OPERATION, SIZING AND
INSTALLATION MANUAL
NOW WITH
FIVE YEAR WARRANTY
ON PARTS AND ACCESSORIES
For Models:
AH40DHW
AH60DHW
AH40BHW
AH60BHW
AH80BHW
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
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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 cov-
ered 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
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Description and Purpose
single system has the potential to increase effi-
ciency and reduce overall capital costs. However,
the proper design, installation, and commissioning
of these systems is critical if these advantages are
to be realized.
IMPORTANT NOTE
The purpose of this manual is to act as an instal-
lation guide only for the LIFEBREATH Air Handler.
Manufacturers' instructions for other components,
such as the waterheater/boiler, must be followed.
This manual provides a guideline of good engi-
neering practice in the design, installation and
commissioning of Integrated Combo Systems.
The guidelines in the manual are designed for res-
idential 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 accor-
dance with recognized Residential Heat Loss and
Heat
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.
Gain Calculation methods. Duct design shall com-
ply 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.
All piping and components connected to this appli-
ance shall be suitable for use with potable water.
Toxic chemicals, such as used for boiler treat-
ment, 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
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Combo System Basic Principles
Closed/Open Combo System
Therefore, an expansion tank (or equivalent
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.
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.
DOMESTIC HOT WATER
COLD WATER INLET
CHECK
VALVE
VALVE
(shut off)
SUPPLY AIR
COOLING COIL
(OPTIONAL)
ANTI-SCALD VALVE
(WHEN REQUIRED)
SCHEMATIC SYSTEM
DIAGRAM
(Closed Loop System)
EXPANSION TANK
VALVE
(shut off)
OR OTHER MEANS
(WHEN REQUIRED)
RETURN AIR
VALVE
VALVE
(balancing)
(shut off)
CHECK
VALVE
WATER HEATER
HEATING COIL
DRAIN
VALVE
BLOWER
DOMESTIC HOT WATER
COLD WATER INLET
SCHEMATIC SYSTEM
DIAGRAM
VALVE
(shut off)
SUPPLY AIR
COOLING COIL
(OPTIONAL)
ANTI-SCALD VALVE
(WHEN REQUIRED)
VALVE
(shut off)
(Open System)
RETURN AIR
VALVE
VALVE
(balancing)
(shut off)
CHECK
VALVE
WATER HEATER
Note:
HEATING COIL
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.
DRAIN
VALVE
BLOWER
5
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Call for Space Heating Only
Operation
Air System
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:
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.
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.
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.
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.
6
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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.
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 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
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.
Globe Valve
Balance Valve
Ball Valve
Gate Valve
7
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Shut Off Valves
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.
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 con-
nection. 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.
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.
• One valve (b) on the hot water supply side of
the heating loop, downstream of its connection
to the domestic water.
Check Valves
• One valve (c) on the return side of the heating
loop upstream of its connection to the domes-
tic cold water.
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.
The two valves in the heating loop allow the
heating loop to be isolated for service or repair.
(a)
Supply
(b)
(c)
Return
C
H
SHUT OFF VALVES
CHECK VALVE
Drain Valve
* Check valves should always be installed in a
vertical rise with the flow of water shown.
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
8
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Note: There are a number of pressure balancing
valves and mixing valves on the market which are
not certified as a anti-scalding device.
Expansion Tanks
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.
Time to Scald
(1st degree burns)
Temperature
120˚F
Time
8 min.
20 sec.
3 sec.
<1 sec.
130˚F
cold
hot
140˚F
water
160˚F
Off Season Circulation Controls
(Models with a ‘T’ in the model number)
air cushion
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.
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 pip-
ing from the water heater downstream of the
heating loop connection and upstream of any
domestic hot water connection.
Thermostats
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.
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.
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.
9
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Water Heater Thermostat
to achieve higher outputs from the furnace
an anti-scald valve must be used to prevent
domestic hot water temperatures above
140˚F (60˚C). The manufacturer of the
Hot Water Tank should be consulted for
temperatures higher than 140˚F.
The water heater 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.
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.
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.
Air Handler Return Air Temperature
Energy Saving Room Thermostat
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.
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 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
Air Handler Temperature Rise
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)
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).
The hot water inlet temperature is typically 140˚F
(60˚C). If this temperature must be increased
10
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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.
With an Integrated Combo System, the hot water
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).
Flow Rate
Design vs. Field Conditions
Flow rate is the amount of water flowing in
the system. It is directly related to the head pres-
sure and the resistance to flow. Flow rate
is measured in gallons per minute (liters
per minute).
