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Installation, Service and
Operating Instructions
for use by heating contractor
Viessmann AirflowPLUS AH2A series
Hydronic forced air handler
Viessmann Airfl owPLUS
5680 011 - 10 06/2016
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
for future reference
.
Please file in Service Binder
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Table of Contents
Related Manuals for Viessmann AirflowPLUS AH2A-213
Summary of Contents for Viessmann AirflowPLUS AH2A-213
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Page 1: Operating Instructions
Installation, Service and Operating Instructions for use by heating contractor Viessmann AirflowPLUS AH2A series Hydronic forced air handler Viessmann Airfl owPLUS Product may not be exactly as shown IMPORTANT Read and save these instructions for future reference Please file in Service Binder... -
Page 2: Safety
WARNING - If skin contact occurs, wash affected areas gently with soap and warm water after handling. Follow the Viessmann maintenance schedule of the boiler contained in this manual. WARNING Operating and service documentation Appliance materials of construction, may contain toxic... -
Page 3: Table Of Contents
Table of Contents Viessmann AirflowPLUS AH2A Installation, Operating and Service Page Safety Safety, Installation and Warranty Requirements....2 Product documentation...........2 Warranty...............2 Licensed professional heating contractor....2 Advice to owner............2 Operating and service documentation.......2 Fiberglass wool materials........2 First aid measures..........2 General Information About these Installation Instructions......5 Necessary Tools............5... - Page 4 Table of Contents Viessmann AirflowPLUS AH2A Installation, Operating and Service Page Startup Quick Check.............35 Pre-start Checklist.............35 Startup Procedure............36 Air handlers LED Indications for Temperature....36 Closing the Air Handling Unit........37 Operation Indicators..............38 Flashing LED............38 Normal Operation............38 Heating mode.............38 Cooling mode............38 Summary............38 External Heat Demand via Switching Contact - Boilers equipped with HO1B User Interface....39...
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Page 5: General Information
General Information Viessmann AirflowPLUS AH2A Installation, Operating and Service About these Installation Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. Indicates an imminently hazardous situation which, WARNING if not avoided, could result in death, serious injury or substantial product/property damage. -
Page 6: Important Regulatory And Installation Requirements
Literature for the Viessmann AirflowPLUS air handler: - Technical Data Manual - Installation, Service, and Operating Instructions - Instructions of other Viessmann products utilized and installed - Installation codes mentioned in this manual Leave all literature at the installation site and advise the system operator/ultimate owner where the literature can be found. -
Page 7: Product Description
Viessmann AirflowPLUS AH2A Installation, Operating and Service Introduction The Viessmann AirflowPLUS AH2A series air handlers are to be used in conjunction with Viessmann boilers. The automatic adjustments are made in heating as well as cooling. This minimizes selecting an oversized heating appliance just to accommodate the cooling load. -
Page 8: Features
Product Description Viessmann AirflowPLUS AH2A Installation, Operating and Service Features Condenser freeze protection If the evaporator coil outlet air temperature is too low or operating outside of normal conditions, the control will shut off the outdoor condenser for 5 minutes. Evaporator coil freezing can cause slugging at the compressor. -
Page 9: Equipment Selection And Sizing
Product Description Viessmann AirflowPLUS AH2A Installation, Operating and Service Equipment Selection and Sizing Proper sizing of systems components is crucial for proper operation; 1. Obtain room by room heat loss and/or heat gain 2. Determine heating water temperature 3. Determine duct layout... - Page 10 Product Description Viessmann AirflowPLUS AH2A Installation, Operating and Service Compatibility Charts (continued) Air handler model AH2A-354 Boiler supply water temperature 120°F (44 MBH) 140°F (61 MBH) 160°F (83 MBH) 180°F (98 MBH) Vitodens 100 WB1B-26 Vitodens 100 WB1B-35 ...
