INGENIA CAH User manual

Installation, Operation and Maintenance Manual for Ingenia Outdoor Units CAH-OD-16-00
1
Installation, Operation and
Maintenance Manual for Ingenia
Outdoor 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 Outdoor Unit CAH-OD-1600

Installation, Operation and Maintenance Manual for Ingenia Outdoor Units CAH-OD-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 Outdoor Units 10
8.1 Condensate Traps 18
8.1.1 Draw-thru Traps 18
8.1.2 Blow-thru Traps 18
8.2 Coil Removable Access Panel 18
8.3 Ingenia Panels 18
8.4 Door Hinge Adjustment 22
8.5 Filter Clips 23
8.6 Electrical Field Connections 24
8.7 Monorail Operation 26
8.8 Exhaust and Outside Air Hoods 28
9.0 Start-up (checklists pg 34) 28
10.0 Service and Maintenance 38
10.1 Bearing Lubrication 38
10.2 Unit Cleaning 38
10.2.1 Coil Cleaning 38
10.3 Sheaves and Belts 39
10.4 Winter Shut-down to prevent Water Coils from Freezing 39
10.5 Antimicrobial Coating Protection 39
11.0 Warranty 40
11.1 Addition / Modification of components to ETL units in the field (ETL Disclaimer) 40
12.0 Replacement Parts 41
Appendix A Stacked modules and Floor Opening 42
Appendix B Pulling together wide modules on roof curb or structural steel 44
Appendix C Fan IOM 46

Installation, Operation and Maintenance Manual for Ingenia Outdoor Units CAH-OD-16-00
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1.0 Receipt and Inspection
A. Upon arrival at the job site, remove protective shrink wrap and thoroughly in-
spect units. Report any damaged equipment to the transport company on the packing slip.
All Ingenia 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 condi-
tion as received at Ingenia. The individual receiving the equipment is responsible for inspect-
ing 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. 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
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) Outdoor units must be installed on a level structural steel platforms or roof
curbs. 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. Use a level
bar to check the levelness of the module at every module split before butting the next module.
2) Shims (if necessary) or supports should be installed at every 8 feet maximum
interval 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 Outdoor Units CAH-OD-16-00
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4.0 Duct Connection
Figure 4 shows a typical through the floor 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
available from Ingenia including: plenum enclosures, inlet screens, outlet screens, motor co-
vers, 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
proximity to turn off electrical service. Service disconnects shall be locked out when mainte-
nance is being performed.
D. Moving parts
All moving parts must have guards to protect personnel. Refer to local codes as to the num-
ber, 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
dangerous 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 Outdoor Units CAH-OD-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 and roof
cladding of the unit (refer to Figure 5). Caution should be taken that door handles, elec-
trical 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.
COVER THE UNIT
Cover the Unit properly if it is not fully assembled by the end of the work day and exposed to
the environmental conditions (wind and rain).
Figure 5 - Unit Rigging
Spreader bars must
be utilized to prevent
lateral contact to
side walls and roof
cladding

Installation, Operation and Maintenance Manual for Ingenia Outdoor Units CAH-OD-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 (including Drift pins)
 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.
VIS FTSQ 1/4”-20X5/8
(Zinc Bolt or Stainless steel) VIS AP HH 12-3/4”
(Self Drilling Zinc or
Stainless steel screws)
BOUL 1/2-13X1 1/2”
GASK 20100MAA
(3”x5”x1/8” FOAM GASKET)
MEMB TPO 2265 2
2” MEMBRANE SCEL SOLIDSEAL
(Silaprene Caulking)
VIS SS H-L 1/4 x 3/4
Floor screws HI LO
Coarse Threads
Philips #3
Robertson #3
Squeegee
Impact drill Heat gun
Level
Caulking gun
(silaprene will be pro-
vided by Ingenia)
Knife 1/2” threaded rod
(approx 12” long)

