INGENIA CAH Installation guide

Installation, Operation and Maintenance Manual for Ingenia Indoor Units CAH-ID-16-00
1
Installation, Operation and
Maintenance Manual for Ingenia
Indoor Units
Forward this manual to the person responsible for the
installation and maintenance of the product described
herein. Without proper installation and maintenance
equipment damage will result.
August 2016
© Copyright Ingenia Technologies Inc.
All rights reserved.
CAH Indoor Unit CAH-ID-16-00

Installation, Operation and Maintenance Manual for Ingenia Indoor Units CAH-ID-16-00
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Table of Contents
1.0 Receipt and Inspection 3
2.0 Unit Identification 3
3.0 Unit Supporting Structure 3
4.0 Duct Connection 7
5.0 Caution 7
6.0 Rigging 8
7.0 Hardware and Tools needed for Installation 9
8.0 Installation Procedure for Modular Indoor Units 10
8.1 Condensate Traps 17
8.1.1 Draw-thru Traps 17
8.1.2 Blow-thru Traps 17
8.2 Coil Removable Access Panel 17
8.3 Ingenia Panels 17
8.4 Door Hinge Adjustment 21
8.5 Filter Clips 22
8.6 Electrical Field Connections 23
8.7 Monorail Operation 25
9.0 Start-up (Checklists pg 32) 26
10.0 Service and Maintenance 36
10.1 Bearing Lubrication 36
10.2 Unit Cleaning 36
10.2.1 Coil Cleaning 36
10.3 Sheaves and Belts 37
10.4 Winter Shut-down to prevent Water Coils from Freezing 37
10.5 Antimicrobial Coating protection 37
11.0 Warranty 38
11.1 Addition / Modification of components on ETL units (ETL Disclaimer) 39
12.0 Replacement Parts 39
Appendix A Stacked Modules with Floor opening 40
Appendix B Fan IOM 42

Installation, Operation and Maintenance Manual for Ingenia Indoor Units CAH-ID-16-00
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1.0 Receipt and Inspection
A. Upon arrival at the job site, remove protective shrink wrap and thoroughly inspect
units. Report any damaged equipment to the transport company on the packing slip. All In-
genia air handling systems are shipped fully shrink wrapped to prevent damage during transport.
The transporting carrier is responsible for delivering all items in their original condition as re-
ceived at Ingenia. The individual receiving the equipment is responsible for inspecting the unit
for obvious or hidden damage, recording any damage on the bill of lading before acceptance and
filing a claim (if required) with the final carrier.
B. Long Term Storage: The protective shrink wrap is not intended to protect equipment for
long term storage. Long term storage must take place in a dry, climate controlled environment
without the protective shrink wrap.
The fan (and motor if supplied) should be rotated several times, on a monthly basis, by hand
while adding enough grease to replenish the bearing surfaces with fresh grease and to maintain a
full bearing cavity.
Refer to Fan IOM for storage instructions. 
2.0 Unit Identification (If unit is not ETL certified)
A. The tag in Figure 1 is an example of an identification label on the unit. The information pro-
vides the unit identification, the model number, the unit serial number and the date of fabrica-
tion. For ETL certified units the label will be custom made with project specific information.

Figure 1: Unit Nameplate
3.0 Unit Supporting Structure
IMPORTANT:
1) Indoor units must be installed on a level structural steel platforms or on concrete
pads. Inspect field conditions to verify mounting surfaces. If the supporting surfaces are not 100
% level then shim the underside of the units to correct the existing condition.
2) Shims (if necessary) or supports should be installed at every 8 feet maximum in-
terval in both the “X” and “Y” axis and at every module split. Figures 2 and 3 show the
different types of mounting surfaces for indoor units.
Idenficaon:

Modèle/Model:

No.Série/SerialNo.:

DatedeFabricaon:
ManufacturedDate:
IngeniaTechnologiesInc.
18101J.A.BombardierMirabel,
Quebec,Canada,Tel.:(450)979‐1212

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Installation, Operation and Maintenance Manual for Ingenia Indoor Units CAH-ID-16-00
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4.0 Duct Connection
Figure 4 shows a typical duct connection detail.
5.0 Caution !
A. When installing an air handler, ensure the proper protective devices are used to protect per-
sonnel from moving parts and other hazards. A complete line of protective accessories are avail-
able from Ingenia including: plenum enclosures, inlet screens, outlet screens, motor covers, belt
guards and electrical disconnects.
B. Verify local codes to ensure complete compliance for all protective devices.
C. Electrical disconnects
All fan motors and high voltage electrical equipment shall have disconnects located in close prox-
imity to turn off electrical service. Service disconnects shall be locked out when maintenance is
being performed.
D. Moving parts
All moving parts must have guards to protect personnel. Refer to local codes as to the number,
type and design. Before the initial start-up or any restart, check the following items to make sure
that they are installed and secure.
Guards
Do not operate fans without proper protective devices in place. Failure to do so may result in
serious injury and property damage.
Access doors
Before opening access doors ensure the fan wheels have stopped moving and that the wheel has
been secured from being able to rotate. Do not operate the fans without access doors in their
fully closed positions.
Air pressure and suction
In addition to the usual hazards associated with rotating machinery, fans can also create a dan-
gerous suction at the inlet of the fan or the air handler. Special caution needs to be used when
moving around a fan whether it is operation or not. Before start-up, make sure the inlet area is
clear of personnel and loose objects.