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Page 11: Installation
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Before Set-up Before placing Viessmann AirflowPLUS in its installation CAUTION location, ensure all necessary accessories are installed. The air handler must be installed in such a way that electrical components are protected from water (spraying, splashing, etc.) during operation and service. -
Page 12: Dimensions
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Dimensions IMPORTANT AH2A-213 AH2A-354 AH2A-385 The maximum ambient temperature must not exceed (mm) (584 mm) (711 mm) (578 mm) 104ºF (40ºC). (mm) (457 mm) (559 mm) (559 mm) (mm) (826 mm) (876 mm) -
Page 13: Heating Circuit Pumps
A Speed 1 Pump curve B Speed 2 Pump curve C Speed 3 Pump curve Note: All Viessmann AirflowPLUS air handlers come with pump speed factory set to speed 3. Installation The contractor shall adhere to all local, state and national... -
Page 14: Installation Examples
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Installation Examples Horizontal installation IMPORTANT A field fabricated auxiliary drain pan with drain pipe is recommended in all configurations. Note: Field selected suspension materials must be sized Discharge air by installing contractor so as to be of sufficient strength to support air handler weight of 150 lbs. -
Page 15: Vertical Installation
Vertical installation The A/C coil is installed in the upstream air flow of the Viessmann AirflowPLUS air handler. This will require the use of the remote return air temperature sensor mounted upstream of the A/C coil. See page 41 for additional information regarding the remote return air temperature sensor. -
Page 16: Proper Piping Practice
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Proper Piping Practice Support piping by proper suspension method. 2 imperfect threads Piping must not rest on or be supported by the air handler. Use moderate amount of dope. This section constitutes an overview only! Refer to subsequent sections for detailed information on individual piping connections. -
Page 17: Removing The Blower Shipping Bracket
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Removing the Blower Shipping Bracket 1. Remove the bracket retaining thumb screws and discard. 2. Remove the bracket and discard. Opening the Air Handler Unit 1. Remove the lower front panel retaining screws and set aside. -
Page 18: Panels
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Panels There are 2 return air openings on the air handler. One is located on the left side for vertical installations and one is located at the bottom for horizontal installations. For horizontal installations, remove the bottom panel and install it to the left side panel opening. - Page 19 Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Panels (continued) To change the duct connection side of the air handler for vertical installation, the right and left side panel can be interchanged. To interchange the panels refer to the following instructions.
- Page 20 Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Panels (continued) 5. Install the side panel (removed from step 2) by placing the panel into the air handler and pushing down with the handle. 6. Reinstall the retaining screws. Note: To install the filter tray, see page 19.
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Page 21: Accessing The Connection Board
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Panels (continued) Filter tray for vertical installation Note: If an A/C condenser is installed upstream, a field supplied filter tray maybe placed elsewhere in the ducting, see page 15. 1. Remove the retaining screws from the side panel. -
Page 22: Vitodens 100 Wb1B Wiring
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Vitodens 100 WB1B Wiring Viessmann AirflowPLUS Connection Board Thermostat Power Pump Module (PPM) Connect call for heat (K2) relay of the air handler to the For more details, refer to the Vitodens 100-W RT connection (X4 terminals 3 and 4) of the Vitodens Installation Instructions. -
Page 23: Vitodens 100 Wb1B Wiring Using Dhw Connection
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Vitodens 100 WB1B Wiring using DHW Connection Viessmann AirflowPLUS Connection Board Thermostat A Heating circuit control connection. Power Pump Module (PPM) Connect call for heat (K2) relay of the air handler to the... -
Page 24: Ho1B Wiring
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service HO1B Wiring Viessmann AirflowPLUS Connection Board Thermostat HO1B Connections (Vitodens 200-W B2HA and B2HB Vitodens 222-F B2TA and B2TB Vitocrossal 300 CU3A) Refer to the appropriate boiler Installation Connect call for heat (K2) relay of the air handler to Instructions. -
Page 25: Control Function
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Control Function Temperature sensors Alarm conditions include: The Viessmann AirflowPLUS integrated Control includes • Heat exchanger freeze protection limit exceeded five temperature sensors. Temperature sensors are 2-wire • Return air temperature is too low devices that are connected to the control board with a •... -
Page 26: Remote Return Air Sensor (T5)
• Set dip switches as per the system preference. The remote return air sensor is preinstalled within the Viessmann AirflowPLUS cabinet complete with a 10 ft. (3 m) cable lead for remote sensor locations. Remove the strap from the sensor lead and install in the required location. -
Page 27: Override Settings
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Override Settings Dip switch settings The dip switch will allow the selection of custom setup options. Refer to Variable Table for system options. Maximum heating override The return air temperature will be monitored for unreasonably high values. -
Page 28: Door Safety Switch
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Door Safety Switch The door safety switch is located on the internal center support panel. Once the lower front panel is removed, the switch will disconnect power to the control board and fan motor. -
Page 29: Electrical
Viessmann AirflowPLUS Connection Board Note: Before making the connection to the thermostat for a two stage cooling function, remove the jumper across terminals Y1 and Y2 on the Viessmann AirflowPLUS connection board. Single stage thermostat field supplied (typical) -
Page 30: Power Supply
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Power Supply WARNING WARNING Power connections L and N are not interchangeable. If system components are not grounded, serious injury from electric current can result if an electrical fault occurs. Main power supply... -
Page 31: Control Inputs
Installation Viessmann AirflowPLUS AH2A Installation, Operating and Service Control Inputs Heating control A 24VAC input is provided to control the heating function. When the thermostat calls for heat 24VAC is applied to the W contact and a heating cycle will be initiated. -
Page 32: Setting Fan Speed
Time Min. Time Min. Time Min. Note: Power to the Viessmann AirflowPLUS air handler must be turned off before changing switch settings. The above values are approximations only, actual results may vary. Note: Factory switch set positions are shown in bold. - Page 33 Time Min. Time Min. Time Min. Note: Power to the Viessmann AirflowPLUS air handler must be turned off before changing switch settings. The above values are approximations only, actual results may vary. Note: Factory switch set positions are shown in bold.