Installation, Operation and Maintenance Manual for Ingenia Outdoor Units CAH-OD-16-00
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8.0 Installation Procedure for Modular Outdoor Units
Lifting Lugs:
Install the lifting lugs on the longer side of the module or unit (if not already done) PRIOR
TO RIGGING, as indicated on the lifting lugs drawings.
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
module 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 in
stalled on one side of the module for ease of installation. Don’t forget to verify if the module
is level and shim the module in consequence, where necessary. See Addendum B for wide
modules (if necessary).
IMPORTANT:
1) Outdoor units must be installed on a level structural steel platforms or roof
curbs. 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
interval 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.
STEP 3: The Second Module (figure 7)
Set the second module in place allowing for a certain distance from the first to remove the lift
ing lugs if needed. Relocate the lifting lugs on the side of the unit to provide an anchor point
when bringing the modules together. The lifting lugs will always be installed by the factory on
the longer side of the module. 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 mod
ules 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 t h e
modules are completely touching one another. If the rive-nuts on the roof are not in line
(provided the floor base is properly in line), the problem can be easily corrected by placing ny
lon straps in a diagonal arrangement anchoring one end to the a lifting lug and the other to
the opposite diagonal 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 In
genia) to keep the modules compressed against each other.

Installation, Operation and Maintenance Manual for Ingenia Outdoor Units CAH-OD-16-00
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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 andthen 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.
Loosely install the screws and once all the screws are in, tighten the screws in place.
STEP 6: Sealing the Module Interior seams (figure 10)
Caulk the interior wall and roof seam with either gray or white Silaprene depending on the ap
plication and interior colour. The caulking will be supplied by Ingenia.
STEP 7: Installation of the Roof top Cladding
Each modular roof top joint requires a roof cladding segment to be field installed after com
pleting steps 1 through 6. Prior to installing the clad segments, please ensure that the
membrane and compression plates have been adequately installed at each modular joint. This
is a 3 step process.
1. The first step consists of installing the two perimeter channel (PCM) water deflectors lo-
cated on either end of the roof slope (refer to Figure 11). Each clad piece will be identified
with its appropriate part number and will be clearly shown on the project assembly draw-
ings.
2. Install the seam caps/panel (refer to Figure 11). Match the holes in the panel with the
rive-nut inserts and use the SST 1/4-20 x 5/8 bolts, if not, use self drilling screws.
3. Install the side flashing on the high side of the roof cladding. (refer to Figure 11).
Please note that the cladding installation shown in this manual is for a single slope
roof and may be slightly different for every project design. A complete installation de
tail package will be included for each project and may differ from what is shown in this IOM.
Figure 8A
Threaded rods to
keep the modules
together at all
times.

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CAULK SEAM PRIOR TO INSTALLING MEMBRANE

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STEP 1: Install the side PCM over modular seam (bolt them to top of roof panel with the gutter lip overhanging the roof) STEP 2: Install the seam CAP (panel). Match the holes on the long side and bolt to attach. STEP 3: Install and bolt side Flashing on high side of slope.
Hardware: Use 1/4-20 VIS FTSQ 1/4"-20 X 5/8 SST for bolts.
REFER TO ASSEMBLY DRAWINGS FOR SPECIFICS TO THE PROJECT.

Installation, Operation and Maintenance Manual for Ingenia Outdoor Units CAH-OD-16-00
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COVER THE UNIT
Cover the Unit properly if it is not fully assembled by the end of the work day and exposed to
the environmental conditions (wind and rain).
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 sup
plied with more than one drain, each drain connection must have its own independent trap
(refer to Figure 12A). A trap should be equipped with two tees and plugs to allow for easy
access for cleaning, inspection and priming (refer to Figure 12B).
8.1.1 Draw-thru Traps (Figure 12B)
P is the fan inlet pressure in (in. W.G.). Filter loading, duct losses, external system ef-
fects 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 12B)
P is the fan outlet pressure in (in. W.G.) Filter loading, duct losses, external system ef-
fects 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 elim-
inates 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 plas-
tics and soy based materials. 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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12A
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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