IBC AHU Series Installation & Operating Manual

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

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 2 Section: Contents

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

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

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

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 8 Section: Specifications

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 9 Cabinet and air supply dimensions

Figure 4 Bottom return air opening Figure 5 Left side return air opening Figure 6 Right side return air opening 10 Section: Specifications

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

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: Specifications

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

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 14 Section: Specifications

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. 15 Thermostat connections

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

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

responsibility ceases upon delivery of the air handling appliance to the carrier. Any claims for damage or shortage must be filed immediately against the carrier. No claims for variances or shortages will be allowed by the manufacturer. This section provides installation guidelines for the air handling appliance including locating the appliance, mounting positions, ducting, piping, and wiring. 2.1 Locating the appliance 2.1.1 Conditioned space Even though the air handling appliance operates quietly, try to locate the appliance to minimize noise transmission to conditioned spaces. Avoid locating the appliance next to bedrooms or other noise sensitive locations. If connecting a cooling system to the appliance, we recommend insulating the supply air ducting with a minimum of 1" thick fiberglass insulation with a vapor barrier. All insulated joints must be sealed 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 required to prevent freezing of the coil. Use a minimum of 25% to a maximum of 50% mixture of propylene glycol with water. Insulate the supply air and return air ducting with a minimum 2" thick fiberglass insulation with a vapor barrier. All insulated joints must be sealed with tape designed for this purpose. The appliance should also be insulated with a minimum 2" thick fiberglass insulation with a vapor barrier. 2.1.3 New construction The appliance is not designed to provide temporary heat during construction. If used, you must thoroughly clean the appliance (including the fan and coil) to remove all contaminates and install with a new air filter . If used for temporary heating during construction, the warranty may be void. 2.1.4 Mobile home The appliance can be installed in a mobile home. Appliances installed in a mobile or manufactured home must conform to the Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280 and/or CAN/CSA Z240 MH Series, Mobile Homes.

Figure 19 View from top of air handling appliance and duct in a closet Figure 20 Front view of air handling appliance in a closet with ducting on the left Orientation Clearance to Combustible Clearance for servicing Top 6" 6" D Left Side 0" 3" min. B Right Side 0" 3" min Bottom 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 is not suitable for outdoor installations. Danger Install the appliance at a minimum of 18" above the garage floor to prevent flammable vapors reaching the appliance. Failure to follow this directive could result in an explosion or electric shock, potentially causing serious personal injury and/or property damage. 20 Section: Installation

must be removed for access to the filter for replacement and access to the control board for wiring and setup. For more information on maintenance, see Service and maintenance on page 59. For wiring diagrams, see Electrical connections on page 32. 2.2 Positioning and mounting the appliance This section provides guidance on ways to orient and install 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 secured to the mounting system. The appliance offers four mounting options for supply air discharge: up, down, left, or right. For diagrams on the possible orientations including dimensions, see Cabinet and air supply dimensions on page 9. 2.2.1 Return air openings for ducting The appliance provides three options for return air opening: left or right side return air and bottom return air. Figure 21 Left return air opening Figure 22 Right return air opening 21 2.1.7 Serviceability

filter brackets. For instructions, see Repositioning the air filter brackets on page 24. 2.2.2 Positioning the air handling unit You can install the 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 installation Figure 26 : Right side installation 2.2.3 Adding air conditioning coils or heat pump coils Cased evaporator coils used for providing cold air can be positioned above or below the air handling appliance as shown below. 22 Section: Installation

mounted on top of the appliance - upflow 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. Figure 29 : Wall mounted air handling appliance 23 2.2.4 Mounting an appliance on the wall

All appliances are delivered with the filter positioned for an appliance installed with a left or bottom return air supply opening. If you install the appliance with a 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 the appliance, and set aside. 2. Slide out the filter. The filter brackets highlighted below will need to be repositioned. 3. Remove the two wing nuts securing the upper left bracket, and set them aside. 24 Section: Installation

