IBC AHU 800 Installation instructions

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

Note
If using a heat pump or air conditioner:consult the heat pump or air conditioner's wiring
instructions before connecting to the AHU.
A heat pump or air conditioner producing its own control voltage will require isolation relays. If
the heat pump or air conditioner's wiring diagram shows a thermostat connecting directly to the
heat 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
before connecting to it, and measure for voltage across control contacts Yand C:a voltage
greater than ~2 Volts ACor DCindicates that isolation relays will be necessary.
Note
When using medium and high velocity systems, ensure proper duct design for optimal system
performance and noise levels. For reference, see "DuctWork" under "Installation."

1
Contents
Safety information 5
Specifications 7
Heating capacity 8
Cabinet and air supply dimensions 10
Dimensions for the AHU 800 model 10
Dimensions for the AHU 1200 LV and AHU 1200 models 11
Dimensions for the AHU 1600 and AHU 2000 LV models 13
1.0 Introduction 15
1.1 Standard features and benefits 17
1.2 Conformity 18
2.0 Installation 19
2.1 Locating the appliance 19
2.1.1 Conditioned space 19
2.1.2 Un-conditioned space 19
2.1.3 New construction 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 handling unit 22
2.2.3 Adding air conditioning coils or heat pump coils 22
2.2.4 Mounting an appliance on the wall 23
2.2.5 Repositioning the air filter brackets 24
2.3 Duct work 26
2.3.1 Sizing the ducts 26
2.3.2 Ducting installed in conditioned space 27
2.3.3 Ducting installed in un-conditioned spaces 27
2.3.4 Making the return air openings 27
2.4 Connecting the appliance to a boiler 28
2.4.1 Sizing pumps 28
2.4.2 Using Propylene Glycol 29

2.5 Connecting the appliance to a tankless water heater 29
2.6 Cold Air Sentry (a.k.a. Freeze Protection) 31
2.7 Electrical connections 31
2.7.1 Thermostat connections 32
2.7.2 Wiring of the external pump and 120VAC line 34
2.7.3 Connecting line voltage 35
2.8 Worked examples 35
2.8.1 Wiring single-stage heating with a boiler or combi boiler 37
37
2.8.2 Wiring single-stage heating with a tankless water heater as a heat source 38
38
2.8.3 Wiring single-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-stage heat pump with a boiler or combi boiler as backup 41
41
2.8.6 Wiring single-stage heat pump with a boiler or combi boiler as backup
(emergency heat on T-stat) 43
43
2.8.7 Wiring two-stage heat pump with a boiler or combi boiler as backup (2-
stage thermostat) 45
45
2.8.8 Wiring two-stage heat pump (2-stage thermostat) 47
47
2.8.9 Wiring single-stage heating, single-stage cooling, with the tankless water
heater as the heat source 48
48
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Section: Contents

2.8.10 Wiring two-stage cooling with a tankless water heater as a heat source 49
49
2.8.11 Wiring single-stage heat pump with a tankless water heater as a backup 50
50
2.8.12 Wiring two-stage heat pump with a tankless water heater as a backup 52
52
2.8.13 Wiring make-up air with a boiler or a combi as a heat source 54
54
3.0 Before operating the air handler 57
4.0 Operation 59
4.1 Sequence of operation 59
4.2 Status indicators 60
4.3 Operating the air handler using the IBCconnect 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 and maintenance 73
5.1 Maintenance checklist for owners 73
5.2 Maintenance checklist for service contractor 73
5.3 Maintenance for the heating contractor 73
5.3.1 Removing the fan assembly 73
5.3.2 Replacing the heating coil in the air handler 76
5.3.3 Replacing the control board 78
5.4 Temperature sensors 80
6.0 Troubleshooting 82
6.1 Using the IBCconnect app to troubleshoot the AHU 82
6.2 Warning / fault codes 82
6.3 Measuring voltage on AHU boards 84
6.4 Pump not energized 84
3

6.5 Troubleshooting the IBCconnect app 84
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 Appendice: Wiring diagram 89
4
Section: Contents

Safety information
Manual safety markings
Danger
Points out an immediate hazardous
situation that must be avoided to
prevent serious injury or death.
Warning
Points out a potential hazardous
situation that must be avoided to
prevent serious injury or death.
Caution
Points out a potential hazardous
situation that must be avoided to
prevent possible moderate injury
and/or property damage.
Note
Points out installation, maintenance and
operational notes to enhance efficiency,
longevity and proper operation of the air
handling appliance.
Danger
Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or
any other appliance. If you smell gas vapors, do not try to operate any appliance - do not
touch any electrical switch or use any phone in the building. Immediately, call the 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, service or maintenance can cause property
damage, personal injury, or loss of life. Read and understand the entire manual before
attempting installation, start-up, operation, or service. Installation and service must be
performed only by an experienced, skilled installer or service agency.
Failure to follow all instructions in the proper order can cause personal injury or death.
Read all instructions, including all those contained in component manufacturers’ manuals
before installing, starting up, operating, maintaining, or servicing the appliance.
Warning
Disconnect power supply before any wiring/service is performed. Failure to do so could
result in damage to appliance and/or electric shock.
Caution
Do not pierce cabinet as internal damage may occur to electrical and hydronic
components.
5
Safety information

