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Installation Instructions Issue Date

December 14, 2004

Indoor Air Handling Unit (Model AMI)
The equipment covered in this document is designed for safe and reliable operation when installed and operated within its design specification limits. Observe the following cautionary statements.

DANGER: Electrical Shock Hazards. All power must be disconnected prior to installation and servicing this equipment. More than one source of power may be present. Disconnect all power sources to avoid electrocution or shock injuries.

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WARNING: All unit temporary and permanent supports must be capable of safely supporting the equipment's weight and any additional live or dead loads that may be encountered. All supports must be designed to meet applicable local codes and ordinances.

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DANGER: Moving Parts Hazards. Motor and blower must be disconnected prior to opening access panels. Motors can start automatically; disconnect all power and control circuits prior to servicing to avoid serious crushing or dismemberment injuries.

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WARNING: All fastening devices must be designed to mechanically lock the assembly in place without the capability of loosening or breaking away due to system operation, vibration, impact, or seismic events.

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DANGER: Hot Parts Hazard. Electric resistance heating elements must be disconnected prior to servicing. Electric heaters may start automatically; disconnect all power and control circuits prior to servicing to avoid burns.

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CAUTION: Secure all dampers when servicing the damper, actuator, or linkages. Dampers may activate automatically; disconnect control circuits or pneumatic control systems to avoid injury.

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CAUTION: Protect adjacent flammable materials when brazing. Use flame and heat protection barriers where needed. Have a fire extinguisher available and ready for immediate use.

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WARNING: Check that the unit assembly and component weights can be safely supported by rigging and lifting equipment.

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WARNING: All assemblies must be adequately secured during lifting and rigging by temporary supports and restraints until equipment is permanently fastened and set in its final location.

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© 2004 Johnson Controls, Inc. Code No. LIT-1201887

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Receiving and Inspecting
To receive and inspect the unit, perform the following steps: 1. Upon receipt of the equipment, carefully check all items against the bill of lading to ensure that all of the equipment has been received. Note any discrepancy on the bill of lading before signing for the shipment. Inspect all equipment for any signs of damage caused during transit. Note any visual damage on the bill of lading before signing. Immediately report all visual and concealed damage to the carrier and file a claim with the carrier.

WARNING: When steam cleaning coils, verify that the area is clear of all personnel.

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WARNING: Do not remove access panels until the impeller has completely stopped. The pressure that is developed by a moving impeller can cause excessive force against the access panels.

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Safety Considerations
DANGER: Never reach into a unit while the fan is running. Never open an access door downstream of the fan while the fan is running.

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WARNING: Do not work on dampers until their operators are disconnected.

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DANGER: Lock open and tag the fan motor power disconnect switch before working on the fan. Take the fuses with you and note their removal on the product tag. Because the unit may have more than one power source, disconnect all power.

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CAUTION: Secure drive sheaves with a rope or strap before working on the fan to ensure that the blower wheel cannot freewheel.

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CAUTION: Never pressurize equipment above the specified test pressure.

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Introduction
DANGER: Lock open and tag the electrical heater coil power disconnect switch before working on or near the heater. Because the unit may have more than one power source, disconnect all power.

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General To ensure long and trouble-free life, the equipment should have proper care and maintenance. Accordingly, enough space should be left around the unit for service and repair. As shipped, the equipment is factory-assembled as much as job specifications and shipping limitations allow. Where field assembly is required, bolts, nuts, and gasketing material are provided with each module. Modules bolt together from the inside of the upstream module. Unit Identification To ensure that the assembled AMI modules are in the proper sequence, each module has an identifying code and an airflow direction label. The proper assembly sequence is listed on the supply fan nametag. The first listed module is the first section in the direction of airflow.

WARNING: Check the assembly and component weights ensure that the rigging equipment can handle them safely; note the centers of gravity and any specific rigging instructions.

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WARNING: Check for adequate ventilation so fumes will not migrate through ductwork to occupied spaces when welding or cutting inside the air-handling equipment. 2

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Indoor Air Handling Unit (Model AMI) Installation Instructions

Do not lift equipment by coil connection or headers. do not rig the equipment until after field assembly. Observe the following important guidelines: • The equipment must be rigged as it was shipped from the factory. damage to bottom of equipment can result. Do not remove protective caps from the piping connections until you are ready to connect the piping. rough handling may cause bearing misalignment and/or shaft damage. Because all fans are dynamically balanced. Lift the equipment using slings and spreader bars (not shown) to prevent damage to the equipment (see Figure 1). Always take special care when handling the blower module. • • • • Figure 1: Rigging and Handling Indoor Air Handling Unit (Model AMI) Installation Instructions 3 . • All AMI equipment can be rigged by means of the lifting holes on the bottom of base rail (see Figure 1). Avoid twisting or uneven lifting of equipment. Do not remove the shipping skid or protective cover until equipment is ready for final placement. fully assembled or in assembled sections depending on the unit size and application.Rigging and Handling The AMI air handler can ship as separate modules.

Secure the cover with adequate tie downs and store indoors. Remove all loose parts from the job site to minimize theft. lift only from the heavy end of the skid. as damage to stationary bearings can occur. Cover all of the equipment with a protective tarp or moisture proof cover. observe the following storage precautions: • Choose a dry storage site that is reasonably level and sturdy to prevent undue stress or permanent damage to the equipment structure or components. Do not store the equipment on a vibrating surface. see the Rigging and Handling section. Stacking can cause damage or deformation. open the fan access panel. remove belt ties. Tag and store the loose parts in a safe place until needed.Storage To transfer the equipment from a truck to a storage site. Bolt holes are accessible through the inside of the upstream module. CAUTION: If a forklift is used. and rotate the fan and motor slowly by hand to redistribute bearing grease and to prevent bearing corrosion. Monthly: Remove the cover from the unit. Set the equipment off of the ground if in a moisture prone area. If the equipment is to be stored for more than 2 weeks prior to installation. ! Figure 2: Bolt Holes (1 of 2) • • • • Figure 3: Bolt Holes (2 of 2) 4 Indoor Air Handling Unit (Model AMI) Installation Instructions . Assembling the Equipment All modules ship with the required bolts. and gasket material to assemble the equipment. Do not stack the unit modules or accessories during storage. nuts. Extend the cover under the equipment if it is stored on the ground. Be sure that the piping connections have protective shipping caps installed.