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 brackets

Ducting design and installation should adhere to SMACNA and/or ASHRAE guidelines. Install the ducting system to NFPA 90B (latest edition). Adhere to the following: Size the supply air plenum duct fitting to the size of the appliance's supply air opening, and extend for 3' above the appliance. Size the supply and return air ducting according 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 excessive pressure drop on the system. 2.3.1 Sizing the ducts If using flex / insulated flex ducting, ensure that you allow for a higher pressure drop. Branch Duct - CFM at .25"wc external static pressure (galvanized duct) Round CFM range 3" 20-30 4" 30-35 5" 55-65 6" 90-100 7" 135-160 Table 5 Sizing round galvanized duct for CFM range 26 Section: Installation

Round Rectangular CFM range 8" 8 x 6 8 x 7 160-190 190-230 9" 8 x 8 230-275 10" 10 x 8 275-360 11" 12 x 8 360-460 12" 14 x 8 460-570 13" 16 x 8 570-650 13" 18 x 8 650-750 14" 20 x 8 750-850 14" 22 x 8 850-950 15" 24 x 8 950-1050 Table 6 Supply air trunk size CFM at galvanized duct .3"wc ESP for return and supply air 2.3.2 Ducting installed in conditioned space If a cooling system is connected to the appliance, we recommend insulating the 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-conditioned spaces Supply air and return air ducting should be insulated with a minimum 2" thick fiberglass insulation with a vapor barrier. All insulated joints must be sealed with a tape designed for this purpose. 2.3.4 Making the return air openings Both sides as well as the bottom of the appliance provide markings for the maximum return air opening. Use suitable metal cutters to perforate the marked area for the return air supply. Ensure that you cut within the marked area. 27 2.3.2 Ducting installed in conditioned space

2.4 Connecting the appliance to the boiler Generally it’s best to place the appliance as close as practical to the boiler. If placing the appliance away from the boiler, 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 ½" 16,000 BTU ¾" 36,000 BTU 1" 72,000 BTU 1¼" 110,000 BTU Table 7 Pipe sizing 2.4.1 Sizing pumps Note To size the pump, refer to the Installation manual of the boiler manufacturer for boiler head loss specifications. 28 Section: Installation

Fill station or glycol 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 coil head loss at 180°F (82°C) - AHU 800 29 2.4.1 Sizing pumps

Flow rate (gpm) 3 4 5 Fluid pressure drop (ft/water) 2.7 4.6 6.3 Table 9 Air handler coil head loss at 180°F (82°C) - AHU 1200 Air Handler Coil Head Loss - AHU 1600 Flow rate (gpm) 3 4 5 Fluid pressure drop (ft/water) 2.2 3.4 5.1 Table 10 Air handler coil head loss at 180°F (82°C) - AHU 1600 2.4.2 Using Propylene Glycol Using a propylene glycol / water mixture with the boiler/ air handling appliance reduces the heating capacity of the system by up to 10%, and increases the pump head required to circulate the heating fluid. Use a minimum of 25% to a maximum of 50% mixture. It is important to install the system with the correct pipe size to achieve optimum heating capacity 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 to a tankless water heater is allowed. The air handling appliance must be installed in close proximity to a tankless water heater. As a guideline, we recommend a maximum distance of 10 feet between the appliance and the tankless water heater using ¾" copper piping. The table below provides pipe sizing specifications for IBC's tankless water heater. Refer to other manufacturers' manuals for correct sizing of pipes. Note For pipe sizing, refer to the Installation manual of the water heater manufacturer for boiler head loss specifications. Tankless Water Heater Head Loss - Superflow SFT 199 Flow rate (gpm) 3 4 5 Head loss @ flow (ft) 14 23 33 Table 11 Tankless water heater head loss: SFT 199 30 Section: Installation

by local code. Non-ferrous pump (sized for combined head loss of boiler/water heater, air handler - interconnecting piping) Check valve (may be built into pump) Potable water expansion tank Filter required 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 enough to meet the heating requirements of the space being heated. If piped correctly, DHW takes priority over space heating. When the appliance detects reduced water temperature (that is, a call for DHW), the system will reduce the fan speed. 31 2.5 Connecting the appliance to a tankless water heater