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 important to do a
thorough and complete commissioning of the
integrated combo system to ensure the design
parameters are met.
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).
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.
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.
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 or 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.
11
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Specifications
Model AH40DHW
Filters 1" pleated in return plenum side.
Case
Prepainted galvanized steel for superior corrosion resistance.
AH40DHW OUTPUT (MBH)
Dimensions & Clearances
Model
AH40DHW
16"
Side
Front
Top
Voltage
Hp
120 VAC 60 Hz
1/3
7
Amps (total)
Supply Air
17.25"
19"
Water
1/2" Copper Soldered
Connection
Connections
Airflow (High)
.25 in wg
32.5"
22"
1030 CFM
890 CFM
.5 in. wg
29.5"
Blower Section
14"
Return Air
Net Weight
111 lbs.
130 lbs.
Shipping
Weight
19"
29.5"
Note: Return plenum opening
available off either side of
cabinet. All units conform
to CSA and UL Standards
(SERVICE CLEARANCE 1')
(SERVICE CLEARANCE 3')
Warranty
Units carry a five year replacement parts warranty on all components.
12
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Specifications
Model AH60DHW
Filters 1" pleated in return plenum side.
Case
Prepainted galvanized steel for superior corrosion resistance.
AH60DHW OUTPUT (MBH)
Dimensions & Clearances
Model
AH60DHW
22.25"
Top
Side
Front
Voltage
Hp
120 VAC 60 Hz
1/2
8.7
17.25"
19"
Supply Air
Amps (total)
Water
3/4" Copper Soldered
Connection
Connections
32.5"
22"
Airflow (High)
.25 in wg
.5 in. wg
29.5"
1350 CFM
1180 CFM
Blower Section
14"
Return Air
Net Weight
121 lbs.
140 lbs.
Shipping
Weight
19"
29.5"
Note: Return plenum opening
available off either side of
cabinet. All units conform
to CSA and UL Standards
(SERVICE CLEARANCE 1')
(SERVICE CLEARANCE 3')
Warranty
Units carry a five year replacement parts warranty on all components.
13
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Specifications
Model AH40BHW
Filters 1" pleated in return plenum side.
Case
Prepainted galvanized steel for superior corrosion resistance.
Dimensions & Clearances
Model
AH40BHW
16"
Side
Front
Top
Voltage
Hp
120 VAC 60 Hz
1/3
7
Amps (total)
Supply Air
17.25"
19"
Water
1/2" Copper Soldered
Connection
Connections
Airflow (High)
.25 in wg
32.5"
22"
1280 CFM
1075 CFM
.5 in. wg
29.5"
Blower Section
14"
Return Air
Net Weight
111 lbs.
130 lbs.
Shipping
Weight
19"
29.5"
Note: Return plenum opening
available off either side of
cabinet. All units conform
to CSA and UL Standards
(SERVICE CLEARANCE 1')
(SERVICE CLEARANCE 3')
Warranty
Units carry a five year replacement parts warranty on all components.
14
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Specifications
Model AH60BHW
Filters 1" pleated in return plenum side.
Case
Prepainted galvanized steel for superior corrosion resistance.
Dimensions & Clearances
Model
AH60BHW
22.25"
Top
Side
Front
Voltage
Hp
120 VAC 60 Hz
1/2
8.7
17.25"
19"
Supply Air
Amps (total)
Water
1/2" Copper Soldered
Connection
Connections
32.5"
22"
Airflow (High)
.25 in wg
.5 in. wg
29.5"
1402 CFM
1220 CFM
Blower Section
14"
Return Air
Net Weight
121 lbs.
140 lbs.
Shipping
Weight
19"
29.5"
Note: Return plenum opening
available off either side of
cabinet. All units conform
to CSA and UL Standards
(SERVICE CLEARANCE 1')
(SERVICE CLEARANCE 3')
Warranty
Units carry a five year replacement parts warranty on all components.
15
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Specifications
Model AH80BHW
Filters 1" pleated in return plenum side.
Case
Prepainted galvanized steel for superior corrosion resistance.
