IBC AHU Series Installation instructions

INSTALLATION &
OPERATING MANUAL
Air Handling appliances
AHU 800
AHU1200
AHU 1600

1
Contents
Safety information 5
Specifications 7
Heating capacity 8
Cabinet and air supply dimensions 9
Dimensions for the AHU 800 model 9
Dimensions for the AHU 1200 model 11
Dimensions for the AHU 1600 model 12
Thermostat connections 14
1.0 Introduction 17
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 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 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 the boiler 28
2.4.1 Sizing pumps 28

2.4.2 Using Propylene Glycol 30
2.5 Connecting the appliance to a tankless water heater 30
2.6 Electrical connections 32
2.6.1 Wiring of the external pump and 120VAC line 33
2.6.2 Connecting line voltage - examples for different scenarios 33
3.0 Operation 45
3.1 Checklist for electrical conditions, ducting and water connections 45
3.2 Default settings 46
3.3 Default fan speed settings 46
3.4 Sequence of operation 47
3.4.1 Heating Mode 47
3.4.2 Cooling Mode 47
3.4.3 Heat Pump Mode 47
3.4.4 Humidification Mode 48
3.4.5 De-humidification Mode 48
3.4.6 Freeze 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 AHU WiFi 51
3.6.3 Programming the air handling unit using the app 53
3.6.4 Using the app to view the AHU's information 55
3.7 Configuring settings and parameters via a USB text file 57
4.0 Service and maintenance 59
4.1 Maintenance checklist for owners 59
4.2 Maintenance for the heating contractor 59
4.2.1 Removing the fan assembly 59
4.2.2 Replacing the hot water coil appliance 61
4.3 Replacing the control board 62
4.4 Temperature sensors 64
5.0 Troubleshooting 67
5.1 Measuring voltage on AHU boards 67
5.2 Pump not energized 67
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Section: Contents

5.3 Fault Codes 67
Air handling appliance - parts diagram 70
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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.
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Section: Safety information

Specifications
Specification AHU 800 AHU 1200 AHU 1600
Max. water temperature (°F/C°) 195 / 90
Coil performance at 180°F (Btu/hr) 66,800 80,600 99,300
Water pipe connections (inches) ¾ MPT
External static pressure (" wc) 0.50
Max. operating water pressure (PSI) 150
Width (inches) 17.5 21 24.5
Depth (inches) 26
Height (inches) 32 38 42
Supply air opening width (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
Bottom return air opening depth
(inches)
23
Max. internal current power rating
120Volts (Amp)
2.4
External pump supply 120V (Amp) 5
Voltage (V) 120
Max. air flow @ rated static pressure
(CFM)
1138 1334 2900
Maximum return air temperature (°F/C°) 122 / 50
Filter size (MERV 8) (inches) 16 x 25 x 1 25 x 20 x 1 (not
included)
25 x 20 x 1 (not
included)
7
Specifications

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 MBH
180°F (82°C) 60 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 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 (cubic feet / minute) - AHU 800
AHU 1200 - 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 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 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 MBH
110°F (43°C) 25.3 MBH 27.4 MBH 28.7 MBH
Table 2 Heating Capacity rating at 1200 scfm (cubic feet / minute) - AHU 1200
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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 MBH 84.8 MBH 90 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 MBH 33.2 MBH 35.3 MBH
Table 3 Heating Capacity rating at 1600 scfm (cubic feet / minute) - AHU 1600
Cabinet and air supply dimensions
Dimensions for the AHU 800 model
Figure 1 Supply and return air, boiler supply and return Figure 2 Frontal view
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Cabinet and air supply dimensions

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

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
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Dimensions for the AHU 1200 model

Figure 11 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
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Section: Specifications

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

Thermostat connections
Three types of thermostats are compatible with the appliance: conventional, power stealing, and
OpenTherm.
Low Voltage Terminal Description Notes
R 24V power Power to the low voltage
thermostat.
W1 Heating Stage 1 Thermostat connects R to
W1 for first stage heating.
Note: A jumper between W1
and W2 will initiate W2
speed.
W2 Heating 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 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.
T-T Dry Contacts
Boiler call for heat.
Auxiliary
Com
S1 O/B Reversing valve Connects to outdoor
appliance on heat pump.
Note: Energized for cooling.
S2 Not used
Compressor
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Section: Specifications

Low Voltage Terminal Description Notes
Com Connects to outdoor
appliance.
S1 Compressor Stage 1 Connects to outdoor
appliance.
S2 Compressor Stage 2 Connects to outdoor
appliance (2nd Stage if
applicable).
Humidifier
Com Humidifier 24VAC powered
Closes to activate the
humidifier.
HUM Humidifier
De-humidifer
Com De-humidifier 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) the boiler
(subordinate).
OpenTherm Slave From OpenTherm thermostat The thermostat (master)
controls the air handling
appliance (subordinate).
Note
OpenTherm is a standard communications protocol used in central heating systems for the
communication between a central heating device and thermostat.
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Thermostat connections

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17
1.0 Introduction
The IBC air handling appliance is designed for ducted heating and cooling. 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 9.
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
Slide out fan assembly
Optional 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
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
OpenTherm 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, de-
humidifier, and frost protection
Not included - (optional)outdoor sensor (IBC Part # 240-025), air conditioning coil
supply, air sensor kit
Maximum return air temperature 122°F (50°C)
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.
18
Section: Introduction