All electrical wiring to the boiler (including grounding) must conform to local electrical codes and/or the National Electrical Code, 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 connections such as the thermostat, accessories, heat pump, and external pump. Figure 33 Air handling appliance - electrical wiring diagram 32 Section: Installation

You will need to use a 3 mm flat-bladed screwdriver to wire the external pump and the 120VAC line. Insert a wire into the connector (at the front of the block). Inserting a screwdriver into the connector releases the wire. Figure 34 : Inserting a wire for 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 Pump – maximum 4 Amps 120 Volts, thermostat connections – Standard TH or OpenTherm (communications thermostat protocol), external pump control, boiler connection for a call for heat, and connection to an AC or HP appliance (air handling appliance side only). 33 2.6.1 Wiring of the external pump and 120VAC line

jumper between W1 and W2 will initialize this speed without the time delay. Figure 36 Single-stage heating, on-demand heat source 34 Section: Installation

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 Connecting line voltage - examples for different scenarios

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-demand heat source 36 Section: Installation

jumper 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 control, on-demand heat source backup 37 2.6.2 Connecting line voltage - examples for different scenarios

Dry contact from air handler to boiler / enables call for heating Figure 40 Single-stage heating from boiler, primary/secondary piping 38 Section: Installation

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 - examples for different scenarios

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: Installation

Dry contact from air handler to boiler / enables call for heat. Timer must close TT 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 Single-stage heat pump with boiler backup - primary/secondary piping 41 2.6.2 Connecting line voltage - examples for different scenarios

Dry contact from air handler to boiler / 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 with boiler backup, primary/secondary piping (2-stage thermostat) 42 Section: Installation

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 line voltage - examples for different scenarios

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 thermostat) 44 Section: Installation

following guidelines: Checklists for electrical conditions, ducting and water connections Default settings Default fan speed settings Sequence of operation LED status indicators. Operating the appliance with a mobile app Using the app to view the appliance's settings 3.1 Checklist for electrical conditions, ducting and water connections Checking electrical conditions Check Ensure the power supply to the air handling appliance is 120V 15A circuit. The appliance is not designed to work with 208-240V. If connected to 208-240V, electrical damage will result, and 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 suitable location. □ Checking supply and return water piping connections Check All connections are pressure tested and leak-free. □ All piping flushed to ensure all air is removed. □ Check valve is installed and the external pump is flowing in the correct direction. □ Boiler / water heater is installed as per the manufacturer's instructions and is safe to operate. □ Checking ducting connections Check All connections are pressure tested and leak-free. □ All duct work is sized correctly and joints are sealed. □ All supply air dampers and registers are opened. □ Duct insulation is installed and sealed as required. □ Inspect the filter, return air ducting and registers to ensure free air movement. □

Check Ensure the water temperature to the heating coil is sufficient to meet the heating demands of the space. □ 3.2 Default settings The following table shows the factory-default settings. Default - Basic Settings Heating Mode 1 stage Cooling Mode 2 stage Boiler Heating 1 stage and 2 stage Temperature °F Pump Enable On Tankless Mode Off 3.3 Default fan speed settings 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 Cooling stage 1 = 700 CFM Range 300 – 800 Y2 Cooling stage 2 = 1000 CFM Range 300-1000 (must be ≥ than cooling stage 1) G Fan on speed = 400 CFM Range 150-1000 Note For safety reasons, a switch is built into the door. The switch prevents the fan from operating if the door is not installed. With the door removed, the appliance's control board will remain powered, enabling programming of the mobile app. 46 Section: Operation

