Lifebreath CAF-U-S4A-24-P16, CAF-D-L4A-36-P16, CAF-U-L4A-36-P16, CAF-D-S4A-24-P16, CAF-H-S4A-24-P16 Operation And Installation Manual
...
* LEAVE FOR HOMEOWNER
NOTE: Due to ongoing research and product development, specifications,
ratings and dimensions are subject to change without notice.
CAF-02-MB
1203
Installing Contractor
Telephone / Contact
Serial Number
Installation Date Model
TO BE COMPLETED BY CONTRACTOR AFTER INSTALLATION
OPERATION, SIZING AND
INSTALLATION MANUAL
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.).
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!!!
NOW MANUFACTURED WITH
AIRCOM ELECTRONICS
CLEAN AIR FURNACE
2
Table of Contents
Introduction ............................................................................................................ 3
Description and Purpose ........................................................................................ 4
Combo System Basic Principle ................................................................................ 5
Model Number Nomenclature Breakdown ...................................................................... 12
Specifications ................................................................................................. 13 - 21
Installation .................................................................................................... 22 - 27
Plumbing .............................................................................................................. 28
Function and Controls ..................................................................................................... 29
ECM Motor Settings ........................................................................................................ 30
Operation ......................................................................................................................... 31
Start Up Procedure.......................................................................................................... 32
Troubleshooting .............................................................................................. 33 - 34
System Commissioning .......................................................................................... 35
Work Sheets ................................................................................................. 36 - 41
Wiring Diagrams ....................................................................................................... 42 - 43
3
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.
You will notice that the heated air in your home feels more comfortable than air heated by a conventional
furnace.One reason f or 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 y ou need to do is allo w 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 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 Operating and Installation Guide will help you learn about your LIFEBREATH Clean Air Fur nace 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, ho weve r, yo u d o 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.
Nutech Brands Inc.
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 e xhausting an equal
amount of stale air. An ERV is designed for use in warm humid areas with heavy air conditioning use. The
ERV will transf er both sensib le and latent heat from the incoming fresh air to the outgoing stale air therebyreducing the load (due to ventilation) on the air conditioning system.
ERVs are not suitable for climates where the temperature drops below -4˚C (25˚F).
4
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 waterheater/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 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 are 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.
The LIFEBREATH Clean Air Furnace is a volume
ventilator system and is not intended to replace a
fully ducted Heat Recovery Ventilation (HRV) system. Independent exhaust fans should be used for
bathrooms and kitchen range hoods.
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.
5
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 WA TER INLET
EXPANSION T ANK
OR OTHER MEANS
(WHEN REQUIRED)
CHECK
VALVE
VALVE
(shut off)
WATER HEATER
DOMESTIC HOT WATER
ANTI-SCALD VAL VE
(WHEN REQUIRED)
(shut off)
VALVE
(shut off)
VALVE
VALVE
(balancing)
CHECK
VALVE
HEATING COIL
HRV/ERV CORE
DRAIN
VALVE
SUPPLY AIR
COOLING COIL
(OPTIONAL)
RETURN AIR
COLD WA TER INLET
VALVE
(shut off)
BLOWER
WATER HEATER
DOMESTIC HOT WATER
ANTI-SCALD VAL VE
(WHEN REQUIRED)
VALVE
(shut off)
VALVE
(shut off)
VALVE
(balancing)
CHECK
VALVE
HEATING COIL
HRV/ERV CORE
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 ad ditives)
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 V alves
There are a number of manual valv es required f or
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 v ery
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.
7
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 water
heater 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 V alve
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 V alve
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 V alves
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 ha v e a w ater 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.
8
(a)
Supply
(b)
(c)
Return
H
C
SHUT OFF VALVES
CHECK VALVE
Expansion T anks
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.
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 V alve
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 Timer
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 concer n 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
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
EXP ANSION T ANKS
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
placed 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).
With an Integrated Combo System, the hot water
10
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).
Design vs. Field Conditions
The factors discussed above become very
important to consumer comfort. Even small
differences between design parameters and
actual field conditions can impact greatly on
output capacity. Therefore, it is impor tant to do a
thorough and complete commissioning of the
integrated combo system to ensure the design
parameters are met.
