IFlow IFLH-140000 Bedienungsanleitung

iNTELLIGENT SMART IoT TECHNOLOGIES

iFLOW HYDRONIC AIR HANDLER

NEW GENERATION OF HEATING & COOLING

iFLOW MANUAL A2

www.iflowhvac.com

iFLOW HVAC INC.

iFLOW HVAC INC. www.iflowhvac.com

Table of Contents

Introduction

Safety ………………………………………………………………………………………………………….… 2

Summary of air handler ………………………..………………………………………………………………. 2

Technician checklist ……………………………………………………………………………………………. 2

Product Description

Components ………………………………………………………………...…………………………………3

Standard features and benefits ………………………………………………………………………….…..4

Equipment selection and sizing ………………………………………………………………………….….. 5

Suitable Applications (Choosing the correct heat source) ………………………………………………… 5

Installation

Location requirements and clearances ………………………………………………………….…….. 8

Dimensions …………………………………………………………………………………………….……. 8

Installation examples ………………………………………………………………………………………… 9

Boiler Piping …………………………………………………………………………………………………… 9

Domestic Piping ………………………………………………………………………………………….…. 9

Electrical requirements and making connections ………………………………………………………. 10

Temperature sensors ………………………………………………………………………………………… 10

A/C Evaporator Coil Freeze Protection and the Importance of Wiring the A/C Compressor to

the Proper and Dedicated A/C Connector on the iFLOW PCB.…………………………......................... 11

Start-Up

Procedure ……………………………………………………………………………………………………. 13

Flushing the heat exchanger ……………………………………………………………………………….. 13

Sequence of operation………………………………………………………………………………………… 13

Service and Maintenance

Maintenance ………………………………………………………………………………………………...... 17

Checking temperature sensors …………………………………………………………………………….. 17

Wiring Diagram ………………………………………………………………………………………………. 18

A2 Field Wiring ……………………………………………………………………………………………… 19

iFLOW Set up and Wiring of an iFLOW with a Heat Pump ……………………………………………… 20

Troubleshooting

Fault Codes and Explanations ……………………………………………………………………………… 23

Problems and Solutions ……………………………………………………………..………………………. 24

Component Assembly Diagram and Parts Lists……………………………………………………… 25

Commonwealth Of Massachusetts Board Policy ......................................................... 34

Warranty

Warranty Information………………………………………………………………………………………… 35

Contact Information …………………………………………………………………………………………… 35

iFLOW HVAC INC. www.iflowhvac.com

WARNING

This Air Handler Unit (AHU) is not intended for installation in a

unconditioned space where the potential may exist for the water

and/or drain lines to freeze.

1. Introduction Safety

Ensure the instructions and requirements provided in this manual are

read and understood before installation. Failure to comply with these

instructions can cause product and property damage, serious injury

or death.

Pay attention to the following safety symbols and words:

DANGER

Indicates an imminently hazardous situation, which if not

avoided, will result in death or serious injury.

WARNING

This product can expose you to chemicals including lead,

lead compounds, and carbon bisulfide which are known to the

State of California to cause cancer and birth defects or other

reproductive harm. For more information, go to

www.P65Warnings.ca.gov.

CAUTION

Indicated a potentially hazardous situation, which if not

avoided, may result in minor or moderate injury. It is also used

to alert against unsafe practices and hazards involving property

damage.

• Be sure to bleed all air from all system components and piping prior

to start-up.

• It is recommended to install purge valves between the air handler

and water heater’s isolation valves.

• If connected to domestic piping creating an open system, make

sure all piping, components, and solder are lead-free and approved

for potable-use.

CAUTION

Return air openning shall not be installed

on the back side of unit.

IMPORTANT

The maximum ambient temperature must

not exceed 122℉ (50℃)

• Ensure fan assembly is clear of any obstruction

• Check that air filter is installed upstream of air conditioning coil.

• If the appliance is installed with air conditioning,the A/C refrigerant

charge and system operation must be verified by a certified/ licensed

mechanic prior to commissioning.

2. Summary of air handler

The iFLOW hydronic air handlers are designed to deliver the highest

performance rating of any air handler regardless of the hot water

source. This unique hydronic furnace is built for use in residential and

commercial applications.

