Model 60ELE
“ELECTRIC” CLEAN AIR FURNACE MANUAL
General
Introduction
Congratulations on your selection of the Lifebreath Clean
Air Furnace. This is a very advanced unit that combines
an electric furnace with the tremendous health benefits of
year-round fresh air ventilation in every room of your
house.
The purpose of this manual is to act as an
installation guide only for the Lifebreath Clean Air
Furnace.
All national and local code requirements must be met
when installing a Lifebreath Clean Air Furnace. Be sure to
consult the proper authorities.
With the addition of Lifebreath T.F.P. Air Cleaner (option-
al) you will have the ultimate in comfort and healthy indoor
air quality. (See back cover of this manual)
Table of Contents
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.
Introduction ......................................................................1
Table of Contents.............................................................1
General ............................................................................1
Specifications................................................................2-4
Installation...................................................................5-10
Wiring Diagram ..............................................................11
Start-up Procedure.........................................................12
Operation .......................................................................13
Troubleshooting .............................................................14
Maintenance and Service Record..................................15
This Operating and Installation Guide will help you learn
about your Lifebreath Clean Air Furnace quickly and easi-
ly. 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 fur-
nace. 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.
CAF-03
0606
Specifications
60ELE-DF
Core
Specifications 18kw = (60,000 BTUH)
Ventilation system has patented aluminum heat
recovery core for energy-efficient ventilation.
Voltage
Hp
240 VAC 60 Hz
1/3
Filters
Amps (total)
Stages
85
Washable air filters in exhaust and supply air streams of
ventilation section, 1" Pleated in return plenum side.
Single (4 sequence)
6"
Ventilation
Ducts
Case
Prepainted galvanized steel for superior corrosion
resistance.
Return
14" x 22"
Plenum
Supply
Airflow
17.25" x 16"
1350 CFM @ .25 ESP
1180 CFM @ .5 ESP
Ventilation
Airflow
140 CFM
70%
Effectiveness
(HRV)
Note: All connections to be made by qualified contractors.
Net Weight 150 lbs. Shipping Weight 165lbs.
Dimensions & Clearances
Front
Side
Service Clearance 3'
Service Clearance 1'
29.5"
19"
16"
Top
Blower Section
14"
*Return
Plenum
Duct (coil)
Opening
17.25"
22"
19"
®
C
L
E
A
N
A
I
R
F
U
R
N
A
C
E
*Ventilation
Exhaust Air
Outlet
6"
6"
47.5"
29.5"
*Ventilation
Supply Air
Inlet
4"
Latches
12"
Options
Warranty
99-186
Weatherhoods, Two - 6" c/w
1/4" mesh screen
Units carry a lifetime warranty on the heat recovery core and a
five year replacement parts warranty on all other components.
99-130W
Remote Wall Mount Dehumidistat
Control 24 VAC only,
99-122
6” Balancing Damper
6” Backdraft Damper
99-RSK6
3
Figure 1
Blower Performance Curve
4
Installation
The purpose of this manual is to give the contractor guide-
lines for installing the Lifebreath Clean Air Furnace. All
national and local codes relating to this type of equipment
must be followed.
Duct Connections
To accommodate various installations, the Clean Air
Furnace has knockouts for the return air plenum and ven-
tilation ducts, on both sides of the cabinet. Special care
and attention should be given to determining which knock-
outs are to be removed. (See Fig. 2 & Fig. 3).
Locating The Unit
The Clean Air Furnace is designed to be installed vertical-
ly, in a conditioned space,where the surrounding
temperature does not fall below 50°F (10°C). Attic installa-
tions are not recommended. Typically the unit is installed
in a mechanical area of the basement, or other
partitioned mechanical room, elsewhere in the home.
Slide Heat Recovery Core out to remove ventilation
knockouts. Never install ductwork directly to the cabinet
that is smaller than the opening provided.
A location close to an outside wall is recommended, as
the ventilation supply and exhaust portion will need to be
ducted to the outside air.
Sufficient clearance around the unit is required for service
of the filter, heat recovery core and components.
Figure 2
Option 1 - Ventilation Ports Off Left Side
Remove
styrofoam
knockout
Remove
styrofoam
knockout
Model 60ELE-DF
Model 60ELE
NOTE: Return plenum opening can be on either side of cabinet and is not dependent on which side the ventilation ports are on.
5
Installation
Figure 3
Option 2 - Ventilation Ports Off Right Side
Remove
styrofoam
knockout
Remove
styrofoam
knockout
Model 60ELE
Model 60ELE-DF
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.