Figure 4: Gasket Overlap Mounting the Actuator The installing contractor takes all responsibility for the mounting of all field-installed actuators. they must be driven by individual actuators and controlled separately. Installation Install this equipment in strict accordance with any applicable local. 2. To apply a gasket to the unit. Mixing Box Fresh air and return air dampers can be connected together and driven from the same actuator if the dampers are the same size. On single-wall equipment. perform the following steps: 1. but not limited to. Before hanging the equipment. Apply a gasket the perimeter of each module. drives. Each module must be supported with an angle iron or channel. all field assembly must be completed. IMPORTANT: Ensure proper actuator support to prevent unnecessary stress in the linkage. including all equipment. No requirements are made for the position of these actuators due to the number of options and arrangements available and the assortment of specific applications. and mechanical codes. The AMI product line is not designed to be suspended from the top of the equipment. plywood). and all live or dead loads. a base rail. If the dampers are different sizes. All supports must be designed to meet applicable local codes and ordinances. or damper shaft. Indoor Air Handling Unit (Model AMI) Installation Instructions 5 . building. A hanger rod must be installed in each corner of a module to properly support the equipment and maintain the unit's structural integrity. gasketing material is supplied with each module. inside the equipment to protect the insulation during installation. Suspending a Unit Using Factory Base Rail Factory optional base rails have a 5/8” diameter hole located in each corner for hanger rods. angle iron.Gasketing For sections that require job site assembly. lay rigid temporary protection (for example. motor. Note: Hanger rods must be located so they do not interfere with access panels. electrical. state. Suspending a Unit Using Field-Supplied Supports All field-supplied structural supports must be designed to support the entire unit weight. or channel must support the equipment. and national codes including. The angle iron or channel must cover the width and length of the equipment base and must be designed to mechanically lock the unit to the field supports (see Figure 5). Overlap the gasketing approximately 1/8” when splicing to prevent air leakage between modules. Multiple damper assemblies must not be actuated from the shaft extension opposite the connection link. cabinet. Suspending a Unit When the equipment is suspended from a ceiling.

Figure 5: Units Suspended Using Field-Supplied Supports 6 Indoor Air Handling Unit (Model AMI) Installation Instructions .

wiring. Isolate all piping. failure to do so may cause cracking at the headers. the piping must be isolated or have a flexible connection to prevent coil header damage due to equipment movement. All piping must be in accordance with local codes and follow accepted industry standards. Field penetration of panels is required for liquid line piping. Figure 6: Shipping Hold-Downs External Isolation Install vibration isolators in accordance with the job specifications and the instructions of the isolator manufacturer base. All coil connections are stubbed out of the cabinet panel with the exception of the refrigerant (DX) coils. Condensate Drain All condensate drains must have a trap installed to prevent excessive condensate buildup and/or condensate overflow. If the coil module is also isolated. Figure 8: Condensate Drain Trap Figure 7: Vibration Isolators Indoor Air Handling Unit (Model AMI) Installation Instructions 7 . Clearance must meet or exceed applicable local and national codes. and repair. maintenance. bearings. ductwork. Panel Removal To remove access panels. the trap depth and the distance between the pan outlet and the trap outlet should be twice the negative static pressure of the coil module under normal operation. Service Clearance Access to at least one side of the equipment is required for routine service. coil. Consideration should be given to the fan shaft. To ensure that the trap remains sealed. and damper linkage access. lift off the hinges with quick turn fasteners. Before mounting the Thermostatic Expansion Valve (TXV). General Piping All pipe connections need to be supported independently from the header. loosen the four retaining screws and lift the panel off. removal of the shipping hold-downs is required before equipment startup. and external connections. filter removal. you must remove the Direct Expansion (DX) coil distributor cap for testing and nitrogen charging. Alternately.Internal Isolation Equipment may be supplied with internal spring isolation. Base rails are required for external isolation. If so. fan. motor.

2. 2. 3. make sure that the fan electrical power source is disconnected and locked in the OFF position. • • CAUTION: Equipment damage due to loose setscrews or fasteners represents improper startup and equipment abuse. If the fan is operating backward. Note: Motor and ball bearings on the fan shaft are prelubricated and do not need grease before startup. It is not covered by the warranty. Perform the following steps prior to starting the unit: 1. Start the fan and observe its rotation. Notes: • • • Door electrical interlock is not offered. 3. connect the fan segment’s metal casing to the building’s electrical ground. If retightening is needed.Electrical Installation To wire the unit. Rotate the shaft manually to make sure it is free. a combined variation in voltage and frequency of 10% (the sum of absolute values) of rated values. Check the tightness of sheave setscrews and/or capscrews. provided the frequency variation does not exceed 5% of rated frequency Pre-startup IMPORTANT: Before entering the fan section. See Table 1 for torque settings. Thermal protection and a disconnect switch are provided by others. ! 8 Indoor Air Handling Unit (Model AMI) Installation Instructions . make certain the fan wheel(s) are positioned accordingly and that setscrews are torqued appropriately. Check that the unit is completely and properly installed with ductwork connected. 6. Check the tightness of the setscrews in the bearings and fan wheel(s). leak test the piping systems. Some motors have internal automatic reset overload protection. Thermal motor protection is external to the unit. Check that condensate drain is trapped. 7. perform the following steps: 1. AC power is within 5% of rated frequency with voltage. disconnect the power and reverse the two legs of the three-phase supply power. 8. Review the wiring diagram and make any necessary connections. Check the alignment of fan and motor sheaves and belt tension. Check that all electrical work is finished and properly terminated. Startup Alternating Current (AC) power current imbalance must not exceed 2%. Observe the following guidelines: • AC power is within 10% of rate voltage with frequency (see the equipment nameplate for ratings). 5. Check that all construction debris is removed and filters are cleaned. Check that all electrical connections are tight and that the proper voltage is connected. To ensure that water connections and joints are tight. Verify that the electrical service to the fan is compatible to the rated voltage on the motor nameplate and is in accordance with local codes. 4. On isolated units.