CAUTION

The air handler must be installed such that electrical components

are away from water (spraying, splashing, etc.) during operation and

service.

IMPORTANT

A field fabricated auxiliary drain pan with a drain pipe connection is

recommended in all configurations.

Introduction

3. Installer’s checklist

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Water Outlet Temp.

Cabinet:

All cabinets are made of high quality, and durable heavy gauge

galvanized steel. The inside of the cabinet is fully insulated with ½”

polyethylene sheets. This prevents moisture and mold growth, as well

as unwanted heat loss due to an R-Value. The smaller cabinet size

and shape is designed to maximize installation flexibility.

Heating Coils:

All iFLOW heating coils are constructed of potable, water-grade

copper for use in plumbing systems. Lead-Free solder has been used

for assembly on all components. All coils and internal piping conform

to ASTM B-68, ASTM B-88 and/or B-743 standards. Carefully

engineered, high-density aluminium fins allow for maximum heat

transfer across smaller coils. This provides warmer, more comfortable

heating with lower air flow for minimal operating noise.

Fan Motor:

All iFLOW air handlers are equipped with variable speed ECM

motors. This allows for separate heating, cooling, and continuous run

speeds. They reduce electrical-use and are dynamically balanced

for extra quiet operation. Blowers are mounted with four screws on

rails for easy removal and service. Multi-directional motors allow for

mounting in any direction.

Circulating Pump:

All air handlers require a field supplied single speed or 3-speed pump,

to be controlled by the iFLOW circulator control. This the speed of the

pump increases or decreases depending on the information provided

by the temperature sensors. The pump also provides maximum

performance when used in conjunction with an instantaneous water

heater or a storage-type water heater.

Check Valve:

A spring-loaded check valve must be installed either with the field-

supplied pump or externally to prevent the by passing of water to the

appliance.

Multi-Function Control Board:

This intelligent control board comes factory installed. No dip

switches are required or included with the iFLOW control board.

Easy programming allows for user-friendly startup and service/

maintenance. Some of the parameters the user is able to configure

are: heating output, CFM for heating, cooling and continuous low-

speed fan, outdoor design temperature and circulating pump speed.

Product Description

Water Inlet Temp.

Supply Air Temp. Sensor

Supply Water Temp. Sensor

Transformer AC24V

Blower Assembly Bracket

Main Control

Blower Assemble

Dehumidifier Eva. Temp. Sensor

(Option)

Humidity Sensor

A/C Evap. Air Temp. Sensor

Heat Exchanger Ass'y

(Hydronic Coil)

Return Water Temp. Sensor

Power Terminal

Return Air Temp. Sensor

Blower Motor

Motor Power Cable

Motor Control Cable

iFLOW HVAC INC. www.iflowhvac.com

2) Standard Features and Benefits:

• Highest performance at 98% efficiency (CAN/CAS P.9-11

Performance Ratings: TPF 0.98)

• Ultra-efficient heat-exchanger design with high-density aluminum

fins

• Offers installation flexibility allowing for up-flow, down-flow or

horizontal applications

• Cost effective and extremely quiet variable speed ECM fan motor /

constant CFM

• Slide-out blower rail assembly for easy maintenance & removal with

4 screws

• 6 fully modulating models: 3 ‘standard duct’ models (S, M, L) & 3

high-static pressure models (S, M, L)

• Easy installation: Lightweight, “one-man job” with Optional EZEE

Plumbing Kit

• Approved for potable water (‘open’) systems with buit-in anti-

stagnation and DHW priority included in the control board

• Air and water supply and return temperature sensors included

• Humidity sensor included for cooling fan speed modulation

• Freeze Protection/ Evaporator Temperature Sensor

• Outdoor temperture sensor included

• Intelligent iFLOW control board

• All models are compatible with mercury or digital thermostats

• Supports the use of two stage and inverter-driven variable speed

cooling equipment

• Accessories are controlled by AC24V power

• LED light indicates alarm, test mode and normal operation

• Auxiliary contacts (dry contact) for boiler or water heater activation

• Bottom or left or right side return air supply

• 0” clearance to combustibles

• Cabinet lined with 1/2” Polyethylene High-Density Insulation

• Cabinet manufactured with heavy gauge galvanized steel and

powder-coated to prevent corrosion

iNTELLIGENT PUMP CONTROL:

• Pump modulation control

• Low flow pump exercise function (Water Circulation / Seize

Protection)

• Low ambient freeze protection

iNTELLIGENT CONTROL:

• Boiler demand control

• Installer & user-friendly interface

• Informative display: error code, temperture, humidity, fan & pump

speed

• Easily configure all parameters smartphone App.

• 22 segment LED indicator / all input & output signals: built-in

programmable and diagnostic control display

• Outdoor reset function / outdoor temperature sensor

• Full modulation a single or two stage settings for heating & cooling

• Humidity control / humidity sensor

• ΔT auto-adjustment air and water (air and water flow control)

• Fan "ON" delay & Fan "OFF" heat purge control

• DHW priority & dual mode (heating and DHW)

• High & low limit safety control: air temperature sensor

• Home freeze protection: low ambient temperature sensor

• Evaporator freeze protection: compressor protection

• Virtual termostat mode with the smartphone app

• Smart zoning control (saving gas & hydro)

• Maximize heat pump performance / (AVOID) Peak Time AVOID

Electricity Function

• Hybrid heating system switching control and backup with heat pump

• Communication with NAVIEN Tankless Water Heater

OPTIONS:

• Multi-system central control for building HVAC systems

• Wi-Fi connection with a smartphone (Free app available on iOS and

Android)

• Remotely adjust and monitor operation through web integrated plug-

in control, or directly via a smartphone connection

• All-in-one package (EZEE plumbing kit and stand) for easy

Installation: iFLOW AHU with any TLWH/TWH

Freeze Protection:

iFLOW Air handlers include a freeze protection sensor that will

temporarily disable the outdoor condenser for 5 minutes if the

evaporator coil outlet temperature drops below 40°F/4°C. This will

allow the system to warm up and return back to normal operating

conditions.

To protect the hydronic heating coil from freezing, the pump will

operate for a minimum of 30 seconds. Dirty air filters, oversizing of A/

C equipment, improper A/C installation or poor duct design will also

play a role in the evaporator coil freezing.

Water Circulation / Pump Exercise:

In section 4.2.5.1 Prevention of Stagnation of the 'CAN/CSA-B214-12

Installation Code for Hydronic Heating Systems', it states: "a means

shall be provided to prevent the stagnation of potable water in a

hydronic system by recycling or flushing the contents not less than

once every 24 hours."

The iFLOW controller is defaultset to turn on the circulating pump to

cycle the total volume of potable water in the system, once every 24

hours. This will prevent stagnation and protect the pump from seizing.

There is a test button to verify that this operation is working. The

setting can be adjusted to circulate more frequently if desired.

Alarms:

In the event of a service problem (i.e. temperature sensor failure, low

ambient temperature, cooling lockout, etc.), the iFLOW air handler

will notify the user/owner with an audible alarm and red light. The

alarm on the control board can be silenced by turning the power off

for 5 seconds and then back on.

iFLOW HVAC INC. www.iflowhvac.com

Set Back Recovery:

If a programmable thermostat with setback is used or a sudden

increase in temperature is required, the iFLOW intelligent control

board will modulate the air handler to its maximum output to speed

temperature delivery. The next cycle will return to normal operation.

See "Heat Boost Delay" Parameter.

Test Mode:

Entering ‘test mode’ on the controller will allow the technician to test

the iFLOW air handler heating and cooling mode parameters. Once

completed, push the test button again to return to normal operation.

Heating:

The iFLOW air handler will automatically change the fan and pump

speeds to control the temperature output of the unit and cycle-time

length. This will allow the heat output of the air handler to match the

current heat loss of the home. Maximum ‘matching’ performance is

achieved when used in conjunction with the outdoor sensor. This

leads to a longer runtime, providing superior warmth and comfort.