Locating Intake Weatherhood
The intake weatherhood should be located as follows:
* 4-6' from ventilation exhaust hood, and upstream of
prevailing winds, if possible.
* At least 6' from a dryer vent, oil fill pipes, combustion
outlets, gas meters, garbage containers or anything
else, which may contaminate the air.
Ducting
The duct sizing for the furnace section can be determined
using HRAI Residential Air System Design Manual,
SMACNA, or any other industry-recognized manuals.
* Do not locate fresh air intake in garages, crawl
spaces or attics.
Any ductwork running through unconditioned space must
be sealed properly and insulated to prevent heat loss. All
local codes must be followed in determining the amount of
insulation needed.
* Install 18" above grade, or above expected snow
accumulation.
The ventilation section consists of two 6" (15.2cm) round
ports located on the side of the cabinet, which vent to the
outside. Insulated ducting with a vapour barrier such as
flex-ducting, or ridged pipe wrapped in pipe sleeve, is
required to prevent condensation from occurring on the
pipe. Also the airflow in these lines is designed to be bal-
anced. (See "Balancing Airflows" in this manual, for
damper location and procedure.)
Warning: A backdraft damper is required in the exhaust air
duct to prevent cold air from entering the unit when the
Clean Air Furnace is not running. Fig. D Page 9.
6
Installation
Locating the Exhaust Weatherhoods
The Exhaust Weatherhood should be located as fol-
lows:
A small piece of rigid duct (1-2') can be fabricated for
joining the outside ducting to the port collars. (Fig. D,
page 12). This section of pipe is needed to accommo-
date the balancing damper, as required in the
"Balancing Procedure" in this manual. After installing
the dampers, the small section of pipe can be fastened
to the port collars. The ductwork from the outside
weatherhoods to the unit, is usually flexible ducting,
although rigid pipe may be needed if the runs are
greater than 20 feet. In either case the pipes (both
exhaust and supply and the added fittings) must be
insulated, with a complete vapor barrier Fig. 4. To mini-
mize restriction in airflows the ducting should be short,
with as few bends as possible. See diagram below for
recommended connection of insulated ducting to out-
side weatherhoods and the Clean Air Furnace port
collars.
* At least 4-6' from the supply inlet.
* At least 18" above grade or expected snow accu-
mulation.
* At least 3' from gas meters, combustion vents, or
dryer vents.
* Do not install in garages, crawl spaces or attics.
Outside Ducting the Weatherhoods
The ventilation portion of the Clean Air Furnace can be
vented off either side of the unit by removing knockouts
provided. Once the knockouts in Fig. 2 / Fig. 3 are
removed, a bead of silicone can be placed on the plastic
thermo-collars (provided), to form a seal between the
collars and the cabinet. The collars can then be fas-
tened into place with screws. Note the exhaust outlet is
always the port on the bottom, and the supply inlet is
always the port on the top, both ports should be labeled
from the factory as such.
Figure 4
Locating Weatherhood
WEATHERHOODꢀINSTALLATION
COLLARꢀISꢀSUPPLIEDꢀTOꢀ
ENSUREꢀVAPOURꢀBARRIERꢀ
ISꢀ100%ꢀSEALEDꢀTOꢀ
WALLꢀPLATE
SCREEN
(sideꢀview)
12"ꢀgalvanized
pipeꢀsupplied
EXTERIORꢀ
WALL
1/4"ꢀ(6ꢀmm)ꢀSCREEN
(frontꢀview)
1.ꢀ ThermalꢀCollarꢀslidesꢀoverꢀgalvanizedꢀ
sleeveꢀofꢀWeatherhood.
2.ꢀ FastenꢀThermalꢀCollarꢀtoꢀBelt.
3.ꢀ SlideꢀtheꢀInsulatedꢀFlexibleꢀDuctingꢀoverꢀ
theꢀWeatherhood'sꢀgalvanizedꢀsleeveꢀandꢀ
fastenꢀitꢀtoꢀtheꢀThermalꢀCollar.
4.ꢀ Hoodꢀisꢀhingedꢀtoꢀallowꢀforꢀeasyꢀaccessꢀ
ꢀꢀ forꢀcleaningꢀofꢀbirdꢀscreen.
7
Installation
Pitot Tube Air Flow Balancing
Balancing Procedure
It is necessary to have balanced air flows in an HRV. The
volume of air brought in from the outside must equal the
volume of air exhausted by the unit. If the air flows are not
properly balanced then:
The following is a method of field balancing an HRV using
a Pitot tube, advantageous in situations when flow sta-
tions are not installed in the ductwork. Procedure should
be performed with the HRV on high speed.