they are set to the mid RPM range. braces. 7. it is a common industry recommendation that the variable pitched motor sheave be replaced with a properly sized fixed sheave.First-Time Motor Startup IMPORTANT: Check to see that all power to the equipment is off. motor bearings. Ensure that all shipping materials. a. Momentarily apply power and check the rotation of the motor shaft. fixed sheaves maintain balance and alignment more effectively. and electrical continuity. 2. Ensure that motor is properly ventilated. disconnect the power and connect the load to the motor shaft. the current draw of the motors should be checked and compared to the full load current rating of the motor. Initially. Check the lubrication of the fan. c. After one hour of operation. Also. 3. 4. Note that all bearings are shipped completely full of grease for corrosion protection. and construction debris is out of equipment. If it is. A matching fixed sheave provides longer belt and bearing life and vibration-free operation. Sheaves Upon completion of the air balance. check the winding insulation integrity with the megger. When final field alterations are concluded. Perform the following steps the first time you start the motor: 1. but once balance has been achieved. mechanical strength. If motor rotation is wrong. Bearings may temporarily run warm on startup until excess grease is discharged. b. it is best to have a variable pitched motor sheave for the purpose of air balancing. Indoor Air Handling Unit (Model AMI) Installation Instructions 9 . 6. and damper linkage. ensure that power is off and change the motor lead connections. Make sure that the mechanical installation is secure and that all bolts and nuts are tightened. verify rotation before you continue. 8. Air Balancing When units are supplied with a variable pitch motor sheave. Hand operate all damper linkages to check freedom of movement. Check the tightness of the bearing setscrews or locking collars. Start the motor and ensure that operation is smooth without excessive vibration or noise. Ensure that all construction debris is removed from the inside of the equipment. If the equipment has been in storage or idle for some time. 5. run the motor for 1 hour with no load connected. see the Adjusting Variable Pitched Sheaves (Motor Only) section in this document. check the tightness of the setscrews on the fan wheel and sheave. Manually rotate the motor shaft to ensure that it rotates freely. clearance. Inspect all electrical connections for proper terminations. and ensure that the motor shaft is disconnected from the load and does not cause fan rotation. 9. Replace all of the panels removed during installation. For variable pitch sheave adjustment instructions. 10. 12. For variable pitch sheave adjustment instructions. The amperage must not be above that shown on the motor nameplate. see the Adjusting Variable Pitched Sheaves (Motor Only) section in this document. Field adjustment may be necessary to achieve the required airflow. 11.

moist or dirty air. Detailed procedural information is given after this checklist. be sure not to overtighten the belt. Relubricate fan bearings if operating conditions include high speeds. tighten the sheave setscrews to the proper torque check and adjust fan belt tension tighten electrical connections inspect coils for dirt build-up or coil freeze-up 10 Indoor Air Handling Unit (Model AMI) Installation Instructions . the nylon damper rod bushings. and dampers. repair or replace as necessary. recommendations are provided on the motor label check bearing and motor bracket bolt torque Note: See Table 1 for torque settings. clean and paint the surface with a rust-resistant primer and vinyl chlorinated lacquer. moist or dirty air. the wheel should not rub on the fan housing. Check the condition of gasketing and insulation around the unit. door. Monthly Observe the following monthly guidelines: • • Check air filters. Rotate the fan wheel and check for obstructions in the fan housing. using a fin comb. Examine flex connections for cracks or leaks. if damage is found. Inspect the condensate pan and drain line. or high temperatures (see the motor label for more information). Inspect control and power box wiring for secure connections and insulation. clean or replace if they are clogged or dirty. Clean the damper operators. but do not lubricate. the lines should be tight to the bearings relubricate fan bearings check motor lubrication. Remove obstructions from the unit. After 48 Hours of Operation Belts will achieve their permanent stretch and will require readjustment. clean. Yearly Observe the following annual guidelines: • Inspect the unit casing for corrosion. Clean the coils. Adjust the fan wheel to center if necessary and tighten wheel setscrews to the proper torque. or high temperatures. remove any rust with an emery cloth and apply a coat of heavy-duty rust inhibitor. Relubricate motor bearings in accordance with the motor manufacturer's recommendations if operating conditions include high speed. straighten any bent fins. • align fan and motor sheaves. Weekly Observe the unit weekly for any changes in running condition and unusual noise. • • • • • • • • • • • • Every 3 to 6 Months Observe the following quarterly and semi-annual guidelines: • • • • • • • • check the fan bearing grease line connections. repair or replace damaged material. Clean the fan wheel and fan shaft.Periodic Maintenance and Service The following checklist is provided as an abbreviated guide to periodic maintenance. set screws and blade adjustment. Check and adjust the fan belt tension. remove sludge or foreign materials that might obstruct proper drainage. Check damper linkages.

Carefully follow the sanitizer manufacturer’s instructions regarding the use and the disposal of their product.Table 1: Minimum Hex Head Bolt Torque in Foot lbs. 4. Ventilating. clean the pan immediately. Remove all standing water. it must be removed immediately and that portion of the unit properly cleaned and sanitized. Properly dispose of all contaminated materials and cleaning solution. If microbial growth (mold) in the drain pan is observed. Be careful that the contaminated material does not contact other areas of the unit or building. IMPORTANT: Standing water in drain pans can promote microbial growth (mold) that may cause unpleasant odors and serious health-related indoor air quality problems. 8. identify and remedy the cause immediately. If mold is found. Allow the unit to dry thoroughly before putting the system back into service. Perform the following steps to inspect and clean drain pans: 1. 5. Disconnect all electrical power to the unit. Immediately rinse the drain pan thoroughly with fresh water to prevent potential corrosion from the cleaning solution of the drain pan and drain line components. Put on appropriate personal protective equipment.3-micron particle size.97% at 0. 6. 2. Determine and correct the cause of the microbial contamination. and tag and lock out the power source. 7. Thread Designation UNC UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF UNC UNF Minimum Torque 6 14 16 24 28 42 45 69 83 99 118 150 176 254 301 358 422 500 602 Indoor Air Handling Unit (Model AMI) Installation Instructions 11 . 3. (Grade 5 Bolt) Size (inches) 1/4 – 20 5/16 – 18 5/16 – 24 3/8 – 16 3/8 – 24 7/16 – 14 7/16 – 20 1/2 – 13 1/2 – 20 9/16 – 12 9/16 – 18 5/8 – 11 5/8 – 18 3/4 – 10 3/4 – 16 7/8 – 9 7/8 – 14 1-8 1-14 Drain Pan Inspecting and Cleaning Drain Pans If evidence of standing water or condensate overflow exists. and Air Conditioning (HVAC) use. Use a scraper or other tool to remove any solid matter. 9. Remove solid matter with a vacuum device that uses High-Efficiency Particulate Air (HEPA) filters with a minimum efficiency of 99. Thoroughly clean the contaminated area with mild bleach and water solution or an Environmental Protection Agency (EPA)-approved sanitizer specifically designed for Heating.