AH80BHW Output (MBH)
1639
1618
1575
56.8
56.5
55.8
61.1
59.9
58.1
61.5
61.1
60.3
66.7
65.2
63.0
64.6
64.2
63.3
70.5
68.8
66.3
37.5
37.3
36.9
40.4
39.6
38.3
43.9
43.7
43.2
47.3
46.3
44.9
50.3
50.0
49.5
54.2
53.1
51.4
63.3 69.7
62.9 69.3
62.2 68.6
68.1 75.1
66.7 73.6
64.7 71.3
40.7
40.4
39.9
44.1
43.1
41.6
47.6
47.2
46.7
51.6
50.5
48.7
54.5
54.2
53.5
59.2
55.8
55.9
68.5
68.0
67.2
74.3
72.7
70.2
75.5
75.0
74.0
81.9
80.1
77.3
42.8
42.5
41.9
46.7
45.5
43.9
50.0
49.7
49.0
54.6
53.3
51.3
57.3
56.9
56.1
62.5
61.1
58.8
71.9
71.5
70.5
78.5
76.7
73.8
79.3
78.7
77.7
86.6
84.5
81.4
1967
1868
1728
Water
Temp.
130 140
150
160
170
180
130 140
150
160
170
180
130 140
150
160
170
180
3 GPM
4 GPM
5 GPM
Dimensions & Clearances
22.25"
Top
Side
Front
Model
AH80BHW
Voltage
Hp
120 VAC 60 Hz
Supply Air
17.25"
19"
1/2
8.7
Amps (total)
Water
1/2" Copper Soldered
Connection
36.5"
Connections
22"
29.5"
Airflow (High)
.25 in wg
.5 in. wg
1967 CFM
1639 CFM
18"
Blower Section
Return Air
Net Weight
135 lbs.
155 lbs.
Shipping
Weight
19"
29.5"
Note: Return plenum opening
available off either side of
cabinet. All units conform
to CSA and UL Standards
(SERVICE CLEARANCE 1')
(SERVICE CLEARANCE 3')
Warranty
Units carry a five year replacement parts warranty on all components.
16
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Installation
T
he purpose of this manual is to give the contractor
Any ductwork running through unconditioned space
must be sealed properly and insulated to prevent
heat loss. All local codes must be followed in deter-
mining the amount of insulation needed.
guidelines for installing the LIFEBREATH Air Handler.
All national and local codes relating to this type of
equipment must be followed.
Locating The Unit
Piping
The Air Handler is designed to be installed vertically,
in a conditioned space, where the surrounding
temperature does not fall below 50°F (10°C). Attic
installations are not recommended. Typically the unit
is installed in a mechanical area of the basement, or
other partitioned mechanical room, elsewhere in the
home.
The hot water piping between the hot water tank and
the Air Handler should be new copper type, and
should not be treated with chemicals, sealant or any-
thing else, that will interfere with the purity of the
potable water. Only non-lead, low temperature solder
is permitted for sealing copper joints. The copper sol-
dered pipe size for each model is:
Sufficient clearance around the unit is required for
service of the filter and components. As a rule , this
unit should be installed adjacent to the hot water
heater. If this is not possible, or if the piping layout is
complex, the total head pressure on the pump should
be calculated.
Model AH40DHW
AH60DHW
1/2" nominal
3/4" nominal
1/2" nominal
1/2" nominal
1/2" nominal
AH40BHW
AH60BHW
AH80BHW
Where possible the length of pipe should not exceed
200' total equivalent length. Any piping running
through unconditioned space must be insulated
toprevent heat loss, and possible freezing of the line.
Stickers indicating direction of flow, (Supply to fur-
nace, and Return to water heater) are labeled on
the outside of the cabinet. Do not reverse these lines,
as this will cause the unit to malfunction.
Duct Connections
To accommodate various installations, the Air
Handler has knockouts for the return air plenum on
both sides of the cabinet. Special care and attention
should be given to determining which knockouts are
to be removed.
Penetrations from sheet metal screws used to fasten
the ductwork to the cabinet of the unit should only be
placed into the duct flange provided. This is to avoid
contact and damage of the heating/air conditioning
coils and internal wiring.
For piping conventional water heaters or boilers, con-
nections to and from the Air Handler to the heater
should be made at the point where the pipes leave
the heater vertically. A "T" fitting used in each vertical
line, with the Air Handler piping connected to the hor-
izontal side of this fitting, will work best in avoiding air
locks in the circulation pump of the furnace.
Ducting
The duct sizing for the furnace section can be deter-
mined using HRAI Residential Air System Design
Manual, SMACNA, or any other industry-recognized
manuals.
*Note: Remove all shipping packaging and discard.
Note: "Combo units" normally deliver air at approx.
110°F (43°C), and therefore may require larger than
normal ductwork. When installing the Air Handler as a
replacement unit on a retrofit application, always calcu-
late the size of duct that is there.