* The HRV may not operate at its maximum efficiency
* A negative or positive air pressure may occur in the house
* The unit may not defrost properly
Choose the straightest section of duct between the HRV
and the weatherhoods. This will be used for both the sup-
ply and return ducts.
* Failure to balance the HRV may void warranty
Drill a small hole in the duct (about 3/16"), three feet
downstream of any elbows or bends, and one foot
upstream of any elbows or bends. These are recommend-
ed distances but the actual installation may limit the
amount of straight duct.
Prior to balancing, ensure that:
1. All sealing of the ductwork system has been completed.
2. All of the HRV's components are in place and functioning
properly.
3. Balancing dampers are fully open.
4. Unit is on high speed.
The Pitot tube should be connected to a magnehelic
gauge or other manometer capable of reading from 0 to
0.25 in. (0 - 62 Pa) of water, preferably to 3 digits of reso-
lution. The tube coming out of the top of the Pitot is
connected to the high pressure side of the gauge. The
tube coming out of the side of the Pitot is connected to the
low pressure or reference side of the gauge.
5. After taking readings of both the stale air to the HRV duct
and fresh air to the house duct, the duct with the lower
CFM ([L/s] velocity) reading should be left alone, while the
duct with the higher reading should be dampered back to
match the lower reading.
6. Return unit to appropriate fan speed for normal operation.
Insert the Pitot tube into the duct, pointing the tip into the
airflow.
8
Installation
For general balancing it is sufficient to move the Pitot tube
around in the duct and take an average or typical reading.
Repeat this procedure in the other (supply or return) duct.
(Fig. B.). Determine which duct has the highest airflow
(highest reading on the gauge). Then damper that airflow
back to match the lower reading from the duct. The flows
should now be balanced.
The Pitot tube comes with a chart that will give the air flow
velocity based on the velocity pressure indicated by the
gauge. This velocity will be either feet per minute or
metres per second. To determine the actual airflow, the
velocity is multiplied by the cross sectional area of the
duct being measured.
This is an example for determing the airflow in a 6" duct.
The Pitot tube reading was 0.025 inches of water. From
the chart, this is 640 feet per minute.
Actual airflow can be determined from the gauge reading.
The value read on the gauge is called velocity pressure.
The 6" duct has a cross sectional area of:
= (3.14 x [6"÷12]2) ÷ 4
= 0.2 square feet
Figure A:
Pitot Tube Air Flow Balancing Kit
The airflow is then 640 ft./min x 0.2 square feet = 128cfm
For your convenience, the cross sectional area of some
common round duct is listed below:
DUCT DIAM. (inches)
CROSS SECTION AREA (sq. ft.)
5.0
6.0
7.0
.14
.20
.27
The accuracy of the airflow reading will be affected by
how close to any elbows or bends the readings are taken.
Accuracy can be increased by taking an average of multi-
ple readings as outlined in the literature supplied with the
Pitot tube.
c/w magnetic gauge, Pitot tube, hose and carry case.
PART NO. 99-167
Figure B:
Pitot Tube and Gauge
Figure D
Note: For best results, keep Pitot tube well away from dampers and
motor turbulence.
Figure C:
Placement of the Pitot Tube
Pitot Tube
Note: For best results keep Pitot tube
well away from dampers.
*Note: All dampers & fittings must be covered with insulation and sealed with tape
9
Installation
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. See Fig. 5,
for connection.
Figure 5
Drain Line Diagram
DRAIN
SPOUT
2"
DRAIN
SPOUT
KNOCKOUT
TAPE
KNOCKOUT
TEE
CONNECTOR
THROUGH KNOCKOUT
TO DRAIN
10
Wiring Diagram
R - W
R - G
= Heat
= Fan Only (optional dehumidistat)
G - R - Y - C = A/C
Electrical
The low voltage thermostat (not provided) connects to the
R & W terminals for heating and the R & Y & C terminals
when calling for cooling.
The Clean Air Furnace operates at 240V, single phase
and requires a maximum 100amp fused circuit or breaker.
IMPORTANT
WIRE IN ACCORDANCE WITH LOCAL AND
CANADIAN ELECTRICAL CODES. READ
CAREFULLY INSTALLATION INSTRUCTION
BEFORE WIRING AND OPERATING.
