­mal operation for these models to automatically run the circulation pump intermittently for a short period of time.
4
The Recovery Core
Stale Air from Building
Stale Air to Outside
Fresh Outdoor Air
Fresh Air to Building
The ERV - Enthalpic Core is not suitable for climates where the outdoor temperature drops below -4°C (25°F).
ATTENTION
HRV - Aluminum Core
A Heat Recovery Ventilator (HRV) is designed to provide fresh air into a building while exhausting an equal amount of stale air. During the winter months, the incoming cold fresh air is warmed by utilizing the heat recovered from the stale air before it is exhausted to the outdoors. During sum­mer months when the indoor space is air conditioned, the Heat Recovery Ventilator will help in cooling the incoming fresh air with the stale air that is being exhausted.
ERV - Enthalpic Paper Core
An Energy Recovery Ventilator (ERV) is designed to pro­vide fresh air into a building while exhausting an equal amount of stale air. An ERV is designed for use in warm humid areas with heavy air conditioning use. The ERV will transfer both sensible and latent heat from the incoming fresh air to the outgoing stale air thereby reducing the load (due to ventilation) on the air conditioning system.
5
WATER HEATER
DOMESTIC HOT WATER
SUPPLY AIR
BLOWER
HEATING COIL
HRV/ERV CORE
CHECK
VALVE
RETURN AIR
COLD WATER INLET
ANTI-SCALD VALVE
(WHEN REQUIRED)
VALVE
(shut off)
VALVE
(shut off)
VALVE
(shut off)
VALVE
(balancing)
COOLING COIL
(OPTIONAL)
DRAIN VALVE
EXPANSION TANK
(WHEN REQUIRED)
CHECK
VALVE
Combo System Basic Principles
ATTENTION
Check valves should always be installed in a vertical rise with the flow of water shown.
Open and Closed Systems
Open and Closed systems both deliver hot water and space heating.
Water systems that incorporate a pressure tank (i.e. well systems) are normally Open Systems and most municipal water systems are Closed Systems.
Closed Loop System
A system becomes closed when a Check Valve or a back­flow prevention valve is installed in the cold water piping upstream of the water heater.
A check valve will prevent water being relieved into the cold water system due to pressure created when water is heated in the water heater.
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 to be near the water heater. Ball, Globe or Gate Valves are suitable for drain valves.
IMPORTANT
Refer to local codes, local bylaws and installation manuals supplied with water heater before starting any installation work.
This Check Valve minimizes Thermo-Siphoning. Thermo Siphoning is the cold water backflowing through the heating loop when domestic hot water is called for.
Conventional Cooling (Not available through Airia)
6
Plumbing
Water
Heater
Check
Valve
To
House
CAF
or
AH
Min. 12" (305 mm)above
top of CAF / AH
12"
Water
Heater
CAF
or
AH
Check
Valve
Min. 12" (305 mm)
above top of CAF / AH
To
House
12"
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.
The check valve should be installed in a vertical run of pipe with the flow of water in an upward direction.
An arrow on the check valve indicates its correct orienta­tion and must match the direction of water flow.
This will allow for ease of service to remove any installa­tion debris or service required due to extended hard water conditions.
Figure 1
Note: Take care during soldering to avoid debris or solder from lodging in the check valve. Note: It is critical to follow the piping configuration shown. Maintain a minimum distance of 12” above the CAF/AH. This will minimize thermal siphoning in the combo system.
Figure 2
* It should be noted that problems have been observed when using the side tappings on certain water heaters; therefore, it is strongly recommended to use the top water tappings as indicated in Figure 1 to minimize thermal-siphoning and related issues.
7
Plumbing
WATER HEATER
DOMESTIC HOT WATER
SUPPLY AIR
BLOWER
HEATING COIL
HRV/ERV CORE
CHECK
VALVE
RETURN AIR
COLD WATER INLET
ANTI-SCALD VALVE
(WHEN REQUIRED)
VALVE
(shut off)
VALVE
(shut off)
VALVE
(shut off)
VALVE
(balancing)
COOLING COIL
(OPTIONAL)
DRAIN VALVE
EXPANSION TANK
(WHEN REQUIRED)
CHECK
VALVE
Expansion Tanks
Expansion tanks are required in addition to a Check Valve for Closed Systems because pressure is created when water is heated in the water heater.