3.4.1 Heating Mode Upon a call for heat from the thermostat: R to W1 or W2 is energized. The External Pump relay is closed, energizing the external pump if connected (required when connecting the air handling appliance to a tankless water heater or SL series boiler). The TT (boiler on Heat 1) contacts close creating a call for heat at the boiler. The fan is energized and: Operates at W1 or W2 speed. Fan speed ramps up to the maximum value of its W1 range value or W2 range value. When a demand for heat is satisfied, the system: Opens TT (or 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: R to Y1 or Y2 is energized The fan is energized and: Operates at Y1 or Y2 speed. Energizes the O/B terminal if there is a heat pump. When cooling demand is satisfied, the air handling appliance: Opens the compressor S1 and /or S2 contacts, and de-energizes O/B if there is a heat pump. The fan continues to operate for 45 seconds. 3.4.3 Heat Pump Mode Upon a call for heat from a heat pump: R to Y1 or Y2 is energized. R to O/B remains de-energized. The fan is energized and: Operates at Y1 or Y2 speed. Operates a low speed for 60 seconds. 47 3.4 Sequence of operation

The air handling appliance opens the compressor S1 and /or S2 contacts. The fan continues to operate for 45 seconds. 3.4.4 Humidification Mode Upon a call for humidification from the thermostat: G to W is energized. The humidifier's contacts (24V output) will close. 3.4.5 De-humidification Mode Upon a call for de-humidification from the thermostat: G to W or Y is energized. The de-humidifier's contacts (24V output) will close. 3.4.6 Freeze Protection 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 handling appliance will energize the fan, the pump contacts, and the TT (boiler) contacts to create a call for heat. When the return air temperature increases to 46°F or more the air handling appliance will turn off the fan, TT (boiler) contacts, and pump contacts. If the internal return air temperature sensor detects a return air temperature below 35°F, the air handling appliance will turn off the fan, and continue to energize TT (boiler) contacts and pump contacts. 48 Section: Operation

The appliance displays four LED indicators, each representing an operating status. POWER (Green background) FAULT (Red background) HEAT (Green background) COOL(Green background) State LED(s) Description Standby FAULT HEAT COOL Each LED blinks on and off in a “chasing” sequence. Heating HEAT LED displays a steady state. Cooling COOL LED displays a steady state. Fan only (G) HEAT COOL Short synchronized flashing. Warning FAULT LED flashes on. The appliance will continue to operate; however, certain operations may not function correctly. Fault FAULT 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 enables you to obtain information on settings, faults, and errors. To view diagnostics: 1. Insert a USB stick into the controller, wait approximately 10 seconds, and then remove the USB stick. The controller generates a text file that contains all the settings and any faults or warnings that are present on the appliance. 2. To view the text file, insert the USB stick into any computer, and open the generated text file with “Wordpad” or a similar program. The file name will be: “AHUxxxxx.TXT”, where “xxxxx” is the serial number of the controller. 49 3.5 LED status indicators

All air handlers come configured with default factory settings. IBC's free mobile app "IBCconnect" (Android or iOS app) enables users to monitor and adjust default settings in a single air handling appliance. This app is compatible only with Android and iOS devices and with the IBC air handler. Note Alternatively, it's possible to change settings using a USB stick with a custom configuration text file. Using a USB with a custom text file is the best approach for configuring multiple air handlers that will use the same settings (see Configuring settings and parameters via a USB text file on page 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 handling unit with the app. 3.6.1 Loading IBCconnect Loading the app will depend on whether you are using an Android or Apple iPhone device. 3.6.1.1 Loading IBCconnect from the Android Google Play Store 1. In the Google Play Store search box, enter IBC Technologies (case sensitive). 2. Select the icon, and tap Install. To verify that the app has loaded, see the icon in the list with existing apps. For next steps, see Using the app to connect to IBC's AHU WiFi on page 51. 3.6.1.2 Loading IBCconnect from the iOS Apple Store 1. In the iOs Apple Store search box, enter IBC Technologies (case sensitive). 2. Select the icon, and tap Install. 50 Section: Operation

