IBC AHU 800, Installation & Operating Manual

Page 1: ...INSTALLATION OPERATING MANUAL AHU 800 model IAHCCF1 0800 AHU 1200 Low Velocity model IALCCF1 1200 AHU 1200 model IAHCCF1 1200 AHU 1600 model IAHCCF1 1600 AHU 2000 Low Velocity model IALCCF1 2000...

Page 2: ...t pump or air conditioner s board without an external transformer then isolation relays will be required See Worked Examples under Installation If in doubt power the heat pump or air conditioner befor...

Page 3: ...ruction 19 2 1 4 Mobile home 19 2 1 5 Closet 19 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 Positioning the air...

Page 4: ...e stage heating with boiler or combi boiler and single stage cooling 39 39 2 8 4 Wiring two stage cooling with a boiler or combi boiler heating using a 2 stage thermostat 40 40 2 8 5 Wiring single sta...

Page 5: ...app 61 4 3 1 Connecting the IBCconnect app 61 4 3 2 Operational settings in the app 64 4 3 3 Programming the air handler 69 4 4 Configuring settings and parameters via a USB text file 71 5 0 Service...

Page 6: ...5 1 Unstable WiFi connection 84 6 5 2 WiFi Password 85 6 5 3 IBCconnect unable to find air handler on the network 85 6 6 Using built in diagnostics 85 7 Air handling appliance parts diagram 86 8 Appe...

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: ...42 Supply air opening width inches 16 19 6 19 6 23 23 Supply air opening depth inches 19 6 19 6 19 6 19 6 19 6 Side return air opening height inches 7 10 5 10 5 13 13 Side return air opening width inc...

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

Page 11: ...3 MBH Table 3 Heating Capacity rating at 1600 scfm standard cubic feet minute AHU 1600 AHU 2000 LV Heating Capacity Entering Dry Bulb Temperature 70 F 2000 CFM Entering Water Temperature 3 GPM 4 GPM 5...

Page 12: ...net and air supply dimensions Dimensions for the AHU 800 model Figure 1 Front right view Figure 2 Frontal view Figure 3 Top supply air opening Figure 4 Bottom return air opening 10 Section Specificati...

Page 13: ...side return air opening Figure 6 Right side return air opening Dimensions for the AHU 1200 LV and AHU 1200 models Figure 7 Front left view Figure 8 Frontal view 11 Dimensions for the AHU 1200 LV and A...

Page 14: ...Figure 9 Top view Figure 10 Bottom view Figure 11 Left side return air opening Figure 12 Right side return air opening 12 Section Specifications...

Page 15: ...Dimensions for the AHU 1600 and AHU 2000 LV models Figure 13 Front left view Figure 14 Frontal view Figure 15 Top view Figure 16 Bottom view 13 Dimensions for the AHU 1600 and AHU 2000 LV models...

Page 16: ...Figure 17 Left side return air opening Figure 18 Right side return air opening 14 Section Specifications...

Page 17: ...e 61 We ve illustrated the AHU s diverse applications below To view corresponding wiring and configuration instructions see Installation on page 19 For setup instructions see Wiring single stage heati...

Page 18: ...stage thermostat on page 47 For setup instructions see Wiring single stage heating single stage cooling with the tankless water heater as the heat source on page 48 For setup instructions see Wiring t...

Page 19: ...e s mounting position For information on mounting positions and sizing see Cabinet and air supply dimensions on page 10 Appliances installed with a right side air opening will require the air filter p...

Page 20: ...rd thermostat capable WiFi connection for programming with the IBCconnect mobile app Maximum return air temperature 122 F 50 C Sensors for protection and operation Included Sensors for supply air retu...

Page 21: ...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 required to prevent freezing of the...

Page 22: ...ont 1 inch 24 inches A Back 0 0 Table 5 Recommended minimum clearance for combustibles and servicing 2 1 6 Garage Garage installations must be in a fully enclosed garage The appliance is not suitable...

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: ...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 installation Figure 26 Right side...

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: ...right 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 t...

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: ...ose accessories that will not excessively restrict the air flow and create excessive pressure drop on the system Note When using medium and high velocity systems ensure proper duct design for optimal...

Page 29: ...e supply 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 conditio...

Page 30: ...he boiler piping and easy flushing of the system Copper Pipe Sizing BTU HR Capacity 20 F 11 C T 16 000 BTU 36 000 BTU 1 72 000 BTU 1 110 000 BTU Table 8 Pipe sizing 2 4 1 Sizing pumps Note To size the...

Page 31: ...from 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 t...

Page 32: ...ion tank Filter required where contaminants are present in the supply water Figure 31 Basic installation with tankless water heater Note The SFT 199 maximum water temperature is 149 F 65 C Ensure that...

Page 33: ...ode set to Off a boiler heat source can be used for Cold Air Sentry 2 7 Electrical connections All electrical wiring to the boiler including grounding must conform to local electrical codes and or the...