the cause of the contamination must be determined and action taken to ensure it does not reoccur. Put on appropriate personal protective equipment. Disconnect all electrical power to the unit. Wet. Throwaway Filters To replace throwaway filters. and tag and lock out the power source.97% efficient at 0. and tag and lock out the power source. Allow the unit to dry thoroughly before putting the system back into service. Check grease lines for tight connections at the grease fitting. Turn the fan wheel manually while adding grease. The filter should be 99. If no microbial growth (mold) exists. Use a portable vacuum with HEPA filtration to remove the loose dirt and organic matter. Be careful that the contaminated material does not contact other areas of the unit or building. See Table 1 for bearing setscrew torque.Air Filters Refer to the Indoor Air Handling Unit (Model AMI) Product Bulletin (LIT-1201834) for information on air filter size. 5. If microbial growth (mold) is present. type. remove the contamination and thoroughly clean the affected area with an EPA-approved sanitizer specifically designed for HVAC use. 3. 4.3-micron particle size. 12 Indoor Air Handling Unit (Model AMI) Installation Instructions . or more frequently if the unit operating experience dictates another inspection. 3. Dry Dirty. thoroughly clean the fan and associated components with an industrial cleaning solution. Perform the following steps to inspect and clean fans: 1. 2. install new filters with the directional arrows pointing in the direction of airflow. Table 2: Recommended Greasing Intervals – Fan Bearings Operating Conditions Clean. Disconnect all electrical power to the unit. Fan Bearings Aligning Bearing Setscrews Align bearing setscrews. IMPORTANT: If microbial growth (mold) was found. Using a manual low-pressure grease gun. and quantity. add grease until a light bead appears at the bearing grease seal. Accumulated dirt and organic matter on the interior surfaces of fans should be cleaned immediately. High Humid -20 to 140°F 3 – 6 months 1 – 3 months 1 – 4 weeks 140 to 200°F 1 – 3 weeks 1 – 4 weeks 1 – 14 days Table 3: Recommended Greases for Various Operating Ranges Recommended Greases Texaco™ Multifak® #2 Shell™ Alvania® #2 Mobil™ Mobilux® #2 Exxon™ Unirex #2 Exxon™ Beacon Recommended Operating Range -20°F to 250°F -20°F to 250°F -20°F to 250°F -20°F to 250°F -65°F to 250°F Table 4: Fan Bearing Maximum Grease Capacity Shaft Size (inches) 1/2 – 3/4 7/8 – 1 3/16 1 1/4 – 1 1/2 1 11/16 – 1 15/16 2 – 2 7/16 2 1/2 – 2 15/16 Capacity (fluid ounces) 1/8 3/8 5/8 7/8 1 1/4 2 Note: Lubricate fan bearings with a lithium base grease conforming to National Lubricating Grease Institute (NLGI) Number 2 for consistency. b. Properly dispose of all contaminated materials and cleaning solution. Carefully follow the cleaning solution manufacturer’s instructions regarding the use and the disposal of their product. 6. 2. a. Lubricating Fan Bearings Perform the following steps to lubricate fan bearings: 1. Fans Inspecting and Cleaning Fans Fan sections or air handlers should be inspected every six months at a minimum. Dry Dirty. Rinse the affected surfaces thoroughly with fresh water and a fresh sponge to prevent potential corrosion of metal surfaces. Carefully follow sanitizer manufacturer instructions.

If the motor is not properly ventilated. use a high-grade ball or roller bearing grease. Disassemble the motor. Operating conditions vary the frequency of inspection and lubrication. It is important to remember that this recommendation is based on average use. which can accumulate and block motor ventilation.Motor General Inspection Inspect the motor at regular intervals. 4. See Table 1 for torque settings. 3. up to and including National Electrical Manufacturers Association (NEMA) frame 215T. Keep the motor clean and the ventilation opening clear.5 hp Motors Every 5 years Every 2 years Every 6 months 10 hp Motors Every 3 years Yearly Every 3 months Lubricating the Motor with the Grease Outlet Plug Perform the following steps to lubricate the motor: 1. Add grease to the motor. 2. When lubricating the motor. Add the recommended amount of grease to the bearing and bearing cavity.25 to 7. Periodically use the megger to ensure that the integrity of the winding insulation has been maintained. grease. and water. overheating can occur and can cause early motor failure. not suddenly. 3. Remove the grease outlet plug. 2. Note: The bearing should be about 1/3 full of grease and the outboard bearing cavity should be about 1/2 full of grease. CAUTION: To avoid damage to motor bearings. IMPORTANT: Ensure that the grease you are adding to the motor is compatible with the grease already in the motor. Perform the following steps to inspect the motor: 1. Lubricating the Motor without the Grease Outlet Plug Perform the following steps to lubricate the motor: 1. 4. The lubricating ability of grease (over time) depends primarily on the type of grease. record megger readings. Check that all mechanical fasteners are properly tightened. Check all electrical connectors to verify that they are tight. whichever occurs first. Immediately investigate any significant drop in insulation resistance. the speed at which the bearing operates.000 hours of operation. Clean the grease fitting. To relubricate the motor. slowly add a slightly greater quantity of grease until the new grease appears at the shaft hole in the endplate or purge outlet plug. The motor is factory installed with Chevron® SRI with a polyurea base. Check that the motor is clean.800 RPM motor. grease must be kept free of dirt. and the severity of the operating conditions. 3. If greasing the motor while it is running. 13 Indoor Air Handling Unit (Model AMI) Installation Instructions . Check that the interior and exterior of the motor is free of dirt. The recommended lubrication interval for an 1. Consult your factory representative if grease other than the recommended type is to be used. If the motor is stopped. the size of the bearing. Lubrication and Bearings Bearing grease loses its lubrication ability over time. Assemble the motor. 2. Table 5: Recommended Motor Greasing Schedule Average Daily Operating Hours 8 – 16 12 – 24 Any ! Maximum Ambient Temperature 40°C 50°C >50°C or Class H insulation Average Environment Clean and dry Moderate dirt or moisture Severe (very dirty or high temperatures) . is every 12. oil. Reinstall the grease outlet plug. consult the maintenance tag provided on the motor. a. b. approximately every 500 hours of operation or every 3 months. add the recommended amount of grease.