vary slightly depending on the device and the version of iOS your device is using. 3. In the main iPhone Settings, select Cellular. 4. Locate IBCconnect under Cellular Data, and set to Off. Optionally, in the main iPhone settings, select IBCconnect app, and then go to Siri & Search and set Search & Siri Suggestions to Off. See the next section for WiFi connection. 3.6.2 Using the app to connect to IBC's AHU WiFi Once you've loaded the IBCconnect app onto your mobile or tablet, you will need to establish a connection between 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 IBC's air handler. This is done through the app's WiFi network settings. 3.6.2.1 Connecting an Android device The following instructions may vary slightly depending on the device being used. 1. Open the IBCconnect app. The WiFi connection of the device is displayed. If the WiFi connection is not IBC-AHU, a WiFi SETTINGS button is displayed. Tap the WiFi SETTINGS button. The WiFi network screen appears. The IBC-AHU will appear in the device’s list of WiFi available networks as "IBC-AHU-xxxxx", where "xxxxx" is the serial number of the controller in the IBC- AHU. 51 3.6.2 Using the app to connect to IBC's AHU WiFi

be the controller you want to connect to. 2. Select IBC-AHU-xxxxx. 3. The first time you connect, enter 1234567890 when prompted for a password. Depending on the version of Android your device has, after a few seconds you may see a warning, as shown below. With the AHU cover off, the LEDs on the 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 Home page to start adjusting settings. 3.6.2.2 Connecting an iOs device The IBCconnect app requires an IBC-AHU WiFi connection. You need to change some app settings after installation. 1. In the main iPhone settings, select Cellular. 2. Scroll down to IBCconnect (under Cellular Data), and set to Off. 3. Navigate to the device’s WiFi Settings. 4. Connect to the IBC-AHU WiFi. 52 Section: Operation

“xxxxx” is the serial number of the controller in the IBC-AHU. If there are multiple IBC-AHU’s in the area, the appliance with the strongest signal will likely be the controller you want to connect to. 5. Select IBC-AHU-xxxxx. 6. The first time you connect, enter 1234567890 when prompted for a password. With the AHU cover off, the LEDs on the circuit board will start blinking simultaneously 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 display the landing page. The landing page that appears after starting IBCconnect will depend on the device and whether you have connected to IBC's AHU WiFi. 3.6.3 Programming the air handling unit using the app The IBC factory pre-programs the name of the model (AHU 800, AHU 1200 or AHU 1600) in the appliance. However, you will need to use the app to set the heating and cooling mode and to change default settings. 53 3.6.3 Programming the air handling unit using the app

1. Tap (menu 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 applications for optimal performance. 54 Section: Operation

(SAVE). 5. To check the model and mode, go to (menu) and select About. 3.6.4 Using the app to view the AHU's information Once the device 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 Do not check the "Don’t ask again for this network” if prompted; the device will likely default to “NO” for staying connected if this is selected. 55 3.6.4 Using the app to view the AHU's information

WiFi SETTINGS button, and choose the required AHU WiFi connection. To return to the 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. The AHU app Status screen is displayed showing the air handler's factory default settings. You can navigate to the Home page, and begin adjusting settings. 56 Section: Operation

If the IBCconnect app is unable to maintain a connection to the IBC AHU WiFi, the IBCConnect app footer will show an "X" icon above WiFi. It is likely the device is attempting to perform uploads in the background. To prevent cell phone data and WiFi conflict: 1. Remove the IBC AHU WiFi connection from the device. 2. Go to the device’s WiFi Setting. 3. Press and hold the IBC-AHU-xxxxx entry. 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 option is disabled. 7. Start the IBCconnect app again. 3.7 Configuring settings and parameters via a USB text file You can change and customize the default settings in one or more air handlers via a single .config ASCII text file labeled "ahusetup.cfg". The custom text file can be placed on a USB stick and inserted into each air handling appliance. To obtain a custom text file, contact IBC. 57 3.7 Configuring settings and parameters via a USB text file