Cooling/Dehumidifying:

The iFLOW air handler uses a modulating blower fan to regulate

humidity levels. The blower fan speed decreases in high humidity

to remove moisture quicker. The blower fan speed increases under

normal conditions to provide optimal cooling. The balance of the two

is always met. Optimal humidity levels result in increased comfort

for the homeowner, and at the same time reduces cooling loads and

operating costs.

3. Equipment selection and sizing

iFLOW air handlers are available in 3 models. Please use the

following charts to determine which best suits the application:

1. Obtain/calculate/determine a proper heat load for the home

2. Determine the inlet water temperature from water heater(or boilder)

3. Determine the duct layout/ available duct size

4. Be sure the system air flow rate matches the air flow rate of the

selected air handler

System Design Resource Note:

From the CAN/CSA-B214-12 Installation Code for Hydronic Heating

Systems, section 4.2.2.1 Heat-source output, it states: "the heat-

source output shall be not less than the heat load indicated in the

system design."

4.2.2.2 Dual-purpose water heater

Model No. Description

Model No. Description WiFi @ IoT Zoning Temperature

Control

iFLH-140000

iSmart

Control No No Room

Thermostat

iFLH-160000

iFLH-180000

Model No. Description

Model No. Format

4. Suitable applications: Choosing the right heat source

The iFLOW air handler can be installed with various types of

heat sources and heating systems. The following are its primary

applications:

1. Air handler with tankless water heater

2. Air handler with conventional thank-type water heater

3. Air handler with heating boiler

4. Air handler with combi boiler

5. Air handler with heat pump + tankless water heater

6. Air handler with heat pump + tank-type water heater

7. Air handler with heat pump + boiler

8. Air handler with heat pump + combi boiler

Refer to the installation manual for diagrams of each type of installati-

on.

▶

i F L H - 1 4 0 0 0 0

Function / B: basic, W: WiFi,

D: 2 zone, Q: 4 zone

▶

▶Cabinet Size / 14 : 14", 16 : 16", 18 : 18" Width

Static Pressure / L : Low Static Pressure,

H: High Static Pressure, LH : Universal

▶Company Initial

Model No. Initial Size Function Initial

i F L H 14, 16, 18 B, W, D, Q, 0

iFLOW HVAC INC. www.iflowhvac.com

Description iFLH-140000 iFLH-160000 iFLH-180000

Heating

Capacity

Entering

Water

Temperature

120℉ 27,834 BTUH 34,211 BTUH 42,376 BTUH

130℉ 33,478 BTUH 41,357 BTUH 50,966 BTUH

140℉ 37,729 BTUH 48,379 BTUH 59,632 BTUH

150℉ 44,998 BTUH 55,485 BTUH 68,334 BTUH

160℉ 50,869 BTUH 62,632 BTUH 77,065 BTUH

170℉ 56,941 BTUH 69,769 BTUH 85,648 BTUH

180℉ 62,786 BTUH 76,982 BTUH 94,633 BTUH

Flow Rating LPM / GPM 11.4 / 3 11 / 2.9 10.6 / 2.8

Return Air Temp. ℃ / ℉ 22 / 72 22 / 72 22 / 72

E. S. P. inWC 0.6 / 1.2 0.6 / 1.6 0.6 / 1.6

Airflow SCFM 941 / 824 1222 / 1009 1423 / 1093

Cooling Capacity Ton 1 - 2 1.5 - 3 2 - 4

Cabinet Size

(W x D x H)

in 14 x 18 3/4 x 27 1/8 16 x 20 3/4 x 27 1/8 18 x 25 3/4 x 29 1/8

mm 356 x 476 x 689 406 x 527 x 689 457 x 654 x 740

Material Cold Roll Steel Sheet Metal / Powder Coated

Weight

kg 28.6 32 42

lb 63 71 92.5

Supply Air Opening

(W x D)

in 13 x 14 14 x 16 16 x 20

mm 330 x 356 356 x 406 406 x 508

Return Air Opening

(H x D)