The sheave should be as close to the motor as possible with setscrew (A) in full contact with the key. and shaft. see the Adjusting Belt Tension section in this document. WARNING: If the setscrew is not fully in contact with the key. The centerline of the driver sheave must line up with the centerline of the driven sheave. Ensure that the driver and driven sheaves are in alignment and that the shafts are parallel. Verify that all straight bore sheaves are mounted on the motor or driver shaft with the setscrew (A) toward the motor (see Figure 9). Angle A cannot exceed 1/2º (see Figure 10). the sheave assembly could come off. Make sure there are no nicks or burrs on the key. Figure 9) between the sheave and the shaft and tighten the setscrew (A. If there are. perform the following steps: 1. Insert the key (D. 5.Drives Mounting Straight Bore Sheaves To mount straight bore sheaves. 7. Put on the belts and adjust the belt tension properly. 6. 3. ! Figure 9: Mounting Straight Bore Sheaves (1 of 2) Figure 10: Mounting Straight Bore Sheaves (2 of 2) 14 Indoor Air Handling Unit (Model AMI) Installation Instructions . 4. For more information. keyway. Check the setscrew and belt tension after 24 hours of service. Figure 9) in place using the torque value from Table 1. 2. remove them using the appropriate methods. Check the key size with both the shaft and the sheave. Verify that all keys are in place. Make sure all setscrews and capscrews are torqued properly before starting the drive.

Make sure there are no nicks or burrs on the key. 6. The bushing should be loose enough in the hub to move slightly. Make sure all setscrews and capscrews are torqued properly before starting the drive. do not use a wrench at this time. If it does not go on easily. creating an allowance for the endplay of the shaft to prevent rubbing. and tapered bore. Put on the belt and adjust the belt tension properly. 5. some gap should remain between the flange and the hub after tightening. 10. Tighten the capscrews progressively with a wrench. For more information. Angle A cannot exceed 1/2º (see Figure 10). The centerline of the driver sheave must line up with the centerline of the driven sheave. perform the following steps: 1. do not press tightly onto the drive. lubricants or contaminants from the bushing. Check the key size with both the bushing and the shaft. See Table 1 for torque settings. Note: Do not attempt to pull the flange flush with the hub. turning them just enough to engage the threads in the tapered holes on hub. see the Adjusting Belt Tension section in this document. Figure 11: Split Tapper Sheave To mount split tapper sheaves. 2. 7. If there are. Insert the key (D) between the sheave and the shaft. Slide the assembly on to the shaft. 4. Check the setscrew and belt tension after 24 hours of service. Remove any oils. and key size. and shaft. following a star pattern and taking a partial turn on each capscrew successively until all are tight. Do not force the assembly onto the shaft. 9. remove them using the appropriate methods. Start turning the capscrews (C) by hand. Indoor Air Handling Unit (Model AMI) Installation Instructions 15 . 3.Mounting Split Tapper Sheaves 8. Put the bushing (B) loosely in the hub of the sheave (A). Verify that the driver and driven sheaves are in alignment and that the shafts are parallel. bushing. Verify that all keys are in place. keyway. check the shaft. capscrew.

3. Loosen the setscrew (B) in the outer locking ring. remove the belts from the groove(s). Check the setscrew and belt tension after 24 hours of service. Make sure all setscrews and capscrews are torqued properly before starting the drive. 4.Adjusting Variable Pitched Sheaves (Motor Only) To adjust variable pitched sheaves. Note: This key projects a small amount to provide a grip for removal. 2. 4. ! Figure 13: Belt Tension 2. Doing so may cause the belts to sit improperly and cause the flanges to detach while in service. Both movable flanges must be rotated the same number of turns to ensure the same pitch diameter for satisfactory operation. For more information. apply force at a right angle to the midpoint of the belt span. Belts Adjusting Belt Tension To adjust belt tension. and periodically thereafter. 3. 9. Verify that all keys are in place.or full-turn. Opening the flange(s) decrease the blower speed. To measure the belt span. Replace the key (D). see Figure 9 and perform the following steps: 1. Check the tension at least twice during the first day of operation. see the Adjusting Belt Tension section in this document. 7. Use the following formula to calculate the belt span. See Table 1 for torque settings. but do not remove. Note: Two groove sheaves are supplied with both grooves set at the same pitch diameter. Calculate deflection (Deflection = Span ÷ 64). Tighten the setscrew (B) in the outer locking ring and the capscrew (C) with a torque wrench. 5. Adjust the pitch diameter by opening or closing the movable flange(s) by a half. Loosen. 8. 16 Indoor Air Handling Unit (Model AMI) Installation Instructions . where: C = center distance to the drive shaft D = driver sheave (large sheave) pitch diameter d = driver sheave (small sheave) pitch diameter Figure 12: Calculating Span WARNING: Do not open the sheaves more than five turns for the A belt or six turns for the B belt. Put on the belt and adjust the belt tension properly. Slack off all belt tension by moving the motor towards the blower shaft until the belts are free of the groove(s). perform the following steps: 1. lay a tape measure along the top of the belt and measure between the points at which the outside of the belt meets the outside of the sheaves. closing the flange(s) increases blower speed. Using a spring scale. 6. Remove the key (D). the capscrew. For easier adjustment.