The expansion tank has an air bladder which will contract to relieve pressure in the system. The tank 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.
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.
Time to Scald
(1st degree burns)
Temperature Time
120°F 8 min.
130°F 20 sec.
140°F 3 sec.
160°F <1 sec.
Closed Loop System
Conventional Cooling (Not available through Airia)
8
(a)
H
C
(b)
(c)
Supply
Return
Plumbing
Valves
(a) Located on the cold water side of the Heater.
This valve has the ability to isolate the hot water (domestic and space heating) from the household cold water supply. Every water heater requires this valve regardless of space heating use.
(b) Located on the hot water supply side of the heating
loop, downstream of its connection to the domestic water.
(c) Located on the return side of the heating loop upstream
of its connection to the domestic cold water.
These two valves isolate the heating loop for service or repair.
Ball Valve
The Ball Valve can be used as a shut off or drain 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.
Gate Valve
Globe Valve
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.
Balancing (Throttling) Valve
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 tend to be less expensive than other types of valves but are susceptible to chatter (noise) and malfunc­tion with age.
The Balancing (Throttling) 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.
A Globe Valve could also be used for Balancing (Throttling) but has more resistance than the Balancing Valve.
9
Plumbing
WATER HEATER
D
OMESTIC HOT WATER
SUPPLY AIR
BLOWER
CHECK
VALVE
R
ETURN AIR
C
OLD WATER INLET
ANTI-SCALD VALVE
(WHEN REQUIRED)
VALVE
(shut off)
VALVE
(shut off)
VALVE
(
shut off)
VALVE
(balancing)
C
OOLING COIL
(OPTIONAL)
DRAIN VALVE
HEATING COIL
HRV/ERV CORE
Plumbing components and system configuration may vary from diagrams portrayed.
ATTENTION
Chemicals (such as boiler system additives) cannot be added to a domestic hot water system.
ATTENTION
Call for Space Heating
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).
Open Loop System
When the room thermostat calls for heat, the circulation pump is activated. Hot water is then drawn from the top of the water heater through the air handler, and then returned to the water heater.
Conventional Cooling (Not available through Airia)
Hot Water Temperature Drop
The water heater thermostat will initiate the water heater as required as long as there is a 20°F (11°C) temperature drop between the hot water supplied to the air handler and the returning water.
A temperature drop less than 20°F (11°C) can cause the water heater thermostat not to initiate. This will result in a lower hot water supply temperature or poor space heating performance with fluctuating domestic water temperatures.
Call for Domestic Hot Water and Space Heating
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 domestic hot water and space heating at the same time.
10
Quick Connect Kit: PART# 99-CAF-PKit 1/2 or 3/4
WATER HEATER
SUPPLY AIR
RETURN AIR
Balancing
Valve
VALVE
(shut off)
WATER OUT
Assembly
EXPANSION TANK
(WHEN REQUIRED)
CHECK
VALVE
WATER IN Assembly
KIT CONTENTS
WATER IN Assembly
WATER OUT Assembly
The pre-assembled, Quick Connect Kit shortens the installation time. It provides an instant, easy assembly of the major plumbing fittings required for a proper CAF/AH installation.
The Quick Connect Kit includes the WATER IN and WATER OUT assemblies. Kits are available in 1/2” and 3/4”sizes. Refer to the CAF/AH specification sheet located in the Operation and Installation Manual to obtain the correct size of water connections for the unit being installed.
Push-fit Fittings instantly make plumbing connections thereby eliminating the need for solder. Be sure to read the Push-fit Fitting Installation Instructions (included with the Quick Connect Fitting Kit) before making any connections.
PART #99-CAF-PKit1/2
The 1/2” assembled kit.
PART #99-CAF-PKit3/4
The 3/4” assembled kit.