in 12 x 16 13 x 18 14 x 23

mm 406 x 304 457 x 330 584 x 355

Electrical ACV/Hz/Ph AC 120V 60Hz 1Ph AC 120V 60Hz 1Ph AC 120V 60Hz 1Ph

Motor

HP 1 / 2 1 / 2 3 / 4

Type ECM Eon ECM Eon ECM Eon

W431 / 393 519 / 516 592

Piping Connection

Supply 3/4" Male NPT Thread / 1/2" Soldering Connection

Return 3/4" Male NPT Thread / 1/2" Soldering Connection

Hydronic Heating Coil Aluminum Ultra Efficiency Fins, Copper Tubing

Specification

iFLOW HVAC INC. www.iflowhvac.com

Water Heating Capacity (BTUH) / Water Pressure Drop (Feet)

iFLH-140000

H.Ex.

Rows

Entering

Water

Temp.

3 GPM 4 GPM

CFM

W.P.D

CFM

W.P.D

400 600 700 800 950 400 600 700 800 950

120℉ 17,365 21,756 23,654 25,347 27,834 2.9 18,425 23,097 25,653 27,246 29,906 4.3

130℉ 20,756 26,235 28,105 30,632 33,478 2.9 21,365 27,743 30,014 32,954 36,183 4.3

140℉ 24,142 30,754 33,521 36,065 37,729 2.8 24,845 32,469 35,478 38,549 42,376 4.2

150℉ 27,587 35,329 38,013 41,365 44,998 2.8 28,326 37,254 40,024 44,287 48,598 4.2

160℉ 30,965 39,865 43,247 46,759 50,869 2.8 31,824 41,987 45,726 49,976 54,843 4.1

170℉ 34,329 44,432 48,628 52,125 56,941 2.7 35,327 46,743 51,214 55,643 61,176 4.1

180℉ 37,734 49,032 54,573 57,683 62,786 2.7 39,836 51,458 56,429 61,398 67,497 4.0

iFLH-160000

H.Ex.

Rows

Entering

Water

Temp.

3 GPM 4 GPM

CFM

W.P.D

CFM

W.P.D

600 800 900 1000 1250 600 800 900 1000 1250

120℉ 24,625 27,865 29,865 31,087 34,211 3.7 28,268 30,042 31,986 34,109 38,287 5.7

130℉ 28,218 33,572 35,724 37,429 41,357 3.7 33,625 36,256 38,524 41,162 46,456 5.7

140℉ 32,865 39,218 41,625 43,843 48,379 3.7 38,245 42,367 45,412 48,235 53,971 5.5

150℉ 37,536 45,075 47,536 50,327 55,485 3.6 42,765 48,559 52,369 55,149 61,864 5.5

160℉ 42,125 50,732 53,425 56,798 62,632 3.6 47,325 54,632 58,489 62,268 69,832 5.4

170℉ 46,852 56,579 59,425 63,266 69,769 3.5 51,869 60,861 64,542 69,345 77,846 5.4

180℉ 51,425 62,329 65,325 69,747 76,982 3.5 56,465 67,054 72,369 76,486 85,742 5.3

iFLH-180000

H.Ex.

Rows

Entering

Water

Temp.

3 GPM 4 GPM

CFM

W.P.D

CFM

W.P.D

600 800 1000 1200 1450 600 800 1000 1200 1450

120℉ 28,963 34,245 35,648 38,946 42,376 5.6 30,125 36,203 38,224 42,376 46,638 6.9

130℉ 33,412 39,632 42,820 46,981 50,966 5.5 34,845 41,952 45,996 50,996 56,173 6.8

140℉ 37,954 45,126 50,157 54,844 59,632 5.5 39,652 47,623 53,756 59,465 65,789 6.7

150℉ 42,503 50,520 57,489 62,529 68,334 5.4 44,321 53,304 61,533 68,255 75,223 6.7

160℉ 47,127 55,963 64,732 70,931 77,065 5.3 49,032 59,123 69,325 76,905 84,896 6.6

170℉ 51,608 61,412 72,078 78,842 85,648 5.3 53,741 64,745 77,199 85,627 94,441 6.5

180℉ 56,129 66,846 79,354 87,055 94,633 5.2 58,429 70,487 84,923 94,336 104,056 6.4

iFLOW HVAC INC. www.iflowhvac.com

1) Location requirements and clearances:

• The installer shall comply with all local, state/provincial and national

code requirements that apply to the installation of this equipment.