The IBC air handling appliance is designed for durability and easy access to the main components: control board, fan assembly, hot water coil assembly, and filter. Over time, components such as sensors may require replacing and servicing. Note that failure to use the correct procedures or parts could result in unsafe operation. 4.1 Maintenance checklist for owners Owners should arrange follow-up inspections 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 system for unusual noises. Call your local heating contractor for service if needed Monthly □ Have your local heating contractor inspect the system annually. This service should include the heat appliance connected to the Air Handling appliance. Annually □ 4.2 Maintenance for the heating contractor 4.2.1 Removing the fan assembly 1. Remove the two screws from the front cover, and set aside. 2. Remove the two bolts from the fan assembly plate.

control board. 4. Detach the cable and grommet. 5. Slide out the fan assembly. Note When you 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 assembly. Reinsert the split fan grommet correctly. See images below. Note large and small holes. 60 Section: Service and maintenance

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 4.2.2 Replacing the hot water coil appliance

After you replace the control board in the appliance, you will need to program some settings using the IBCconnect app. To replace the control board: 1. Unplug all the connectors from the control board. 2. Remove the four screws securing the control board to the appliance, and set them aside for the replacement board. In the next step, you will separate the humidity sensor strip from the main replacement control board using 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 force. Figure 49 Separating the humidity sensor strip from the main replacement board 4. Secure the replacement board in place with the four screws. 5. Insert the humidity sensor strip into the side slit of the black insulation foam, until the 5 pins engage in the board's 5-pin connector (see below), and secure the strip with a plastic zip tie. Figure 50 Inserting the humidity sensor strip and securing with a cable tie 62 Section: Service and maintenance

for fan power, connector for fan control, connector to the 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 settings: a. Open the IBCconnect app on your phone. b. Go to Configure AHU. c. From the AHU Model dropdown, select the model. 63 4.3 Replacing the control board

e. Close the app, and then open it again. For information on setting the cooling and heating mode and other settings, see Programming the air handling unit using the app on page 53. 4.4 Temperature sensors The resistance of the temperature sensors varies inversely with temperature. You need to measure 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 kΩ at the controller end of the sensor lead). To obtain a resistance reading, remove power to the boiler. Remove the wire leads by disconnecting their respective Molex connectors from the sensor(s) in question. Place multi-meter probes into the sensor’s female Molex connector socket. Do not apply voltage to the sensor - damage may result. 64 Section: Service and maintenance

Temp. °F/°C Resist. Ω – Ohm 0 / -18 85,362 100 / 38 5,828 5 / -15 72,918 105 / 41 5,210 10 / -12 62,465 110 / 43 4,665 15 / -9 53,658 115 / 46 4,184 20 / -7 42,218 120 / 49 3,760 25 / -4 39,913 125 / 52 3,383 30 / -1 34,558 130 / 54 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 11,883 170 / 77 1,403 75 / 24 10,501 175 / 79 1,281 80 / 27 9,299 180 / 82 1,172 85 / 29 8,250 185 / 85 1,073 90 / 35 7,334 190 / 88 983 95 / 35 6,532 195 / 91 903 Table 13 10K Ω Temperature sensor resistance values 65 4.4 Temperature sensors

faults that may appear on the air handling appliance app. A problem that does not prevent the operation of the air handler is declared as a "warning". A problem that prevents the appliance from operating is declared as an "error" and the appliance is shut down. 5.1 Measuring voltage on AHU boards The control voltage transformer is not bonded to the AHU cabinet. When measuring the voltage supplied to the individual control circuit, you must reference the common post of the circuit. If you measure to ground or to another common terminal, misleading readings of approximately 14V will occur. To test for nominal 24V, reference the adjacent COM connection. For example, to test voltage at Compressor S1 terminal, measure for VAC between Compressor COM and Compressor S1. 5.2 Pump not energized If the pump is not energizing: In the IBCconnect 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, the AHU pump is not energized by design, to avoid interfering with circulation through the heat pump. AHU pump is energized at Stage 2 call for heat. Check the AHU board for blown pump fuse—the only fuse rated for 10A. 5.3 Fault Codes Fault Code/Error Message Description Possible Fix Inlet Temperature Sensor Sensor not connected or faulty. Check the sensor. For resistance reading, see Table 13. Outlet Temperature Sensor Sensor not connected or faulty. Check the sensor. For resistance reading, see Table 13. Aux Air In Temperature Sensor Sensor not connected or faulty. Check the sensor. For resistance reading, see Table 13. Air Out Temperature Sensor Sensor not connected or faulty. Check the sensor. For resistance reading, see Table 13. Cool Air Temperature Sensor Sensor not connected or faulty. Check the sensor. For resistance reading, see Table 13. A/C Temperature Sensor Sensor not connected or faulty. Check the sensor. For resistance reading, see Table 13.