Installation, Operation and Maintenance Manual for Ingenia Indoor Units CAH-ID-16-00
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6.0 Rigging
A. Use industry standard lifting and rigging practices. All lifting lugs supplied must be
utilized at the same time for rigging purposes. Cables must be positioned to ensure equal
tension.
B. Spreader bars must be sized to prevent lateral contact to the sidewalls of the unit
(refer to Figure 5). Caution should be taken that door handles, electrical panels, filter gauges,
hoods, etc. are not in the way of cables which could be broken, bent or damaged.
C. Reposition the lifting lugs (if need be) onto the long side of the unit (as shown above)
D. Do not drop the module or unit.
E. REFER TO THE LIFTING LUGS DRAWINGS SUPPLIED.
Figure 5 - Unit Rigging
Spreader bars must
be utilized to prevent
lateral contact to
side walls

Installation, Operation and Maintenance Manual for Ingenia Indoor Units CAH-ID-16-00
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7.0 Hardware and Tools needed for Installation
The following tools are needed to provide a proper installation of a modular outdoor Ingenia unit.
These tools are not supplied by Ingenia.
 SET OF WRENCHES (3/4”, 15/16”) and BASIC SHEET METAL TOOLS
 COME ALONG , STRAPS (short and long) and Jacks
 THREADED RODS with NUTS and WASHERS
The following hardware will be supplied by Ingenia for the installation of a modular outdoor unit.
Philips #3
Robertson #3
Squeegee
Impact drill Heat gun
Bolt 1/2”-13x1-1/2”
Caulking/Silaprene
VIS SS H-L 1/4 x 3/4
Floor screws
Coarse Threads (Hi-Lo)
1/2” threaded rod
(approx 12” long)
4’ Level
Caulking gun
(silaprene will be pro-
vided by Ingenia)
Knife
VIS FTSQ 1/4”-20X5/8”
Zinc Bolt or Stainless VIS AP HH 12-3/4”
(Self Drilling Zinc or
Stainless Steel Screw)
GASK 20100MAA
(3”x5”x1/8” FOAM GASKET)
Membrane 2” TPO
2265

Installation, Operation and Maintenance Manual for Ingenia Indoor Units CAH-ID-16-00
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8.0 INSTALLATION PROCEDURE FOR INDOOR MODULAR UNITS
Lifting Lugs:
Install the lifting lugs on the longer side of the module or unit (if it is not already done), as indi
cated on the lifting lugs drawings PRIOR TO RIGGING.
STEP 1: Installation of the Neoprene gasket (figure 6)
Before installing the unit, it is important that a 3”x5”x1/8” foam gasket be installed at every mod
ule joint at the floor wall junction (refer to figure 6). There will be a total of four foam gaskets
installed at every module split, two on either side of the unit. As a result, when the modules are
pulled together, the foam gaskets will compress against one another creating an air seal at the
floor wall junction.
STEP 2: Installation of the First Module
Install the first module in its final position on a roof curb, structural support or house keeping
pad, whichever the case may be. The modular pressure plate will always be temporarily installed
on one side of the module for ease of installation. Don’t forget to verify if the module is level and
shim the module where necessary.
IMPORTANT:
1) Indoor units must be installed on a level structural steel platforms or on concrete
pads. Inspect field conditions to verify mounting surfaces. If the supporting surfaces are not 100
% level then shim the underside of the units to correct the existing condition.
2) Shims (if necessary) or supports should be installed at every 8 feet maximum in-
terval in both the “X” and “Y” axis and at every module split. Figures 2 and 3 show the
different types of mounting surfaces for indoor units.
STEP3: The Second Module (figure 7)
Set the second module in place allowing for a certain distance from the first to remove the lifting
lugs if needed. Relocate the lifting lugs on the side of the unit to provide an anchor point when
bringing the modules together. Attach nylon straps to the lifting lugs with a come-along in be
tween to bring both modules together (refer to figure 7). Repeat this for the opposite side of the
unit. Slowly crank the come-along allowing for equal tension on both sides until the modules are
completely touching one another.
Aligning the modules (roof) (figure 8)
It is important that the rive-nut holes on the walls and roof are perfectly in line and that the mod
ules are completely touching one another. If the rive-nuts on the roof are not in line (and the
floor base is properly in line), the problem can be easily corrected by placing nylon straps in a
diagonal arrangement anchoring one end to the a lifting lug and the other to the opposite diago
nal end of the module lifting lug, across the roof (refer to figure 8). The come-along should be
cranked slowly, until the rive-nuts are in line. Proper care must be taken when performing this
operation.
Keeping the modules together (figure 8A)
By reinstalling the lifting lugs on the side of the unit, use threaded rods (not provided by Ingenia)
to keep the modules compressed against each other. (refer to figure 8A)