Caution
The air handler must be installed so that electrical components are not exposed to
water during operation.
Note
All wiring on IBC air handlers must adhere to the National Electrical Code and/or local
regulations.
Note
All appliances conform to CSA C22.2 NO. 236-15 and UL 1995 Stds. Water coil
conforms to NSF / ANSI Std. 372.
Important safety instructions
Failure to read and comply with all instructions and applicable national and local codes may result
in hazardous conditions that could result in property damage and injury to occupants, and in
extreme cases to death. Keep instructions near the air handling appliance for future 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 accordance with the provided installation
instructions.
Use the air handling appliance only for its intended use as described in this manual.
Do not operate the air handling appliance if it is not working properly, or if it has been
damaged or dropped.
Installation, start-up and servicing of IBC's air handling appliances must be done with care
and attention, and should only be performed by competent, qualified, licensed and trained
plumbing and heating technicians. Contact your nearest authorized service facility for
examination, repair, or adjustment.
If subjected to flooding, the appliance must be replaced.
6
Section: Safety information

7
Specifications
Specification AHU 800 AHU 1200
LV* AHU 1200 AHU 1600 AHU 2000 LV*
Max. water temperature (°F/°C) 195 / 90 195 / 90 195 / 90 195 / 90 195 / 90
Coil performance at 180°F (Btu/hr) 66,800 80,600 80,600 99,300 110,300
Water pipe connections (inches) ¾ MPT ¾ MPT ¾ MPT ¾ MPT ¾ MPT
External static pressure (") default Low 0.50 0.50 0.50 0.50 0.50
Medium 1.0 - 1.0 1.0 -
High 1.5 - 1.5 1.5 -
Max. operating water pressure (PSI) 150 150 150 150 150
Width (inches) 17.5 21 21 24.6 24.6
Depth (inches) 26 26 26 26 26
Height (inches) 32 38 38 42 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 (inches) 23 23 23 23 23
Bottom return air opening width
(inches)
13 10.5 10.5 14 14
Bottom return air opening depth
(inches)
23 23 23 23 23
Max. internal current power rating 120
Volts (Amp)
2.4 2.8 3.2 3.3 3.3
External pump supply 120V (Amp) 4 4 4 4 4
Voltage (V) 120 120 120 120 120
Max. return air temperature (°F/C°) 122 / 50 122 / 50 122 / 50 122 / 50 122 / 50
Filter size - not supplied (inches) 16 x 25 x 1 25 x 20 x 1 25 x 20 x 1 25 x 20 x 1 25 x 20 x 1
Boxed weight (lbs/kgs) 98/45 111/50 111/50 130/59 130/59
* Low velocity only

Heating capacity
AHU 800 - Heating Capacity (Entering Dry Bulb Temperature 70°F) @ 800 CFM
Entering Water Temperature 3 GPM 4 GPM 5 GPM
195°F (90°C) 68.6 MBH 73.2 MBH 76.2 MBH
190°F (88°C) 65.7 MBH 70.2 MBH 73.0 MBH
180°F (82°C) 60.0 MBH 64.1 MBH 66.8 MBH
170°F (77°C) 54.4 MBH 58.1 MBH 60.5 MBH
160°F (71°C) 48.7 MBH 52.1 MBH 54.3 MBH
150°F (66°C) 43.1 MBH 46.2 MBH 48.1 MBH
140°F (60°C) 37.6 MBH 40.2 MBH 41.9 MBH
130°F (54°C) 32.0 MBH 34.3 MBH 35.8 MBH
120°F (49°C) 26.5 MBH 28.5 MBH 29.7 MBH
110°F (43°C) 21.1 MBH 22.6 MBH 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 GPM 4 GPM 5 GPM
195°F (90°C) 81.3 MBH 87.7 MBH 91.8 MBH
190°F (88°C) 78.0 MBH 84.1 MBH 88.1 MBH
180°F (82°C) 71.3 MBH 76.9 MBH 80.6 MBH
170°F (77°C) 64.6 MBH 69.8 MBH 73.1 MBH
160°F (71°C) 58.0 MBH 62.6 MBH 65.6 MBH
150°F (66°C) 51.4 MBH 55.5 MBH 58.2 MBH
140°F (60°C) 44.8 MBH 48.4 MBH 50.8 MBH
130°F (54°C) 38.3 MBH 41.4 MBH 43.4 MBH
120°F (49°C) 31.8 MBH 34.3 MBH 36.0 MBH
110°F (43°C) 25.3 MBH 27.4 MBH 28.7 MBH
Table 2 Heating Capacity rating at 1200 scfm (standard cubic feet / minute) - AHU 1200
8
Section: Specifications