9 6.6" 2501 – 4000 400 – 2500 A 3. in turn causing unpleasant odors and serious health related indoor air quality problems. belts have a specific horsepower rating that must not be exceeded.0 8.3 7.2 6. Give drives clearance. Never force belts.6" 2501 – 4000 B 860 – 2500 5.3.0 . ! • Indoor Air Handling Unit (Model AMI) Installation Instructions 17 . move the motor on the adjustment base so the belts go on easily.5 Increasing Belt Life Observe the following guidelines to ensure longer belt life: • • • • Keep sheaves and belts clean. and acids reduce service life. Matched belts run more smoothly and last longer because the load is evenly distributed.7.8 5.8" 2501 – 4000 400 – 2500 5. • • CAUTION: Fin edges are sharp and fragile. microbial growth (mold) can result. never let belts run against the belt guards or other obstructions.5 4. Coils The frequency of required coil cleaning is dependent on system operating hours.5 6.3 9. Use matched belts. filter maintenance and efficiency.0" 2501 – 4000 860 – 2500 4.0 . which commonly occurs with cooling coils. causing slippage and less air delivery. care must be exercised to avoid damaging fins.4 . Dirt on the surface of the coil reduces its ability to transfer heat and can result in reduced performance and increased operating energy costs. Eliminate slack.0 2.8 4.4.5.7 8. The shaft must be parallel and the sheave grooves must be in alignment to prevent unnecessary belt wear. oils.0 7. If the dirt on the surface of the coil becomes wet.7 5. IMPORTANT: Coils may become externally fouled as result of normal operation.7 RPM Range New Belt 5.4 5. rust. Never partially replace a set of belts. Mount belts straight.4 4. and dirt load.Table 6: Deflection Force Belt Cross Section Smallest Sheave Diameter Range Belt Deflection Force Used Belt 400 – 2500 3.6" 2501 – 4000 6. Slack belts wear excessively.8 3.8 .7 4. Do not overload the belt.8 .9 3. Adjust the motor and tighten the belts in position.8. abrasive dust.

Clean the leaving airside of the coil first. Be careful that any contaminated material does not contact other areas of the unit or building. Perform the following steps to clean water coils: 1. note the following: a. Refrigerant Coils Refrigerant coils should be kept clean to maintain maximum performance. clean them with cold water and detergent or one of the commercially available chemical coil cleaners. Spray perpendicular to the coil face. 4. Using a fin comb. Rinse coils thoroughly after cleaning. Use a block-off to prevent steam from blowing through the coil and into the dry sections of the unit. clean them with steam and detergent. 8. d. straighten any coil fins that may have been damaged during the cleaning process. 18 Indoor Air Handling Unit (Model AMI) Installation Instructions . 9. Carefully follow the cleaning solution manufacturer’s instructions regarding use of the product. Replace all panels and parts and restore electrical power to the unit. Thoroughly rinse both sides of the coil and the drain pan with cool. 10. c. If fins become dirty. 8. hot water. 3. 7. Use a soft brush to remove loose debris from the sides of the coil. Repeat Steps 4 and 5 as necessary. and Chilled Water Coils section. hot water spray and detergent. Place the mixed solution in a garden sprayer or high-pressure sprayer. Follow Steps 1 – 4 in the Steam. then the entering airside. Confirm that the drain line is open. Do not exceed 600 psi. 3.Steam. 9. Access the coil section of the unit.5 or higher). clean water. Be careful that any contaminated material does not contact other areas of the unit or building. b. straighten any coil fins that may have been damaged during the cleaning process. Using a steam-cleaning machine. then the entering airside. 4. Keep the nozzle at least six inches from the coil. 2. it must contain an inhibitor. 2. or one of the commercially available chemical coil cleaners. Protect other areas of the air handler and internal controls from contact with moisture or the cleaning solution. If a high-pressure sprayer is used. Replace all panels and parts and restore electrical power to the unit. Spray the leaving airside of the coil first. Hot Water. Confirm that the drain line is open. and tag and lock out the power source. 7. If fins become dirty. Put on appropriate personal protective equipment. Mix a high quality coil cleaning detergent with water according to the manufacturer’s instructions. Maintain a minimum nozzle spray angle of 15 degrees. and chilled water coils should be kept clean to maintain maximum performance. 5. Properly dispose of all contaminated materials and cleaning solution. Perform the following steps to clean refrigerant coils: 1. Properly dispose of all contaminated materials and cleaning solution. Carefully follow the detergent manufacturer’s instructions regarding use of the product. 5. e. start from the top of the coil and work downward. Note: If the detergent is strongly alkaline after mixing (pH 8. and Chilled Water Coils Steam. Rinse coils thoroughly after cleaning. 10. Disconnect all electrical power to the unit. Use a block-off to prevent spray from going through the coil and into the dry sections of the unit and/or system ductwork. Hot Water. 6. Repeat as necessary. Using a fin comb. 6. Enable the unit to dry thoroughly before putting the system back in service.

The fan shaft is not parallel with the motor shaft. The small amount of anti-freeze solution remaining in the coil must be sufficient to prevent freeze-up. Bad V-belts. A fan wheel that is operated beyond the RPM and temperature limits shown in the table may suffer permanent damage or failure. Table 7: Vibration Levels Fan Speed (RPM) 800 or less 801 or greater Vibration 5 mils maximum displacement . Bent blower shaft 3. Scheduled draining of water cooling coils for winter shutdown cannot be depended upon as insurance against interior tube freeze-up. Vibration Causes Causes of vibration include: 1. or mismatched belts c. there will be a diluting effect.20 inches/section maximum velocity Note: Excessive vibration from any cause contributes to premature fan and motor bearing failure. The fan section is not supported evenly on the foundation. It is recommended that all coils be drained as thoroughly as possible and then treated. and bearing hold-down bolts for tightness every 6 months. Operating Limits Do not exceed the operating limits in Table 8. Motor imbalance 6. 2. Faulty drive a. Vibration Levels Each unit that is shipped has been trim-balanced to function properly. Loose setscrews in the wheel hub or bearing-to-shaft. Overall. b. 4. and wheel hub setscrews. lumpy. Belt tension too tight or loose Operating Guidelines Periodic Service and Maintenance Check all moving parts for wear every 6 months. although factory requirements are much tighter to ensure satisfactory operation after the rigors of shipping and installation. Thoroughly drain each coil. WARNING: Carefully read the instructions for mixing anti-freeze. sheave capscrews. The wheel balance weight is missing. ! c. The wheel is distorted from over-speed. Freeze-up will result in severe coil damage. Wheel imbalance a. 7. IMPORTANT: Due to a small amount of water always remaining in each coil. 2. Using a small circulating pump.Winterizing Water Coils Due to air stratification and the failure of outdoor air dampers and/or preheat controls. fill each coil independently with an antifreeze solution. sheave. vibration levels should be monitored every six months of operation. Perform the following steps to winterize water coils: 1. uneven groove spacing or out of balance. Indoor Air Handling Unit (Model AMI) Installation Instructions 19 . loose bearing hold-down bolts 5. b. Note: Check the freezing point of the anti-freeze before proceeding to the next coil. Bad bearings. Some products have a higher natural state freezing point than when mixed with water. d. coil freeze-up can occur. Variable pitch sheaves – axial and radial run-out of flanges. There may be a similar fault in the driven sheave. and check the bearing collar. An increase in levels is an indication of potential trouble. Dirt or debris on the wheel blades.