THERMOSTAT
LEGEND
A
THR
T
AUTOMATIC RESET CUT-OUT
THERMAL RELAY
R
R
W
G
Y
Y
C
C
FILTRE ELECTRONIQUE
HUMIDIFICATEUR
120VAC 60HZ
PDS
240/1
CONTROL CIRCUIT TRANSFORMER
E1..E4 HEATING ELEMENTS
CH
F
BLOWER RELAY 2 SPEEDS
FUSE 15 AMPS 250 V
PRESSURE DIFFERENTIAL SWITCH
BACK-UP CONTACTOR
COOLING CONTACTOR
HUMIDIFIER
ELECTRONIC AIR FILTER
BLOWER MOTOR 120VAC
CAPACITOR
W
G
HU
FI
N
N
G
L1
L2
PDS
CM
CR
HU
EF
M1
CAP
CG
CM
F1
T
24V
240VAC
COOLING RELAY
THR1
THR2
CG
IMPORTANT
SUIVRE LES CODES ELECTRIQUE NATIONAUX
ET LOCAUX AINSI QUE LES INSTRUCTIONS
CONTENUES DANS L'APPAREIL.
N
LÉGENDE
SONDE THERMIQUE À RESET
AUTOMATIQUE
CG
CR
A
F
THR
T
RELAIS THERMIQUE
TRANSFORMATEUR
E1..E4 ÉLÉMENTS DECHAUFFAGE
ÉLECTRIQUE
CR-2
CR-3
CR-1
CR-4
15A
HI
CH
HU
EF
M1
PDS
RELAIS DE MOTEUR, 2 VITESSES
HUMIDIFICATEUR
FILTRE À AIR ÉLECTRONIQUE
MOTEUR DE VENTILATEUR
INTÉRRUPTEUR À PRESSION
DIFFERENTIELLE
4
1
6
3
5
2
CH
BLOWER
MOTOR
A
A
THR1
CAP
M1
FILTER
CM
CR
CAP
F
CONTACTEUR SECONDAIRE
CONTACTEUR DE CLIMATISATION
CONDENSATEUR
M1
THR1
M2
M4
CM
CH-3
CH-4
FUSIBLE 15 AMP, 250V
M3
THR2
ML
CG
RELAIS DE CLIMATISATION
6
5
2
4
A
A
FAN SW
CH-2
MED
LOW
FOR MINIMUM SUPPLY
CONNECTION USE 75˚C
COPPER. AWG SIZE
SUPPLY
CIRCUIT
LO
M5
THR2
M6
M8
CH-1
MD
240V/1
18 KW
M7
1
3
#3
CODE
DESCRIPTION
AUTOMATIC RESET CUT-OUT
MODEL
MAKE
RATING
PART #
CC0 010
CFH 015
CFU 035
QTY.
A
F
F
60TX11-312373
HKP-HH
4
1
25 AMP 277V
15 AMP 240V
15 AMP 240V
25 AMP 240V
THERMO DISC
BUSS
FAN MOTOR, ELECT. FILTER& HUM. SUPPLY FUSEHOLDER
1
1
1
1
1
1
1
MDL 15
FAN MOTOR, ELECT. FILTER& HUM. SUPPLY FUSE
4 POLE SEQUENCER
BUSS
THR
CR
CCT 130
DEC 010
CCT 145
PMC 012
15S24
THERMODISC
HONEYWELL
COOLING FAN RELAY COIL 120V 50/60HZ
R4222D1039
15A 277V
15A 277V
CH
HEATING FAN RELAY COIL 208/240V 50/60HZ
LOW SPEED CONTINUOUS
9100-233U999
115A13-2XA
PRODUCTS UNLIMITED
CARLINGSWITCH
16A 120V
FAN SW
T
4000-09AW18AE887
TA-6-I
CONTROL TRANSFORMER
GROUND LUG
PRODUCT UNLIMITED
240V/24V 50VA
35 AMP
CTR 090
CLG 010
CP1 054
G
ILSCO
WECO
R--C
15 AMP 240V
CONTROL TERMINAL BLOCK TO THERMOSTAT
324-FU-HDS/12
HU--MD
L1..3
15 AMP 240V
125 AMPS
CPI 056
CP1 070
1
1
BLOWER MOTOR, ELECT. FILTER& HUM. TERMINAL BLOCK
WECO
324-FU-HDS/12
3P-PWR-BLK
THERMOLEC
STEVECO
CLEVELAND
POWER TERMINAL 3 POLE
CG
25 AMPS
1
1
CONTROL RELAY COIL 24V
PRESSURE DIFFERENTIAL SWITCH
CCT 139
CAF 010
134-20102101ZZ
DFS-221-112
PDS
15 AMP 240V
*120 Volt terminals are provided for connecting an air filtration device/humidifier. These termi-
nals are labeled HU F1 N as shown above.