Installation, Operation and Maintenance Manual for Ingenia Indoor Units CAH-ID-16-00
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Threaded rod keeps the modules together at all times (Figure 8A)
STEP 4: Caulking and Application of the membrane (figure 9)
The unit surface must be free of any dirt, oil and/or water. Before installing the membrane,
inject a bead of caulking at the panel seam and then install the membrane and pressure plate.
The membrane and unit surface must be above 50 ºF (10 ºC) to properly adhere. If
the outdoor temperature does not cooperate, use a heat gun to heat the panel (seam) surface
and the membrane.
Once ready, inject a bead of caulking at the panel seam, then apply the 2” membrane on the
roof and wall panel seams (unit exterior) at the modular joints ensuring that the rive-nut holes
are completely covered.
Always overlap the membrane by at least 1” when joining two pieces
together (refer to figure 9)
. A 2” membrane must also be placed on the unit floor modular
joint (unit interior) covering the rive-nut holes completely. A squeegee is used on the mem
brane to compress it onto the unit surface to prevent any air leakage.
STEP 5: Installing the Modular Pressure Plates (figure 10)
The next step is to install the wall, roof and floor modular pressure plates (refer to Figure
10). Identified as PPWM, PPRM and PPFM respectively.
FLOOR Screws
Only use the coarse threaded screws (VIS SS H-L 1/4 x 3/4) for the floor pressure plates and nowhere
else.
Do not tighten the bolts when installing the modular pressure plates in order to allow for room to
move the pressure plate if needed. Once all the bolts are in place, then they can be tightened.
STEP 6: Sealing the Module Interior seams (figure 10)
Caulk the interior wall and roof seam with Silaprene (white or gray) depending on the interior.
The caulking will be supplied by Ingenia.
COVER THE UNIT
Cover the unit properly if it is not fully assembled by the end of the work day and exposed to en
vironmental conditions (wind and rain).

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Page 15
CAULK SEAM PRIOR TO INSTALLING MEMBRANE

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Installation, Operation and Maintenance Manual for Ingenia Indoor Units CAH-ID-16-00
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8.1 Condensate Traps
The purpose of a condensate trap is to allow condensate to drain while preventing air from being
drawn into the unit or air being forced out of the unit. If the cooling coil section is supplied with
more than one drain, each drain connection must have its own independent trap (refer to Figure
11). A trap should be equipped with two tees and plugs to allow for easy access for cleaning, in
spection and priming (refer to Figure 12).
8.1.1 Draw-thru Traps (Figure 12)
P is the fan inlet pressure in (in. W.G.). Filter loading, duct losses, external system effects should
be taken into account when considering the fan inlet pressure. The formula provides the trap
height needed with no safety factor. The designer can include a safety factor as he or she sees
fit.
8.1.2 Blow-thru Traps (Figure 12)
P is the fan outlet pressure in (in. W.G.) Filter loading, duct losses, external system effects should
be taken into account when considering the fan inlet pressure. The formula provides the trap
height needed with no safety factor. The designer can include a safety factor as he or she sees
fit.
8.2 Coil Removable Access Panels
If the coil removable access panel is removed, the contractor must re-apply new membrane
around the access panel when finished. This may also be the case if the coil needs replacing. It is
important to make sure that the grommets , when reinstalling the panel, seal properly around
the coil pipes. In the case of direct expansion refrigeration coils, and if there are no grommets,
caulking around the coil pipes will be necessary.
8.3 Ingenia Panels
Ingenia offers both fiberglass type insulated panels as well as foam injected panels. The foam
panel offers a better thermal resistance, provides a stronger more rigid panel and eliminates any
moisture penetration inside the insulation. The foam used is ecologically friendly which acts as an
insulation as well as a vapor and air barrier. It is made from recycled plastics and soy based ma
terials. It contains no formaldehyde nor CFC’s or HCFC.
Refer to Figure 13 for cutting and sealing an opening in a foam panel.

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B = 1 1/2 P + 2 (INCHES)
PLENUM PRESSURE
(NEGATIVE)
A = 1/2 P + 2 (INCHES)
UNIT DRAIN CONNECTION
NEGATIVE PLENUM PRESSURE
PLENUM PRESSURE
(POSITIVE)
C = P + 2 (INCHES)
UNIT DRAIN CONNECTION
POSITIVE PLENUM PRESSURE
SLOP TO DRAIN
1/8" PER FOOT MINIMUM
FROM COIL DRAIN
RECOMMENDED USE OF
TEES AND PLUGS
HAND-TIGHT PLUG
HAND-TIGHT PLUG (VENT OR PRIMING FUNNEL MAY BE REQUIIRED)
FIGURE B: INDIVIDUAL P-TRAP DESIGN
INDIVIDUAL P-TRAP DESIGN
Detail :
Drawn by : Verified by :
1 of 1
Sheet :
www.ingeniatechnologies.com
Date : 8/9/2016
18101 J.A. BOMBARDIER, MIRABEL, QUÉBEC, CANADA, J7J 2H8
W.N
1
Drawing No :
A.S

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