Page 34: ...planned feature not currently available 2 7 1 Thermostat connections The appliance is compatible with conventional and power stealing thermostats OpenTherm is a planned feature not currently available...

Page 35: ...Y2 for second stage cooling G Fan Thermostat connects R to G to energize fan for ventilation speed C 24V common Common return from the thermostat not required for all thermostats Boiler T Boiler Aux...

Page 36: ...midifier De humidifer Com De humidifier Common for O B Compressor Humid De humid DEH De humidifier 24VAC to activate the dehumidifier 2 7 2 Wiring of the external pump and 120VAC line To wire the exte...

Page 37: ...r handler using the IBCconnect app on page 61 Note If using an air conditioner or heat pump consult the air conditioner or heat pump s wiring instructions before connecting to the AHU An air condition...

Page 38: ...r and single stage cooling on page 39 4 Wiring two stage cooling with a boiler or combi boiler heating using a 2 stage thermostat on page 40 5 Wiring single stage heat pump with a boiler or combi boil...

Page 39: ...air handler to the boiler or combi boiler enables a call for heat Figure 36 Single stage heating with a boiler or combi boiler wiring Settings in the IBCconnect app 1 Tap menu icon and select Basic Se...

Page 40: ...or fan only operation and C for t stat common Figure 37 Single stage heating with a tankless water heater as a heat source wiring Settings in the IBCconnect app 1 Tap menu icon and select Basic Settin...

Page 41: ...ll for heat Required sensors for cooling applications are available separately at IBC A C sensor package P 1015 Figure 38 Single stage heating with boiler or combi boiler and single stage cooling wiri...

Page 42: ...boiler or combi boiler that enables a call for heat Required sensors for cooling applications are available order A C sensor kit P 1015 Figure 39 Two stage cooling with a boiler or combi boiler heati...

Page 43: ...e O B terminal during cooling Required the outdoor sensor for balance point control of backup heat source is available separately as IBC outdoor sensor kit P 9067 Required sensors for cooling applicat...

Page 44: ...5 Set Tankless Mode to Off 6 Tap SAVE 42 Section Installation...

Page 45: ...h the AHU app the default setting energizes the O B terminal during cooling Required the outdoor sensor for balance point control of backup heat source is available separately as IBC outdoor sensor ki...

Page 46: ...nect app 1 Tap menu icon and select Basic Settings 2 Set Heat Mode to Stg 1 HP Stg 2 Boiler 3 Set Cool Mode to 1 Stage HP 4 Set Boiler Heating to Boiler Backup 5 Set Tankless Mode to Off 6 Tap SAVE 44...

Page 47: ...setting energizes O B terminal during cooling Required outdoor sensor for balance point control of backup heat source is available separately as IBC outdoor sensor P 9067 Required sensors for cooling...

Page 48: ...4 Set Boiler Heating to Boiler Backup 5 Set Tankless Mode to On 6 Tap SAVE 46 Section Installation...

Page 49: ...Required outdoor sensor for balance point control of backup heat source is available separately as IBC outdoor sensor P 9067 Required sensors for cooling applications are available separately as IBC A...

Page 50: ...Required Sensors for cooling applications are available separately as IBC A C sensor kit P 1015 Figure 44 Single stage heating single stage cooling with the tankless water heater as the heat source w...

Page 51: ...ng applications are available separately as IBC A C sensor kit P 1015 Figure 45 Two stage cooling with a tankless water heater as a heat source wiring Settings in the IBCconnect app 1 Tap menu icon an...

Page 52: ...al during cooling Required The outdoor sensor for balance point control of backup heat source is available separately as IBC outdoor sensor P 9067 Required Sensors for cooling applications are availab...

Page 53: ...5 Set Tankless Mode to On 6 Tap SAVE 51...

Page 54: ...ng cooling Required The outdoor sensor for balance point control of backup heat source is available separately as IBC outdoor sensor P 9067 Required Sensors for cooling applications are available sepa...

Page 55: ...5 Set Tankless Mode to On 6 Tap SAVE 53...

Page 56: ...r contacts operation configured using the IBCconnect app Required for temperature control of Fresh Air Damper the outdoor sensor is available separately as IBC outdoor sensor P 9067 Figure 48 Make up...

Page 57: ...7 Set FA Damper Open T F to lowest Fresh Air temperature 8 Tap SAVE 55...

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Page 59: ...ontrol voltage will require isolation relays See Installation on page 19 Checking supply and return water piping connections Check All connections are pressure tested and leak free All piping flushed...

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Page 61: ...mostat When there is a call for cooling R Y1 or Y2 is energized fan speed ramps up to the maximum value of its Y1 or Y2 range value If there is a heat pump the O B terminal is energized Once demand is...

Page 62: ...e below 35 F the air handling appliance will turn off the fan and continue to energize TT boiler contacts and pump contacts 4 2 Status indicators The appliance displays four LED indicators each repres...