17
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Plumbing
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.
This will allow for ease of service to remove any
installation debris or service required due to
extended hard water conditions.
The check valve should be installed in a vertical
run of pipe with the flow of water in an upward
direction.
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.
An arrow on the check valve indicates its correct
orientation and must match the direction of water
flow.
Figure 1
To
House
Min. 12" above
top of CAF / AH
12"
Check
Valve
CAF
or
AH
Water
Heater
Figure 2
To
House
Min. 12" above
top of CAF / AH
12"
Check
Valve
CAF
or
AH
Water
Heater
* 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.
For further information, please contact Technical Support (519) 457-1904.
18
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Electrical
Caution should be used if installing a setback
thermostat to control the system. If the
thermostat is set back too far, and, for example,
is set to call for a lot of heat when you get out of
bed, at which time showering and general water
use is at its peak, then the hot water heater may
not keep up.
The Air Handler operates at 120V, singles phase
and draws anywhere from 2-8.7 amps,
depending on fan speed.
The low voltage thermostat (not provided)
connects to the R & W terminals for heating and
the R & Y & C terminals when calling for cooling.
Air Handler - Wiring Diagram
R - W
R - G
= Heat
= Fan Only (optional dehumidistat)
G - R - Y - C = A/C
PUMP TIMER (OPTIONAL)
1 LOAD
2 LINE
4
JUMPER
5
3 ..
GND
24VAC THERMOSTAT CONNECTIONS
Door Interlock
Switch
R
W
C
Y
G
* TEMPERATURE
SENSOR
Field
Connection
3
0
2
0
Wire Nut
WARNING
1 AMP
MAX
NC
NC
TRANSFORMER
NO
NO
C
C
FUSE
* NOTE: Units with
an (Optional) Pump
Timer do not get an
(Optional) Temperature
Sensor
Wire Nut
To change fan speed,
move bottom wires on
1
2
3
4
5
the speed select terminal
block to the high, med-hi
or med location.
FAN
CAPACITORS
PUMP
AH-02
0211
Note: Unit is shipped
on high speed.
FAN MOTOR
19
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Optional Dehumidistat
An optional dehumidistat can be connected to the furnace to help eliminate
excessive moisture during the heating season. When the dehumidistat
senses moisture in excess of the control setpoint, the blower will be
overridden into high speed. This will increase the ventilation airflow and
create a dehumidification affect. Typical settings are between 30-40 during
Dehumidistat
Setting Relative to
Outside Conditions
:
R
m
%
o
e
o
E
T
u
IN
W
d
e
m
t
%
y
i
ta
is
o
id
t
h
e
t
e
S
e
If
ju
h
.
0
4
0
3
n
e
h
e
o
tw
h
b
,
r
d
o
t
h
o
is
ig
t
g.
n
,
tt
e
r
s
o
e
to
t
t
m
s
o
s
d
If
id
a
m
u
h
s
s
i
the winter and OFF for all other seasons.
.
g
t
tin
e
r
e
w
lo
t
ju
d
a
:
is
R
id
E
m
F
M
u
O
M
h
to
U
e
S
d
t
ta
t
e
S
.
F
The dehumidistat will connect to R&G terminals on the furnace.
Note: Do not use dehumidistat for hot southern climates.
Part # 99-130W
When using a Dehumidistat or Interface Relay to initiate high speed blower operation on a
furnace, certain thermostats will initiate the outdoor cooling condenser when R and G are closed.
Use this wiring configuration to stop the Dehumidistat from initializing the condenser unit. This
problem can occur at the thermostat because the Y terminal is connected to the G terminal
internal to the stat. When R and G are closed at the furnace (by dehumidistat or relay) 24 Volts
is sent to G at thermostat. 24 Volts is then sent through Y which will initiate outdoor condenser.
The relay will isolate this problem.
NOTE: This problem does not occur with all thermostats, therefore it is important to fully
commission the installation to determine if this relay configuration is required.
Interface Relay
or Dehumidistat
NO
COM
24 Volt
Relay
NC
G W Y
T-stat
R
G W Y C
Furnace
R
TB-102
1099
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Start-Up Procedure
In order for any appliance to work properly it must be set up and tested by a knowledgeable
technician.
The following conditions must be met prior to start-up
1.
2.
3.
4.
5.
6.
7.