Description Possible Fix Dehumidifier Temperature Sensor Sensor not connected or faulty. Check the sensor. For resistance reading, see Table 13. Outdoor Temperature Sensor Sensor not connected or faulty. Check the sensor. For resistance reading, see Table 13. Air In Temp Sensor (Probe) Sensor not connected or faulty. Check the sensor. For resistance reading, see Table 13. Barometer Probe not connected or device is faulty. Check the probe. Humidistat Probe not connected or device is faulty. Check the probe. Door Open / No Fan Signal Service door is open or fan fault. Check door or if door switch is faulty. Check if harness is disconnected. Check if fan is turning. No Fan RPM No rotation of the fan is detected. Check if fan is turning or disconnected. Check the 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 detected in the A/C coil. The coil needs to defrost. Refer to the manual for the air conditioner for details on how to prevent freezing. Dehumidifier Freeze Freezing detected in the dehumidifier appliance. The coil needs to defrost. Refer to the manual for the dehumidifier for details on how to prevent freezing. Thermostat Fault Simultaneous heating and cooling calls detected Check that the heating lead has not been crossed with the cooling lead from the Nest thermostat. There is also a known bug related to some thermostat models that are over 3 years old: the backing plate allows a short to signal a call for cooling. RTOS Fault 1 Software fault Contact IBC Technical Support for software upgrade. 68 Section: Find troubleshooting for IBC Technologies' air handling appliances.

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 Troubleshooting

70 Section: Find troubleshooting for IBC Technologies' air handling appliances.

P- 1019 Door assembly - AHU 1200 P-1022 Door assembly - AHU 1600 110 P-1001 Air filter size 25 x 16 x 1 - AHU 800 Air filter size 25 x 20 x 1 - AHU 1200, - AHU 1200 120 P-1008 Door switch, SPST-NO. 15A 125V 120 Wiring harness 130 P-1011 Supply water temperature sensor 140 P-1012 Temperature sensor and grommet 150 P-1011 Return water temperature sensor 160 P-1003 Hot water coil 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 bracket wing nuts x 4 200 Air filter lower bracket 210 Air filter upper bracket 220 P-1017 Coil hex bolts, hex nut, washer x 2 Fan plate hex bolts, washer x 2 230 P-1004 P-1021 P- 1024 Fan and motor assembly - AHU 800 Fan and motor assembly - AHU 1200 Fan and motor assembly - AHU 1600 240 Fan wiring grommet 250 P-1009 Sensor wiring harness 260 P-1017 Door thumb screws x 2 * P-1017 = Part of the hardware kit 71 Air handling appliance - parts diagram

R1 (July 2019) Updated wiring diagrams and made 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 default settings and other minor changes. R4 (May) Introduction of the AHU 1200 and AHU 1600 models

USA IBC Technologies USA Inc A 8015 North Fraser Way A 1702 Taylor’s Lane Burnaby, BC Canada V5J 5M8 Cinnaminson NJ 08077 USA T 604-877-0277 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 responsibility for changes made to the manual due to clerical errors, to regulation changes, or to product development. March, 2021 | 120-324E-R4 ©IBC Technologies Inc. 2021