Page 63: ...lers that will use the same settings see Configuring settings and parameters via a USB text file on page 71 4 3 1 Connecting the IBCconnect app 1 Scan the respective QR codes above or search for IBCco...

Page 64: ...want to connect to 2 Select IBC AHU xxxxx where xxxxx is the controller serial number 3 Enter 1234567890 when prompted for a password Depending on the version of Android your device has after a few s...

Page 65: ...device and iOS version 1 In the main iPhone settings select Cellular 2 Navigate to the device s WiFi Settings 3 Locate and select the IBC AHU WiFi The IBC AHU will appear in the device s list of WiFi...

Page 66: ...is connected to WiFi 8 If prompted do not check the Don t ask again for this network the device will likely default to NO for staying connected if this is selected 9 Tap GET STARTED to begin adjusting...

Page 67: ...r Heating Boiler Aux Backup Set boiler heating mode Options None Boiler Aux Backup Boiler Only Temperature Fahrenheit Set temperature format Options Fahrenheit Celsius Tankless Off Set tankless water...

Page 68: ...speed operation on page 68 Fan circulates in cool mode AC HP Stage 2 CFM Varies by model See Fan speed operation on page 68 Fan circulates in cool mode Stage Delay min 10 The minimum time a heating o...

Page 69: ...on the humidity sensor in the return air FA Damper Off Fresh air damper FA Damper Open T F 41 Temperature to open fresh air damper Uses the dehumidifier contact Based on the outdoor sensor Cold House...

Page 70: ...ration Voltage Terminal Description and Defaults Range CFM AHU 800 W1 Heating stage 1 500 CFM 150 800 for mode 1 Stage Heat max 1000 W2 Heating stage 2 800 CFM 150 1000 must be 1 Stage Heat Y1 Cooling...

Page 71: ...Cooling stage 2 1600 CFM 240 1600 must be AC HP Stage 1 G Fan on speed 320 CFM 240 1600 AHU 2000 LV W1 Heating stage 1 1000 CFM 240 1600 for mode 1 Stage Heat max 2000 W2 Heating stage 2 1600 CFM 240...

Page 72: ...3 2 Adjusting the default settings parameters Before adjusting the settings ensure that you have previously set up a Mode 1 Tap menu and then select Advanced Settings We recommend setting Tankless to...

Page 73: ...menu and then select About 4 3 3 8 Connecting to another air handler on the network If you want to connect to another air handling appliance on the landing page tap the WiFi SETTINGS button and choose...

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Page 75: ...equency Check Check and replace filter as needed Replace the filter monthly Inspect system for unusual noises Call your local heating contractor for service if needed Monthly Have your local heating c...

Page 76: ...from the front cover and set aside 2 Remove the grommet around the electrical wires 3 Disconnect the fan electrical wires from the control board 4 Thread the wires through the grommet hole 74 Section...

Page 77: ...into the tabs 8 Reinstall components in the reverse order Note When you install the replacement fan assembly Ensure that you install the fan assembly so that the fan cables can reach the control boar...

Page 78: ...isconnect the water lines from the coil 1 Remove the two screws from the front cover and set aside 2 Carefully unclip each of the sensor wires and then remove the grommet holding the wires in position...

Page 79: ...lide out the hot water coil 7 Remove the temperature probe 8 Insert the temperature probe into the new hot water coil 9 Replace the new heating coil and reassemble parts in the reverse order 77 5 3 2...

Page 80: ...and using a scoring knife score a straight line between the main board and the humidity sensor strip The strip should snap off by hand without force Figure 50 Separating the humidity sensor strip fro...

Page 81: ...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 configure...

Page 82: ...perature 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 controller en...

Page 83: ...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...

Page 84: ...3 Tap Faults and compare active codes with Table 17 for troubleshooting information 6 2 Warning fault codes Fault Code Error Message Description Possible Fix Inlet Temperature Sensor Sensor not conne...

Page 85: ...ng No Fan RPM No rotation of the fan is detected Check if the AHU door is correctly installed Check the door switch Check for power to the unit Check if fan is turning or disconnected Check the fuse A...

Page 86: ...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 the AHU pump is not energized by design to a...

Page 87: ...pp Other permissions may be required depending on the device and the operating system used 6 6 Using built in diagnostics If required by Technical Support information on settings faults and errors can...

Page 88: ...7 Air handling appliance parts diagram 86 Section Air handling appliance parts diagram...

Page 89: ...0 P 1022 Hot water coil 4 ton 5 ton appliance AHU 1600 AHU 2000 low velocity 170 P 1005 Transformer 40VA 120V 180 P 1001 Control board 190 P 1007 Filter bracket wing nuts x 4 200 Air filter lower brac...

Page 90: ...88 Section Air handling appliance parts diagram...

Page 91: ...8 Appendice Wiring diagram Figure 52 AHU Air handler internal wiring diagram 89 8 Appendice Wiring diagram...

Page 92: ...0277 T856 877 0544 F604 877 0295 F856 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 responsibility...