2. perform the following steps: 1. 3. perform the following steps: 1. Use a backup pipe wrench to avoid breaking the weld between the coil connection and the header. it will be shipped loose and you will need to field install it to the distributor. 2. wrap it in a wet rag while brazing. 3. water return. size. drain and vent connections on the end panel. 4. 4. DX coils are shipped capped and sealed with a 20 psig holding charge of dry nitrogen. Follow the recommendations of the control manufacturer regarding type. Direct Expansion (DX) Coils To design and install DX coils. 5. 7. Connect the 1/4-inch diameter external equalizer tube provided on the coil to the connection on the expansion valve. Check the nozzle in the distributor for proper tonnage. Label water supply. 20 Indoor Air Handling Unit (Model AMI) Installation Instructions . Avoid undue stress to the connection extending through the unit panel. In addition. and installation of control valves. Check the water supply and water return connections. size. 6.Table 8: Forward Curve Fan Data Diameter Maximum RPM Class I Maximum RPM Class II Note: 9x4 4800 n/a 9x6 3600 n/a 10 x 7 2800 n/a 12 x 9 2300 n/a 12 x 12 2000 n/a 15 x 11 1600 1700 18 x 13 1200 1475 18 x 18 1200 1450 The maximum air temperature through the fan section is 225°F (107°C). Refrigerating and Air-Conditioning Engineers (ASHRAE) Fundamentals Handbook. When a thermostatic expansion valve is supplied with the unit. Coil Applications General When designing and installing piping. Verify that the coil suction connection is extended through the end panel of the coil section and that the coil distributor is located inside the cabinet on the same side as the suction connection. Water Cooling Coils To design and install water cooling coils. The thermostatic expansion valve must be the same tube type as the external equalizer. Do not apply heat to the body or thermal element of the expansion value. Remove the nitrogen charge from the coil by depressing the Schraeder stem prior to cap removal. and installation information presented in the American Society of Heating. follow the design. observe all local codes and industry standards. Exercise care when piping up the system to ensure all joints are tight and all lines are dry and free of foreign material.

Provision must be made to close the fresh air dampers if the steam supply pressure falls below the specified minimum. 9. Stresses resulting from expansion of closely coupled piping can cause serious damage. Size traps in accordance with manufacturer recommendations. When installing couplings. Generally. Do not drip supply mains through the coil. admit steam to the coil 10 minutes before admitting outdoor air. 8. b. As additional protection against freeze-up. h. 6. c. perform the following steps: 1. the vacuum breaker is connected between the coil inlet and the return main. Modulating valves are not recommended. For coils in parallel. 5. For coils arranged for series airflow. do not undersize. Indoor Air Handling Unit (Model AMI) Installation Instructions 21 . For multiple coil installations: a. but an individual trap for each coil is preferred. g.or three-coils in series with two-position steam control valves on the coil or coils that are handling 35ºF (or colder) air. 4. In addition. Do not attempt to lift the condensate when using the modulating or on/off control. a separate control is required on each back or coil in the direction of airflow. Use a backup pipe wrench to avoid breaking the weld between the coil connection and the header. Provision should always be made to thoroughly mix fresh air and return air before it enters the coil. e. Size modulating valves properly. Consideration should be given to the use of two. Locate traps at least 12 inches below the coil return connection. The desired degree of control can be obtained with a modulating valve on the downstream coil. making the reduction at the branch leading to the trap. Thermostatic traps should be used only for air venting. 14. and the vacuum breaker should be open to the atmosphere and the trap design should enable the venting of large quantities of air. 3. separate traps are required for each coil or bank of coils. carry the return connection size through the dirt pocket. 10. Do not reduce the pipe size at the coil return connection. 12. Ensure that the required pressure differential is always available. Steam supply and steam return connections are male National Pipe Thread (NPT) copper pipe and are labeled on the end panel of the coil section. Connections extend through the coil section end panel. a single trap may be used. Install vacuum breakers on all applications to prevent condensate retention in the coil.Steam Coils (Maximum Steam Pressure 15 psig) To design and install steam coils. 11. temperature control elements must be properly located to obtain true air mixture temperatures. On startup. 5 psi steam must be supplied to coils at all times. 2. For coils in series. f. Float and thermostatic or bucket traps are recommended for low-pressure steam. Estimate 3 feet for each psi of trap differential required. 7. the trap should be installed sufficiently below the coil to provide an adequate hydrostatic head and ensure the removal of condensate during an interruption in the steam pressure. For freezing conditions (entering air temperature below 35ºF): a. c. 13. control should be via face and bypass dampers. d. Each coil or group of coils that is individually controlled must be individually trapped. do not apply undue stress to the connection extending through the unit panel. b. Support the piping independently of coils and provide adequate piping flexibility. do not undersize.

size. Use a backup pipe wrench to avoid breaking the weld between the coil connection and the header. do not apply undue stress to the connection extending through the unit panel.Water Heating Coils To design and install water heating coils. Follow the recommendations of the control manufacturer regarding type. and installation of control valves. If fresh air and return air are to be heated by a hot water coil. 6. 3. When installing couplings. consider the design of the system to ensure thorough mixing before air enters the coil. 2. 4. Label all connections on the end panel. perform the following steps: 1. 22 Indoor Air Handling Unit (Model AMI) Installation Instructions . Extend the water supply and water return connections through the end panel of the coil section. Hot water coils are not recommended for use with entering air below 40ºF. Water supply and water return connections are male NPT copper pipe. 5.