11
Start Up Procedure
In order for any appliance to work properly it must be set
up and tested by a knowledgeable technician.
NOTE: Continuous low speed can be turned ON/OFF
with the ventilation switch, (fig. 6).
The following conditions must be met prior to start-up
1. Blower wheel rotates freely inside its housing.
2. Wiring connections are tight.
NOTE: Continuous high speed can be obtained by
switching thermostat fan switch to manual/on.
NOTE: For models with the ECM blower motor. Low
speed fan is controlled by the thermostat fan
switch (R and G terminals).
3. Water is sitting in the "P" trap below the HRV core.
4. All duct and pipe connections are sealed.
5. Front access door is on tight.
High speed blower operation is obtained by
making a dry contact closure across R and the
Orange wire from the ECM motor.
Once all of the necessary connections have been made,
the Clean Air Furnace Start-Up Procedure is as follows:
1. Turn on power supply to Clean Air Furnace. Caution:
The blower will start running at a lower speed.
NOTE: Downflow models incorporate a flow
switch to verify blower operation and air-
flow. If airflow is not sensed or the
2. Switch the room thermostat to heat. The thermostat
should be set higher than the current room temperature
in order to energize the unit and commence the heating
cycle.Verify heat cycle starts.
pressure switch is blocked, the electric
heating elements will NOT start. NEVER
override or disable safety switches. If air-
flow is blocked or too low, the airflow
MUST be diagnosed and corrected.
3. Set room thermostat at desired temperature setting.
4. Switch fan to manual at the thermostat so the unit will
run at high speed in order to perform the balancing pro-
cedure on the ventilation section.
Note: For ECM motors, refer to note located on this
page regarding high speed fan operation.
5. After balancing the ventilation according to instructions,
set the thermostats fan switch to "auto". On "auto" the
fan will run continuously at a low speed if the ventila-
tion switch (fig. 6) is in the continuous mode, until
heating or cooling is called for and then will switch to a
higher speed. On "manual" the fan will run at high
speed continuously.
12
Operation
Heating/Cooling
Ventilation
When the room thermostat calls for heat, the furnace
blower switches on to heating speed and will start circu-
lating air across the coil, which picks up heat and
delivers it to the rest of your home.
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 fur-
nace blower is activated.
Once the thermostat's temperature is reached the ele-
ments will shut off, and the blower will return to its
pre-set speed or off.
To reduce humidity increased ventilation may be
required. 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 dehumidis-
tat must be switched off during warmer months as it is
not required for air conditioning operation. To increase
humidity a quality humidifier should be added to the sys-
tem.
Note: When the furnace blower is left running on
low speed the air in the home circulates continu-
ously. 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 acti-
vates 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 low speed. Continuous low speed is selec-
table, (fig. 6).
Typically the air flow for ventilation will be set to 50 -
70cfm, for low speed furnace operation, and
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.
Figure 6
Low speed selection switch (PCS motor models only)
(CONTINUOUS or OFF)
Top
13
Troubleshooting
Lack of heat
Humidity levels are too low
1. If you have installed a dehumidistat ensure that its set-
ting is correct.
1. Check that the room thermostat is set to the desired
temperature.
2. Ensure there is power to the unit.
2. Check humidifier settings.
3. 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.
3. Change thermostat fan switch from manual to automat-
ic.
4. Change ventilation switch on furnace from continuous
(low) to automatic.
HRV core freezes up
1. Make sure that the supply and exhaust lines are bal-
anced according to the "Balancing Procedure" in this
manual.
Humidity levels are too high
1. If you have installed a dehumidistat ensure its setting is
correct.
2. If out of balance, ensure that the balancing dampers
have not been moved and that there are no obstruc-
tions in the outside hoods.
2. Install a dehumidistat if necessary
3. Change ventilation switch on furnace from automatic to
continuous.
3. If necessary, install optional defrost kit, according to
instructions.
4. Change thermostat fan switch from
automatic to manual.
Water sits in drain pipes
1. Check drain pans or lines for plugs.
2. Confirm that the HRV core is installed according to
manufactures recommendations.
3. Check the drain line for kinks.
4. Make sure that the O-ring in the drain nozzles sit flat.
5. Ensure the drain line has enough "fall" to it.
Condensation/ice forming inside ventilation ducts
A rip in the vapor barrier or poorly sealed joints may
cause condensation or ice to form on the ducting. If this
occurs, replace the entire line.
14
Maintenance and Service Record
Date:
Particulars
15
|