11
Plumbing
16
1
4
12
10
8
6
4
2
0
Capacity on U.S. gpm
S2 and S4 Models
1 2 4 6 8 10 12
To tal Head in Feet
L2 and L4 Models
1 2 4 6 8 10 12 14 16 18 20
16
14
12
10
8
6
4
2
0
Capacity on U.S. gpm
To tal Head in Feet
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 System Pressures
Within the water system of an Integrated Combo system, a designer/installer must understand the following terms:
1. Hot water supply temperature (EWT)
2. Hot water flow rate (GPM)
3. Air handler return temperature
4. Air handler flow rate (CFM)
Head Pressure
Head pressure is the pressure created by the circulation pump to push water through the piping system. It is this pressure which is used to overcome the resistance to water flow (friction) caused by the water pipe and fittings. It is similar in concept to the external static pressure in an air duct system. Head pressure is measured in feet of water (millimeters of water).
NOTE
The vertical height of the heating loop does not impact on th e he a d p r e ssure as the pr e s s ur e 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.
Pressure Drop (PD)
Pressure drop (PD) is the reduction in total pressure caused by components added to a piping system such as coils, valves, and fittings. The measurement of pressure drop is the difference in pressure on the inlet side of the component and the outlet side. Pressure drop is measured in feet of water (millimeters of water).
When connecting the water lines for heating loop (air han­dler) to the domestic water system, the pipes should be connected with a “tee” to the side of a vertical domestic water pipe or the bottom of a horizontal domestic water pipe. This is to help prevent air from entering the heating loop. The connections should be as near as practical to the water heater.
Water Pump Performance Specifications
Water Flow Rate
Water flow rate is the amount of water flowing in the sys­tem. It is directly related to the head pressure and the resistance to flow. Flow rate is measured in gallons per minute (liters per minute).
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.
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.
12
Plumbing
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)
Hot Water Supply Temperature
The hot water supply temperature is controlled by the water heater thermostat. This is set by the installing contractor to provide the required temperature at the hot water outlet of the water heater.
The hot water supply 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.
It is important that a warning label be placed near the water heater thermostat telling the homeowner not to change the thermostat setting. The label is included with the furnace.
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 c o i l is t h e sa m e a s ch a n g i n g th e w a t e r 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 temperat ure e ntering 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.
NOTE
Although the water in the combo system is
pressurized by the domestic water system, the pump is required to create water flow in the heating loop. The domestic water system applies the same pressure to the supply and return sides of the
heating loop.
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).
Wit h an I n t e g rated C o mb o S y s t e m , th e hot w a t er temp e r a t u r e is a p p r o x . 130°F ( 5 4 °C) w h i c h is 6 0 ° 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).
Room Thermostat
The ro o m ther m o s t a t cont r o l s both the wa t er 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.
Design vs. Field Conditions
The factors discussed between design parameters and actual field conditions can impact greatly on output capacity. Therefore, it is important to do a thorough and complete commissioning of the integrated combo system to ensure the design parameters are met.
13
Plumbing
DRAIN
SPOUT
TAPE
THROUGH KNOCKOUT
TO DRAIN
TEE
CONNECTOR
DRAIN
SPOUT
2” (50 mm)
KNOCKOUT
KNOCKOUT
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.
Piping
The hot water piping between the hot water tank and the Clean Air Furnace should be new copper type, and should not be treated with chemicals, sealant or anything else, that will interfere with the purity of the potable water. Only non­lead, low temperature solder is permitted for sealing copper joints.
Where possible the length of pipe should not exceed 200' total equivalent length. Any piping running through uncon­ditioned space must be insulated to prevent heat loss, and possible freezing of the line.
HRV Drain Line Diagram
Look inside the furnace and locate the pump. Attach the "Hot Water In" (Supply) to the pipe running to the pump. Attach the "Hot Water Out" (Return) to the pipe running to the coil. Do not reverse these lines, as this will cause the unit to malfunction.
For piping conventional water heaters, connections to and from the Clean Air Furnace to the water tank should be made at the point where the pipes leave the tank vertically. A "T" fitting used in each vertical line, with the Clean Air Furnace piping connected to the horizontal side of this fit­ting, will work best in avoiding air locks in the circulation pump of the furnace.
*Note: Remove shipping block from underneath pump and discard.
14
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