Check for loose connections. . Blown fuse or open circuit breaker Overload trip Improper wiring connections Improper current supply Mechanical failure Motor stalls. Check voltage across the AC line. Remove fan cover. check the bearing lubricant. Adjust belt tension. Check wiring with diagram supplied on unit. Loosen and retighten bearing setscrew. Check line for an open phase. Clean surfaces of grease and purge. Reduce load or replace with a larger motor. Open phase Overloaded motor Low line voltage Excessive Vibration Poor alignment Shipping spacers not removed Over-tensioned belts Misaligned drive Motor runs and then dies down. Adjust belt tension. Determine adequacy of main power supply. Check that the motor and drive rotate freely. check shaft level. Contact the power company for adjustments. Apply lubricant. Compare the actual supply power with the motor nameplate recommendations. Replace with larger sized wiring. preventing ventilation. Remove shipping spacers and/or bolts. Align bearing setscrews. Check voltage across the AC line and correct voltage loss if possible. Replace the motor. Check and reset overload. Continued on next page . and turn thermostat down. Possible Cause First start after relubrication (grease distribution) Over-lubrication Over-tensioned belts No lubrication Misaligned bearing Solution Allow the machine to cool down and restart it. Overloaded motor Motor fan is clogged with dirt. Temperature leaving the heating section is too high. Align drive. Partial loss of line voltage Stator shorts when motor warms up Motor does not come up to speed. Increase airflow volume. Indoor Air Handling Unit (Model AMI) Installation Instructions 23 . check the bearing for damage. Low voltage at motor terminals Line wiring to motor is too small Motor overheats. . clean fan. reduce hot water inlet temperature. Reduce load or replace with larger motor. Correct alignment.Troubleshooting Table 9: AMI Troubleshooting Guide Problem Bearing is excessively hot. Replace fuse or reset circuit breaker. Motor fails to start. Correct voltage if possible. and replace cover.

Replace belt or belt set. Excess dirt in unit. Replace sheave with larger one. Check belt tension and overhung load.Problem (Cont. Replace with flexible connections. Prevent bypass with block-offs. Clean and unblock tubes. Poor refrigerant distribution Drain pan is overflowing. Clean and unblock tubes. Check fan operating conditions. Loosen bearing setscrews and realign them. Replace sheaves. Prevent bypass with block-offs. Check for blockage in distributor and tubes. Clean drain line. Realign drive with MVP sheave set at mean pitch diameter. Check fan operating conditions. Check sheave alignment. Adjust tension. valves. Standing water in drain pan or mold inside the air handler. Rapid Motor Bearing Wear Excessive overhung load due to over-tensioned drive Excessive overhung load due to a small diameter motor sheave Loose Fan Belt Motor is poorly positioned Worn or damaged belts Worn sheaves Short Belt Life Worn sheaves Misaligned belt Grease or oil on belts Belt slipping Belts rubbing Bearing Noise Poor alignment Inadequate lubrication Low Coil Capacity (Chilled Water) Air is bypassing coil Coil tubes are blocked Incorrect airflow Incorrect GPM Incorrect water temperature Low Coil Capacity (Refrigerant) Air is bypassing coil. Remove interference in motor fan housing. Level unit. and lines for obstructions Provide proper water temperature. Coil tubes are blocked. 24 Indoor Air Handling Unit (Model AMI) Installation Instructions . Check for leaky bearings. Replace bearings and seals.) Excessive Motor Noise Possible Cause Motor mounting bolts loose Rigid coupling connections Worn motor bearings Fan rubbing on fan cover Solution Tighten motor mounting bolts. Plugged drain line Unit not level Improper trap design Missing filters Filter bypass Replace filters. Clean belts and sheaves. Design trap for unit. Check sensing bulb location and TXV operation. Grease bearing(s). Adjust belt tension. Reduce filter bypass. Replace sheaves. Remove obstruction of realign drive for clearance. Check water pumps. Incorrect airflow Expansion valve not operating.

fittings.S.O. Box 423 Milwaukee.com Indoor Air Handling Unit (Model AMI) Installation Instructions 25 .Inspection and Startup Checklist Receiving and Inspection Unit received undamaged Unit received complete as ordered Unit arrangement/hand correct Unit structural support complete and correct Handling and Installation Unit mounted level and square Proper access provided for unit and accessories Proper electrical service provided Proper over-current protection provided Proper service switch/disconnect provided Proper hot water line to unit Proper chilled water line size to unit Proper steam line sizes to unit Proper refrigerant line sizes to unit Proper steam supply pressure to unit (15 psi maximum) Proper steam condensate trap on return line All shipping screws and braces removed All services to unit in code compliance Cooling/Heating Connections Protect valve package components from heat Mount valve packages Connect field piping to unit Pressure test all piping for leaks Install drain line and traps as required Insulate all piping as required Install condensate pan under piping as required Ductwork Connections Install ductwork. Michigan Street P.A.johnsoncontrols. and grilles as required Proper supply and return grille type and size used Control outside air for freeze protection Insulate all ductwork as required Electrical Connections Refer to unit wiring diagram All field wiring in code compliance Connect incoming power service or services Unit Startup General visual unit and system inspection Record electrical supply voltage Record ambient temperature Check all wiring for secure connections Close all unit isolation valves Flush water systems Fill systems with water/refrigerant Vent water systems as required All ductwork and grilles in place All unit panels and filters in place Start fans Check for overload condition of all units Check all ductwork and units for air leaks Balance air systems as required Record all final settings for future use Check piping and ductwork for vibration Check all dampers for proper operation Verify proper cooling operation Verify proper heating operation Reinstall all covers and access panels Blower/Motor Check sheave set screw tightness Check blower wheel set screw tightness Adjust blower speed as necessary for balancing airflow Check/adjust sheave alignment Check/adjust belt tension Controls Group 507 E. www. WI 53201 Published in U.