IBC AHU Series Installation & Operating Manual Download

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INSTALLATION &

OPERATING MANUAL

Air Handling appliances

AHU 800

AHU1200

AHU 1600

Summary of Contents for AHU Series

Page 1: ...INSTALLATION OPERATING MANUAL Air Handling appliances AHU 800 AHU1200 AHU 1600...

Page 2: ......

Page 3: ...New construction 19 2 1 4 Mobile home 19 2 1 5 Closet 20 2 1 6 Garage 20 2 1 7 Serviceability 21 2 2 Positioning and mounting the appliance 21 2 2 1 Return air openings for ducting 21 2 2 2 Positioni...

Page 4: ...eze Protection Mode 48 3 5 LED status indicators 49 Built in diagnostics feature 49 3 6 Operating the appliance with a mobile app 50 3 6 1 Loading IBCconnect 50 3 6 2 Using the app to connect to IBC s...

Page 5: ...5 3 Fault Codes 67 Air handling appliance parts diagram 70 3...

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Page 7: ...e gas supplier from a phone located remotely Follow the gas supplier s instructions or if the supplier is unavailable contact the fire department Warning Improper installation adjustment alteration se...

Page 8: ...re reference When using electrical appliances follow safety precautions to reduce the risk of fire electric shock or injury to persons including Install or locate the air handling appliance only in ac...

Page 9: ...h inches 16 19 6 23 Supply air opening depth inches 19 6 Side return air opening height inches 7 10 5 13 Side return air opening width inches 23 Bottom return air opening width inches 13 10 5 14 Botto...

Page 10: ...1 MBH 22 6 MBH 23 7 MBH Table 1 Heating Capacity rating at 800 scfm cubic feet minute AHU 800 AHU 1200 Heating Capacity Entering Dry Bulb Temperature 70 F 1200 CFM Entering Water Temperature 3 GPM 4 G...

Page 11: ...71 C 69 1 MBH 76 1 MBH 80 8 MBH 150 F 66 C 61 2 MBH 67 4 MBH 71 6 MBH 140 F 60 C 53 3 MBH 58 8 MBH 62 5 MBH 130 F 54 C 45 5 MBH 50 2 MBH 53 4 MBH 120 F 49 C 37 7 MBH 41 6 MBH 44 3 MBH 110 F 43 C 30 MB...

Page 12: ...Figure 3 Top supply air opening Figure 4 Bottom return air opening Figure 5 Left side return air opening Figure 6 Right side return air opening 10 Section Specifications...

Page 13: ...Dimensions for the AHU 1200 model Figure 7 Supply and return air boiler supply and return Figure 8 Frontal view Figure 9 Top view Figure 10 Bottom view 11 Dimensions for the AHU 1200 model...

Page 14: ...Left side return air opening Figure 12 Right side return air opening Dimensions for the AHU 1600 model Figure 13 Supply and return air boiler supply and return Figure 14 Frontal view 12 Section Speci...

Page 15: ...Figure 15 Top view Figure 16 Bottom view Figure 17 Left side return air opening Figure 18 Right side return air opening 13 Dimensions for the AHU 1600 model...

Page 16: ...Stage 2 Thermostat connects R to W2 for second stage heating Y1 Cooling Stage 1 Thermostat connects R to Y1 for first stage cooling Y2 Cooling Stage 2 Thermostat connects R to Y2 for second stage coo...

Page 17: ...fier 24VAC powered Closes to activate the de humidifier DEH De humidifier OpenTherm OpenTherm Master To X 13 1 2 on boiler IBC SFC SFB series The air handling appliance master communicates to controls...

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Page 19: ...information on mounting positions and sizing see Cabinet and air supply dimensions on page 9 Appliances installed with a right side air opening will require the air filter position to be modified For...

Page 20: ...thermostat capable WiFi connection for programming with the IBCconnect mobile app Sensors for protection and operation Included sensors for supply air return air supply water return water humidifier d...

Page 21: ...aled with a tape designed for this purpose 2 1 2 Un conditioned space If locating the appliance in an un conditioned space protect the hydronic coil from freezing conditions Propylene glycol may be re...

Page 22: ...tom 0 0 if no connection C Front 1 24 A Back 0 0 Table 4 Recommended minimum clearance for combustibles and servicing 2 1 6 Garage Garage installations must be in a fully enclosed garage The appliance...

Page 23: ...the appliance Ensure that You install the air handling appliance level and plumb If the appliance is sitting on the floor shim as needed to level the appliance If the appliance is suspended it is sec...

Page 24: ...appliance so the air flows in a vertical up flow or down flow direction or in a horizontal left or right direction Figure 23 Upflow installation Figure 24 Downflow installation Figure 25 Left side in...

Page 25: ...ow Figure 28 Heat pump cased coil on the bottom of the appliance on the return side upflow 2 2 4 Mounting an appliance on the wall Mount the appliance with a pair of field supplied wall brackets Figur...