AHU 1600 - Heating Capacity (Entering Dry Bulb Temperature 70°F) @ 1600 CFM
Entering Water Temperature 3 GPM 4 GPM 5 GPM
195°F (90°C) 96.9 MBH 106.7 MBH 113.2 MBH
190°F (88°C) 92.9 MBH 102.3 MBH 108.6 MBH
180°F (82°C) 84.9 MBH 93.5 MBH 99.3 MBH
170°F (77°C) 77.0 MBH 84.8 MBH 90.0 MBH
160°F (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) 30.0 MBH 33.2 MBH 35.3 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 GPM
195°F (90°C) 105.2 MBH 117.4 MBH 125.8 MBH
190°F (88°C) 100.8 MBH 112.5 MBH 120.6 MBH
180°F (82°C) 92.1 MBH 102.9 MBH 110.3 MBH
170°F (77°C) 83.5 MBH 93.2 MBH 100.0 MBH
160°F (71°C) 74.9 MBH 83.6 MBH 89.7 MBH
150°F (66°C) 66.3 MBH 74.1 MBH 79.5 MBH
140°F (60°C) 57.8 MBH 64.6 MBH 69.3 MBH
130°F (54°C) 49.3 MBH 55.1 MBH 59.1 MBH
120°F (49°C) 40.9 MBH 45.7 MBH 49.1 MBH
110°F (43°C) 32.5 MBH 36.4 MBH 39.1 MBH
Table 4 Heating Capacity rating at 2000 scfm (standard cubic feet / minute) - AHU 2000
9
Heating capacity

Cabinet 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: Specifications

Figure 5 Left 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 AHU 1200 models

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

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

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

15
1.0 Introduction
Our air handlers (AHUs) provide ducted heating and cooling, combining with other appliances to
satisfy most HVAC requirements. In addition, the AHU offers support for humidifiers and dehumidifiers
to prevent bacteria or mold. And for ease of use and operation, IBC delivers the AHU with pre-
programmed settings for each model. If customizing is required, HVAC professionals can download
the free IBCconnect app to program the air handler (see Operating the air handler using the
IBCconnect app on page 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 heating with a boiler or
combi boiler on page 37.
For setup instructions, see Wiring
single-stage heating with a tankless
water heater as a heat source on page
38.
For setup instructions, see Wiring
single-stage heating with boiler or
combi boiler, and single-stage cooling
on page 39.
For setup instructions, see Wiring two-
stage cooling with a boiler or combi
boiler heating using a 2-stage
thermostat on page 40.
For setup instructions, see Wiring
single-stage heat pump with a boiler or
combi boiler as backup on page 41.

For setup instructions, see Wiring
single-stage heat pump with a boiler or
combi boiler as backup (emergency
heat on T-stat) on page 43.
For setup instructions, see Wiring two-
stage heat pump with a boiler or combi
boiler as backup (2-stage thermostat)
on page 45.
For setup instructions, see Wiring two-
stage heat pump (2-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 two-
stage cooling with a tankless water
heater as a heat source on page 49.
For setup instructions, see Wiring
single-stage heat pump with a tankless
water heater as a backup on page 50.
For setup instructions, see Wiring two-
stage heat pump with a tankless water
heater as a backup on page 52.
16
Section: Introduction

For setup instructions, see Wiring
make-up air with a boiler or a combi as
a heat source on page 54.
The appliance provides up to four mounting options for flexibility and ease of installation. Return air
duct connections can be connected left, right, and bottom to suit the appliance'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 position to be modified. For
instructions, see Repositioning the air filter brackets on page 24.
1.1 Standard features and benefits
Integrated air handling appliance
High efficiency motor with variable speed (ECM) centrifugal fan
Quiet operation
17
1.1 Standard features and benefits

Slide out fan assembly
Flexible filter rack positioning
High efficiency fin tube coil
Multi-position configurations
Industry standard duct sizes – supply air opening compatible with cased and uncased A/C
and heat pump coils
Single stage or 2-stage heating and cooling, or 2-stage heat pump
Compact design for those awkward spaces; the ability to orient horizontally or vertically
Heat pump capable
Control for external pump (5A - 120V)
Flexible electrical connection knock-outs on left and right sides
Standard 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, return air, supply water, return water, humidifier, de-
humidifier, and Cold Air Sentry
Available options
Outdoor sensor IBC part # P-9067
AC Freeze sensor IBC part # P-1015
1.2 Conformity
Installation must conform to the requirements of the authority having jurisdiction. In the absence of
such requirements, the installation must conform to the National Electrical Code ANSI/NFPA No.
70, current edition.
The air handling appliance water circuit is certified to meet the NSF lead-free standard.
18
Section: Introduction