- Page 34 Time Min. Time Min. Time Min. Note: Power to the Viessmann AirflowPLUS air handler must be turned off before changing switch settings. The above values are approximations only, actual results may vary. Note: Factory switch set positions are shown in bold.
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Page 35: Quick Check
Startup Viessmann AirflowPLUS AH2A Installation, Operating and Service Quick Check 7. Is there an installation manual for the home owner? WARNING 8. Is the unit accessible? Are there clearances for service This appliance is not intended for installation in a... -
Page 36: Startup Procedure
Startup Viessmann AirflowPLUS AH2A Installation, Operating and Service Startup Procedure Do not start the air handler or BOILER until ALL Air has 5. Start the boiler according to the instructions provided been purged from water lines and air handler pump! with the boiler. -
Page 37: Closing The Air Handling Unit
Startup Viessmann AirflowPLUS AH2A Installation, Operating and Service Installing Connection Board Installing connection board with hinged cover 1. Close connection board cover. 2. Secure cover with the retaining screws. 3. Slide in blower assembly. 4. Reinstall retaining screw. Installing connection board with removable cover 1. -
Page 38: Indicators
Operation Viessmann AirflowPLUS AH2A Installation, Operating and Service Indicators A bicolour LED is used as a system status indicator to indicate alarm, test mode, normal operation, etc. The indicator will display the temperature sensor values during normal operation. When abnormal behavior is noted the LED will display an indication to indicate the condition. -
Page 39: External Heat Demand Via Switching Contact
Operation Viessmann AirflowPLUS AH2A Installation, Operating and Service External Heat Demand via Switching Contact - Boilers equipped with HO1B User Interface Contact closed: Set address 3A to 3A:2, for external demand upon closure of DE1. • The burner is switched ON subject to load. The boiler heats to the set boiler water temperature selected in coding “9b”... -
Page 40: Dhw Contact For Air Handler - Vitodens 100 Wb1B
There is no adjustment available for this temperature set point. When using the domestic hot water contact, the display shows “ ”, during a call for heat from the Viessmann AirflowPLUS. Note: This is not applicable for Vitodens 100 WB1B boilers equipped with CombiPLUS or DHW storage tank. -
Page 41: Illuminated Alarm Indicator
Service Viessmann AirflowPLUS AH2A Installation, Operating and Service Illuminated Alarm Indicator • All Viessmann AirflowPLUS AH2A series air handlers are equipped with a housing mounted Illuminated alarm indicator. This indicator light illuminates any time the control mounted alarm relay is activated. -
Page 42: Alarm Relay And Led Fault Codes
Service Viessmann AirflowPLUS AH2A Installation, Operating and Service Alarm Relay and LED Fault Codes Control LED flash codes Alarm Alarm Relay is on when an unusual condition is detected. A visual display is provided by the housing mounted LED. The connector is a two terminal connector that provides This display advises of the current status of the air handler a contact closure when the Alarm Relay is on. -
Page 43: Checking Ecm (Dc) Fan Motor Connections
Service Viessmann AirflowPLUS AH2A Installation, Operating and Service Checking ECM (DC) Fan Motor Connections ECM Motor Control Note: The fan motor operates independent of the controller temperature control logic. Externally installed temperature sensors operate as system safeties only. Connector (female) -
Page 44: Troubleshooting
Service Viessmann AirflowPLUS AH2A Installation, Operating and Service Troubleshooting Pump does not run Often, closing the isolation valve on the return leg and opening the drain port so that water flows through the Power is on at the air handler. - Page 45 Service Viessmann AirflowPLUS AH2A Installation, Operating and Service Troubleshooting (continued) Water coil freeze protection This sequence is initiated by extreme low air temperatures The air handler internal water coil crossing over the freeze protection sensor located directly freeze sensor T3 is activated above the air handler water coil.