Page 26: ...ht return air supply orientation for ducting you will need to reposition the air filter brackets in the opposite position To reposition the filter 1 Remove the two screws from the front cover of the a...

Page 27: ...ove the wing nuts from the lower right bracket 6 Reposition the top and bottom brackets on the opposite side 7 Slide the filter into the repositioned brackets 25 2 2 5 Repositioning the air filter bra...

Page 28: ...rding to ASHRAE standards or equivalent Seal all joints and connections to prevent air leakage from the ducting system Choose accessories that will not excessively restrict the air flow and create exc...

Page 29: ...upply air ducting with a minimum of 1 thick fiberglass insulation with a vapor barrier All insulated joints must be sealed with tape designed for this purpose 2 3 3 Ducting installed in un conditioned...

Page 30: ...r ensure the piping system is designed to allow the easy removal of air from the boiler piping and easy flushing of the system Copper Pipe Sizing BTU HR Capacity 16 000 BTU 36 000 BTU 1 72 000 BTU 1 1...

Page 31: ...col feeder field supplied Figure 31 Basic installation boiler water heater with pump Air Handler Coil Head Loss AHU 800 Flow rate gpm 3 4 5 Fluid pressure drop ft water 1 6 2 7 3 5 Table 8 Air handler...

Page 32: ...the air handling appliance It is equally important to choose the correct circulator 2 5 Connecting the appliance to a tankless water heater Check local codes to ensure that piping the appliance to a t...

Page 33: ...equired where contaminants are present in the supply water Figure 32 Basic installation with tankless water heater Note The SFT 199 maximum water temperature is 149 F 65 C Ensure that this is hot enou...

Page 34: ...e ANS NFPA No 70 latest edition or the Canadian Electrical Code C22 1 Part 1 In addition you should refer to the boiler s installation manual The control board diagram below shows the various wiring c...

Page 35: ...r an external pump and 120VAC line Figure 35 Removing a wire 2 6 2 Connecting line voltage examples for different scenarios This section provides diagrams for wiring a 120 VAC 15 amp supply external P...

Page 36: ...is preset enabling the W2 blower speed after a preset period of time A jumper between W1 and W2 will initialize this speed without the time delay Figure 36 Single stage heating on demand heat source 3...

Page 37: ...peed after a preset period of time A jumper between W1 and W2 will initialize this speed without the time delay Optional Figure 37 Single stage heating with fan control on demand heat source 35 2 6 2...

Page 38: ...the W2 blower speed after a preset time period A jumper between W1 and W2 will initialize this speed without the time delay Optional Figure 38 Single stage heating single stage cooling fan control on...

Page 39: ...per between W1 and W2 will initialize this speed without the time delay Optional Not used Reversing valve O or B is selectable via the blower control interface Figure 39 Single stage heat pump fan con...

Page 40: ...uired if boiler does not have an integral pump Dry contact from air handler to boiler enables call for heating Figure 40 Single stage heating from boiler primary secondary piping 38 Section Installati...

Page 41: ...e an integral pump Dry contact from air handler to boiler enables call for heat Figure 41 Single stage heating with fan control boiler with primary secondary piping 39 2 6 2 Connecting line voltage ex...

Page 42: ...boiler does not have an integral pump Dry contact from air handler to boiler enables call for heat Figure 42 Single stage heating single stage cooling boiler with primary secondary piping 40 Section I...

Page 43: ...to create a boiler on command in the HP mode This time delay is initialized after establishing a W1 signal Reversing valve O or B is selectable via the blower control interface Not used Figure 43 Sin...

Page 44: ...oiler enables call for heat Reversing valve O or B is selectable via the blower control interface W1 heat pump W2 energize TT for boiler removes heat pump Not used Figure 44 Single stage heat pump wit...

Page 45: ...pump Dry contact from air handler to boiler enables call for heat W1 boiler low fan W2 boiler high fan Not used Figure 45 Two stage cooling with boiler heating 2 stage thermostat 43 2 6 2 Connecting l...

Page 46: ...ot have an integral pump Dry contact from air handler to boiler enables call for heat W1 boiler low fan W2 boiler high fan Not used Figure 46 Single stage cooling with boiler heating 2 stage thermosta...

Page 47: ...the appliance or components may need to be replaced Check all line voltage electrical connections to ensure all connections are correct and tight Check thermostat connections Thermostat is in a suita...

Page 48: ...For fan speed defaults and ranges see the table below AHU Fan speed Operation W1 Heating stage 1 600 CFM Range 300 800 W2 Heating stage 2 800 CFM Range 300 1000 must be than heating stage 1 Y1 Coolin...

Page 49: ...r Heat 1 to remove the boiler s call for heat Continues to operate the fan for 45 seconds also operates the pump contacts for 30 seconds 3 4 2 Cooling Mode Upon a call for cooling from the thermostat...