Water System Pressures
Within the water system of an Integrated Combo
system, there are three terms that the
designer/installer must understand.These are head
pressure, water flow rate, and pressure drop.
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: 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
heating loop.
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.
Flow Rate
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).
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.
11
12
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
Note:
Refer to individual specification
pages for Hydronic Coil and
Blower configurations.
This sheet is for pre-configured
Model Number Breakdown only.
Hydronic Coil Size
S2A - Small Coil - 2 Row
S4A - Small Coil - 4 Row
L2A - Large Coil - 2 Row
L4A - Large Coil - 4 Row
L2B - Large Coil - 2 Row
00 - No Hydronics (No Heating Coil, No Pump)
* CFM
(output chart A)
(output chart A)
(output chart A)
(output chart A)
(output chart B)
(High Speed)
Cooling Capacity
24 - 2 tons
30 - 2.5 tons
36 - 3.0 tons
48 - 4.0 tons
*Cooling coils not available from Nutech
Motor Configuration
P16 - Standard PSC Motor 120V/60Hz
E15 - Upgrade ECM Motor 120V/50Hz
E16 - Upgrade ECM Motor 120V/60Hz
E25 - Upgrade ECM Motor 220V/50Hz
E26 - Upgrade ECM Motor 220V/60Hz
13
Model CAF-U-S4A-24-P16
Voltage 120 VAC 60 Hz
Hp 1/3
Amps (total) 7
Water
1/2" Copper Soldered
Connections Connection
Airflow (High)
.25 in wg 1030 CFM
.5 in. wg 890 CFM
Ventilation 100 - 140 CFM
Airflow
Effectiveness 70%
(Aluminum Core)
Total Efficiency 50%
(Enthalpic Core)
Net Weight 150 lbs.
Shipping Weight 165 lbs.
Options
99-186 Weatherhoods, Two - 6" c/w
1/4" mesh screen
99-130W Remote Wall Mount Dehumidistat
Control 24 VAC only
99-RSK6 6”back draft damper
99-104 DET - Digital Electronic Timer
Warranty
Units carry a lifetime warranty on the heat
recovery (aluminum) core, a five year warranty
on the energy recovery (enthalpic) core and a
five year replacement parts warranty on all
other components.
Specifications Model CAF-U-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.
Dimensions & Clearances
Note: Ventilation ports and return
plenum opening available
off either side of cabinet.
All units conform to CSA
and UL Standards.
0212
Side
Top
17.25"
19"
16"
Supply Air
29.5"
12"
Ventilation
Supply Air
6"
4"
14"
(SERVICE CLEARANCE 1') (SERVICE CLEARANCE 3')
6"
Inlet
Ventilation
Exhaust Air
Outlet
22"
Return Air
29.5"
Front
Latches
47.5"
Blower Section
19"
14
Options
99-186 Weatherhoods, Two - 6" c/w
1/4" mesh screen
99-130W Remote Wall Mount Dehumidistat
Control 24 VAC only
99-RSK6 6”back draft damper
99-104 DET - Digital Electronic Timer
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.
Dimensions & Clearances
Note: Ventilation ports and return
plenum opening available
off either side of cabinet.
All units conform to CSA
and UL Standards.
Model CAF-U-L4A-36-P16
Voltage 120 VAC 60 Hz
Hp 1/2
Amps (total) 8.7
Water
3/4" Copper Soldered
Connections Connection
Airflow (High)
.25 in wg 1350 CFM
.5 in. wg 1180 CFM
Ventilation 100 - 140 CFM
Airflow
Effectiveness 70%
(Aluminum Core)
Total Efficiency 50%
(Enthalpic Core)
Net Weight 150 lbs.
Shipping Weight 165 lbs.
Warranty
Units carry a lifetime warranty on the heat
recovery (aluminum) core, a five year warranty
on the energy recovery (enthalpic) core and a
five year replacement parts warranty on all
other components.
0212
Side
Top
17.25"
19"
22.25"
Supply Air
29.5"
12"
Ventilation
6"
14"
6"
Supply Air
Inlet
Ventilation
Exhaust Air
Outlet
22"
Return Air
29.5"
4"
(SERVICE CLEARANCE 1') (SERVICE CLEARANCE 3')
Front
Latches
47.5"
Blower Section
19"
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