- Page 46 Service Viessmann AirflowPLUS AH2A Installation, Operating and Service Troubleshooting (continued) Cooling lockout This feature is initiated if three freeze protect cycles occur Power is on at the air handler. within a single cooling cycle or, if three freeze cycles occur when a cooling cycle is not in progress.
- Page 47 Service Viessmann AirflowPLUS AH2A Installation, Operating and Service Troubleshooting (continued) Temperature sensor failure identification Temperature sensor failure is identified by viewing the Power is on at the air handler housing mounted LED. for more than 24 hours. The alarm buzzer is on.
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Page 48: Service And Maintenance
24 hours. Air filter The Viessmann AirflowPLUS AH2A series of air handlers are provided with a disposable filter media. This filter should be inspected monthly and removed and replaced as required. -
Page 49: System Layout 1
An undersized E Indirect fired DHW storage tank pump may cause short-cycling and/or improper operation of the boiler. Refer to page 24 for the Viessmann AirflowPLUS connection to external heat demand of the boiler. -
Page 50: System Layout 2
The low-loss header is available as accessory part. H Low loss header (or closely spaced tees) Please note location of expansion tank. Refer to page 24 for the Viessmann AirflowPLUS System separation is required of underfloor heating connection to external heat demand of the boiler. -
Page 51: System Layout 3
G Low loss header (or closely spaced tees) The low-loss header is available as accessory part. Please note location of expansion tank. Refer to page 24 for the Viessmann AirflowPLUS connection to external heat demand of the boiler. System separation is required of underfloor heating systems employing non-oxygen diffusion barrier tubing. -
Page 52: System Layout 4
The low-loss header is available as accessory part. H Low loss header (or closely spaced tees) Please note location of expansion tank. Refer to page 24 for the Viessmann AirflowPLUS System separation is required of underfloor heating connection to external heat demand of the boiler. -
Page 53: System Layout 5
If the heating system does not include a DHW storage ‘RT’ connection. tank connected to the boiler the DHW demand contacts of the boiler may be connected to the Viessmann AirflowPLUS heat demand, use the DHW temperature set point to set the desired supply temperature to the air... -
Page 54: System Layout 6
G Low loss header (or closely spaced tees) The low-loss header is available as accessory part. Refer to page 22 for the Viessmann AirflowPLUS Please note location of expansion tank. connected in parallel with heating circuit demand to ‘RT’ connection. -
Page 55: System Layout 7
Additional Information Viessmann AirflowPLUS AH2A Installation, Operating and Service System Layout 7 Legend IMPORTANT A Vitocrossal 300 CU3A high mass boiler / Vitodens 200 B2HA/B boilers (shown) The use of a low-loss header (or closely spaced tees B System fill with expansion tank... -
Page 56: System Layout 8
E Low loss header (or closely spaced tees) flow rates of the boiler, or if the system flow rates are Refer to page 24 for the Viessmann AirflowPLUS unknown. connection to external heat demand of the boiler. -
Page 57: Technical Data
Additional Information Viessmann AirflowPLUS AH2A Installation, Operating and Service Technical Data Description AH2A-213 AH2A-354 AH2A-385 Motor (ECM) Electrical VOLTS/PH/HZ 120/1/60 120/1/60 120/1/60 Heating BTUH 120°F (49°C) 28,000 44,000 51,000 (kW) (13) (15) 140°F (60°C) 46,000 61,000 74,000 (13) (18) (22) 160°F (71°C) -
Page 58: Electrical Connections
Additional Information Viessmann AirflowPLUS AH2A Installation, Operating and Service Electrical Connections Main power supply 120VAC, 1Ph, 60Hz, 12A WARNING Main DISCONNECT POWER BEFORE Disconnect SERVICING BOILER. Switch External Connections If any of the original wires as supplied with the appliance must be... - Page 59 Additional Information Viessmann AirflowPLUS AH2A Installation, Operating and Service Electrical Connections (continued) Legend Diagnostic LED Ambient temperature sensor Return air temperature sensor Discharge air temperature sensor Freeze protection temperature sensor Supply water temperature sensor A/C power Pump motor 10 24VAC transformer secondary...
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Page 60: Parts List
Additional Information Viessmann AirflowPLUS AH2A Installation, Operating and Service Parts List Model No. Serial No. AH2A 213 7561230 AH2A 354 7561231 AH2A 385 7561232 Ordering Parts: Please provide Model and Serial Number A when ordering replacement parts. Order replacement components from your Viessmann distributor.