Page 50: ...n Mode Freeze protection mode monitors the return air temperature into the air handling appliance If the internal return air temperature sensor detects a return air temperature below 41 F the air hand...

Page 51: ...T LED displays a steady state The appliance will not service heat or cooling calls Table 12 Status indicators Built in diagnostics feature The appliance contains a built in diagnostic feature that ena...

Page 52: ...57 To connect the following setup steps need to be completed 1 Loading the app from the app store Google Play and Apple store 2 Using the app to connect to IBC s AHU WiFi 3 Programming the air handli...

Page 53: ...en the IBCconnect app and the IBC air handler IBC s AHU has a WiFi access point built into it Your device needs to be connected to IBC s AHU WiFi point before the app can be used to control or monitor...

Page 54: ...circuit board will start blinking simultaneously in a ON OFF ON OFF OFF OFF pattern when connected 4 Tap the device s back button to return to the IBCconnect app then tap GET STARTED to access the Ho...

Page 55: ...usly in a ON OFF ON OFF OFF OFF pattern when connected 7 Exit from the Setting screen and open the IBCconnect app again 8 Check your device is connected to the IBC AHU xxxxx WiFi connection This will...

Page 56: ...enu icon and select Basic Settings 2 Set the Heat Mode and Cool Mode 3 To make adjustments to settings tap menu and then select Advanced Settings We recommend setting Tankless to On in most applicatio...

Page 57: ...is connected to IBC s AHU WiFi the following screens will display Figure 47 Android mobile showing message device is connected to WiFi Figure 48 iOs mobile showing message device is connected to WiFi...

Page 58: ...landing page exit the app and then reopen it 1 Tap the GET STARTED button An Android prompt may request that you make your device s location discoverable 2 Tap Allow and then OK to grant permission Th...

Page 59: ...ntry 4 Tap Forget Network 5 Place the device in Airplane Mode 6 Reconnect the device to the IBC AHU WiFi by selecting the IBC AHU xxxxx from the list of access points Ensure that the WiFi reconnect op...

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Page 61: ...and simple maintenance procedures according to IBC s suggested servicing guidelines below Maintenance Required Frequency Check Check and replace filter as needed Replace the filter monthly Inspect sy...

Page 62: ...install the replacement fan assembly Ensure that you install the fan assembly so that the fan cables can reach the control board that is the cables are positioned towards the front left of the fan ass...

Page 63: ...ce 1 Remove the two screws from the front cover and set aside 2 Carefully unclip the three cables and lean them away from the hot water coil 3 Remove the nuts and bolts 4 Slide out the fan coil 61 4 2...

Page 64: ...a scoring knife 3 Place the replacement board on a flat surface and using the knife score a straight line between the main board and the humidity sensor strip The strip should snap off by hand without...

Page 65: ...door switch and the ground wire connector Now you must use the air handler app IBCconnect to program the model name mode and change default settings if desired 7 To set the model mode and to configur...

Page 66: ...re the temperature of the sensed environment compared with the value from the measurement of the resistance obtained by connecting a good quality test meter capable of measuring up to 100 k at the con...

Page 67: ...3 050 35 2 29 996 135 57 2 754 40 4 26 099 140 60 2 490 45 7 22 763 145 63 2 255 50 10 19 900 150 66 2 045 55 13 17 436 155 68 1 857 60 16 15 311 160 71 1 689 65 18 13 474 165 74 1 538 70 21 11 883 17...

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Page 69: ...onnect app go to Advanced Settings and check that Pump Enabled is set to on In the IBCconnect app go to Basic Settings and check that Heat Mode is not set to Heat Pump During Stage 1 heat pump heating...

Page 70: ...fuse Use a meter to check 120V is present on the external connection to the board If 10V is not coming from the fan it is not receiving 120V Check the 10V signal on the web app A C Freeze Freezing det...

Page 71: ...Error Message Description Possible Fix RTOS Fault 2 Software fault Contact IBC Technical Support for software upgrade Table 14 Warnings and error messages shown on the air handler unit app 69 5 0 Trou...

Page 72: ...Air handling appliance parts diagram 70 Section Find troubleshooting for IBC Technologies air handling appliances...

Page 73: ...il 2 ton appliance AHU 800 P 1020 Hot water coil 3 ton appliance AHU 1200 P 1022 Hot water coil 4 ton appliance AHU 1600 170 P 1005 Transformer 40VA 120V 180 P 1001 Control board 190 P 1007 Filter bra...

Page 74: ...minor edits R2 October 2019 Updated wiring diagrams added LED status indicators and information on using a text file to modify settings in multiple air handlers R3 November Added table of basic defau...

Page 75: ...77 0277 T 856 877 0544 F 604 877 0295 F 856 735 5584 Toll Free 1 844 HEAT IBC 1 844 432 8422 www ibcboiler com Information in this document is subject to change without notice IBC assumes no responsib...

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IBC AHU Series, Installation & Operating Manual

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