Ensure that connecting water lines are purged and free of debris
Caution: solder or other debris may cause the furnace pump or check valve to malfunction
Blower wheel rotates freely inside its housing
Wiring connections are tight
All duct and pipe connections are sealed
Check that all packaging is removed
Front access door is on tight.
Fan speed selection:
Heating/Cooling - factory setting is at high speed and can be changed in the
electrical box to medium-high or medium if required.
Once all of the necessary connections have been made, the Air Handler
Start-Up Procedure is as follows:
1.
2.
3.
Close shut-off valves separating the Air Handler from the water heater/boiler.
Set up water heater/boiler according to manufacturer's instructions.
Purge air from unit. To do so, open the supply shut-off valve to the furnace. Attach a garden
hose to drain valve, and drain water until you get a continuous flow. Close the drain valve and
purge the pump. To purge the air from the pump, turn the large screw on the face of the pump
counterclockwise until water leaks out, then tighten. Open the supply shut-off valve.
4.
5.
Turn on power supply to Air Handler. Caution: blower will start to operate.
Switch the room thermostat to heat. The thermostat should be set higher than the current room
temperature in order to energize the pump and commence the heating cycle. (If the pump does
not start, or the Air Handler is not producing heat, refer to the Troubleshooting Section in this
manual.
6.
Set room thermostat at desired temperature setting.
21
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Operation
Heating/Cooling
Optional Circulation Timer Models
When the room thermostat calls for heat from the
water heater, it activates a circulation pump locat-
ed inside the Air Handler. This pump delivers hot
water through the furnace coil and back to the
water tank/boiler. 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.
Some models are equipped with a circulation
timer. It is normal operation for these models to
automatically run the circulation pump for a short
period of time intermittently.
Continuous Low Speed Hook Up
Continuous low speed can be selected by con-
necting the red wire from the blower to the N/C
contact on the relay as indicated on the wiring
diagram.
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 continuous-
ly. 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 (optional A
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 it’s continu-
ous setting. Continuous low speed can be
selected by a qualified electrician.
22
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Troubleshooting
Lack of heat
Pump is noisy
Pumps can become noisy when air remaining in
the lines interfere with their operation. If this
occurs, re-purge the system as indicated in the
Start-Up Procedure.
1. Check that the room thermostat is set to the
desired temperature.
2. Confirm the units have power and the shut-off
valves are open.
During cooling cycle, hot water cir-
culates through the coil
3. Ensure there is power to the unit and that the
pump is working. If the pump is not working
properly, it may be stuck. Disconnect power
and remove screw in center face of the pump.
Using a screwdriver, turn the pump shaft sev-
eral times to free it from sticking. Replace
center-screw and re-connect power. If pump
still fails to start, it may require replacement.
If the check valve inside the cabinet is stuck in the
open position, hot water may infiltrate the heating
coil. This occurs when the hot pipes are not
capped-off during installation or service and for-
eign debris enters the piping. This debris can set-
tle under the check valve seat and permit hot
water to flow into the coil.The problem can be cor-
rected by repeatedly flushing the heating loop
until it is clean.
4. Confirm that the hot water heater is working
and that hot water is entering the Air Handler.
5. Verify that the airflow in and out of the system
matches designed specs. If airflow is low,
check for blockage in the filter or some other
obstruction.
6. Make sure your water heater is sized large
enough for heat load of house and for domes-
tic hot water use.
7. Air may still be in the water lines. If so, re-purge
the system according to the start up
procedure.
8. Confirm that the inlet and outlet pipe connec-
tions are not reversed.
9. Ensure that there are no other restrictions in
the water lines, such as faulty valves or debris.
23
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System Commissioning
This section of the manual is designed to be used
with the “Commissioning of Integrated Combo
System” worksheet. The worksheet is designed to
guide you through the start-up process in a logi-
cal, step by step method which should minimize
the work and time involved in having the system
meet the designed parameters.
fully open
• The throttling valve for the heating loop (if
applicable), is fully opened
• Electrical power is available at the furnace
• The return air temperature from the house
is approximately 70˚F (21˚C)
The following conditions are assumed:
• The air filter is in place
• All supply diffusers and return grilles are
fully open and unrestricte
• Hot water is available to the furnace
• The drain valve for the heating loop is
closed
• The shut off valves for the heating loop are
Water Pump Performance Specifications
Model 40
Model 60
16
14
12
10
8
16
14
12
10
8
6
6
4
4
2
2
0
0
1
2
4
6
8
10
12
1
2
4
6
8
10
12
14
16
18
20
Capacity on U.S. gpm
Capacity on U.S. gpm
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