• The air handler must be installed in such a way that electrical

components are protected from water during operation and service.

• If installed in an unconditioned space, sealant should be applied

around where the electrical wires, refrigerant tubing, and condensate

lines enter the cabinet. This appliance shall not be installed in a non-

conditioned space where the potential may exist for the appliance,

water lines and/or drain lines to freeze.

• If installed with air conditioning in a suspended application, ensure a

drain pan with a proper slope is installed.

Recommended Clearances:

Be sure to provide a minimum of 24” clearance to the front panel

of the iFLOW air handler. 0” clearance is allowed for all other sides

of the cabinet and for the first 36” of ductwork. Ensure adequate

clearance is left for the installation of ductwork, plumbing, and

electrical connections.

Installation

Model Unit Width Depth Height a b c d

14" Cabinet

in 14 18 3/4 27 1/8 13 14 16 12

mm 355.6 476.3 689 330.2 355.6 406.4 304.8

16" Cabinet

in 16 20 3/4 27 1/8 14 16 18 13

mm 406.4 527.1 689 355.6 406.4 457.2 330.2

18" Cabinet

in 18 25 3/4 29 1/8 16 20 23 14

mm 457.2 654.1 739.8 406.4 508 584.2 355.6

Example only

LEFT SIDE

0 inch

RIGHT SIDE

0 inch

BACK

0 inch

PLENUM

0 inch

BOTTOM

0 inch

FRONT

SERVICING

2) Dimensions

iFLOW HVAC INC. www.iflowhvac.com

3) Installation examples:

The iFLOW air handler is multi-positional and therefore can be

mounted in any position. If installed with air conditioning, proper

positioning of the evaporator coil and drain line must be considered to

install correctly.

Vertical Installation

Horizontal Installation

The evaporator coil must be installed on the supply side of the air

handler.

Hanging Installation

Ceiling Installation

4) Water Heater / Boiler Piping:

When installing the iFLOW air handler with a heating boiler or combi-

boiler in a closed loop system, refer to the boiler manufacturer’s

instructions for proper installation with an air handler. Depending on

the boiler selected and system design, it may be required to use a

primary/secondary piping arrangement to de-couple the flow through

the boiler from the flow through the air handler.

Air-removal device:

Provisions shall be made for the removal of air in the heat-distribution

piping system. The air-removal device shall be located in the area

of the heat-distribution piping system where the air is likely to

accumulate (often the highest point in the system).

Required Components:

Expansion tank, isolation valves, air eliminator, dirt collector/filter/

strainer (if other heating loads are being heated by the same boiler),

make-up water and low loss header (optional).

Sensor Installation

A/C Evaporator Temperature Sensor: Air outlet on the Evaporator

coil (See Installation Illustration: Page 12)

Zone Air Temperature Sensor:

Zone supply side: Air outlet of the damper

Zone return side: Air inlet of the damper (if there is a dedicated return

duct with the damper)

5) Domestic Piping:

Notes: When installing the iFLOW air handler with a water heater,

refer to the manufacturer’s guidelines on coupling the water heater

with an air handler. Use components and piping that are allowable

with potable use. Lead-free solder must be used on all joints.

When both top and side connections are present on the water heater,

the side connections should be used for the space-heating loop.

The heating loop connections should be positioned horizontally in a

vertical section of the domestic water line for both the inlet and outlet.

Refer to the piping diagram for details. Minimize the distance and

piping between the water heater and the iFLOW air handler.

If the main water line has an installed check valve, a potable

expansion tank must be installed to provide room for the expansion

of water.

AHU with

Case Coil or A Coil

Evaporator

Temperature

Sensor position

Filter Rack Filter Rack

Support

Anti-Vibration Pad

The Threaded Rod

Spring

Flat washer

Nut

Minimum 6inch

Filter Rack Filter Rack

Minimum 6inch

Evaporator

Temperature

Sensor position

AHU with

Slab Coil

AHU with

Case Coil or A Coil

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