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 ! WARNING: All unit temporary and
operated within its design specification limits. Observe
the following cautionary statements. permanent supports must be capable of safely
supporting the equipment's weight and any
additional live or dead loads that may be
! DANGER: Electrical Shock Hazards. All
encountered. All supports must be designed to meet
applicable local codes and ordinances.
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.
! WARNING: All fastening devices must be
designed to mechanically lock the assembly in place
without the capability of loosening or breaking away
! DANGER: Moving Parts Hazards. Motor
due to system operation, vibration, impact, or
seismic events.
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. ! CAUTION: Secure all dampers when
servicing the damper, actuator, or linkages.
Dampers may activate automatically; disconnect
control circuits or pneumatic control systems to
! DANGER: Hot Parts Hazard. Electric
avoid injury.

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

! 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.

© 2004 Johnson Controls, Inc. 1

Code No. LIT-1201887 www.johnsoncontrols.com
Receiving and Inspecting
To receive and inspect the unit, perform the following ! WARNING: When steam cleaning coils,
steps: verify that the area is clear of all personnel.
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. ! WARNING: Do not remove access panels
until the impeller has completely stopped. The
2. Inspect all equipment for any signs of damage
pressure that is developed by a moving impeller can
caused during transit. Note any visual damage on
cause excessive force against the access panels.
the bill of lading before signing. Immediately
report all visual and concealed damage to the
carrier and file a claim with the carrier.

Safety Considerations ! WARNING: Do not work on dampers until

their operators are disconnected.
! 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.
! CAUTION: Secure drive sheaves with a
rope or strap before working on the fan to ensure
that the blower wheel cannot freewheel.
! 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.
! CAUTION: Never pressurize equipment
above the specified test pressure.

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

2 Indoor Air Handling Unit (Model AMI) Installation Instructions

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

Figure 1: Rigging and Handling

Indoor Air Handling Unit (Model AMI) Installation Instructions 3

Storage
To transfer the equipment from a truck to a storage
site, see the Rigging and Handling section.
! CAUTION: If a forklift is used, lift only from
the heavy end of the skid.
Assembling the Equipment
All modules ship with the required bolts, nuts, and
gasket material to assemble the equipment. Bolt holes
are accessible through the inside of the upstream
module.

Do not stack the unit modules or accessories during

storage. Stacking can cause damage or deformation.
If the equipment is to be stored for more than 2 weeks
prior to installation, 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, as damage to stationary
bearings can occur. Set the equipment off of the
Figure 2: Bolt Holes (1 of 2)
ground if in a moisture prone area.
• Remove all loose parts from the job site to
minimize theft. Tag and store the loose parts in a
safe place until needed.
• Cover all of the equipment with a protective tarp or
moisture proof cover. Extend the cover under the
equipment if it is stored on the ground. Secure the
cover with adequate tie downs and store indoors.
• Be sure that the piping connections have
protective shipping caps installed.
• Monthly: Remove the cover from the unit, open
the fan access panel, remove belt ties, and rotate
the fan and motor slowly by hand to redistribute
bearing grease and to prevent bearing corrosion.

Figure 3: Bolt Holes (2 of 2)

4 Indoor Air Handling Unit (Model AMI) Installation Instructions

Gasketing
For sections that require job site assembly, gasketing
material is supplied with each module.
To apply a gasket to the unit, perform the following
steps:
1. Apply a gasket the perimeter of each module.
2. Overlap the gasketing approximately 1/8” when
splicing to prevent air leakage between modules.
Figure 4: Gasket Overlap
Mounting the Actuator
The installing contractor takes all responsibility for the
mounting of all field-installed actuators. 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.
IMPORTANT: Ensure proper actuator support
to prevent unnecessary stress in the linkage,
cabinet, or damper shaft. Multiple damper
assemblies must not be actuated from the shaft
extension opposite the connection link.
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. If the dampers are
different sizes, they must be driven by individual
actuators and controlled separately.
Indoor Air Handling Unit (Model AMI) Installation Instructions
Installation
Install this equipment in strict accordance with any
applicable local, state, and national codes including,
but not limited to, building, electrical, and mechanical
codes. On single-wall equipment, lay rigid temporary
protection (for example, plywood), inside the
equipment to protect the insulation during installation.
Suspending a Unit
When the equipment is suspended from a ceiling, a
base rail, angle iron, or channel must support the
equipment. The AMI product line is not designed to be
suspended from the top of the equipment. Before
hanging the equipment, all field assembly must be
completed.
Suspending a Unit Using Factory Base Rail
Factory optional base rails have a 5/8” diameter hole
located in each corner for hanger rods. A hanger rod
must be installed in each corner of a module to
properly support the equipment and maintain the unit's
structural integrity.
Suspending a Unit Using Field-Supplied Supports
All field-supplied structural supports must be designed
to support the entire unit weight, including all
equipment, motor, drives, and all live or dead loads. All
supports must be designed to meet applicable local
codes and ordinances. Each module must be
supported with an angle iron or channel. 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).
Note: Hanger rods must be located so they do not
interfere with access panels.
5
 Figure 5: Units Suspended Using Field-Supplied Supports

6 Indoor Air Handling Unit (Model AMI) Installation Instructions


Internal Isolation
Equipment may be supplied with internal spring
isolation. If so, removal of the shipping hold-downs is
required before equipment startup.
Figure 6: Shipping Hold-Downs
External Isolation
Install vibration isolators in accordance with the job
specifications and the instructions of the isolator
manufacturer base. Base rails are required for external
isolation. If the coil module is also isolated, the piping
must be isolated or have a flexible connection to
prevent coil header damage due to equipment
movement. Isolate all piping, wiring, ductwork, and
external connections.
Figure 7: Vibration Isolators
Indoor Air Handling Unit (Model AMI) Installation Instructions
Service Clearance
Access to at least one side of the equipment is
required for routine service, maintenance, and repair.
Consideration should be given to the fan shaft, coil,
filter removal, motor, fan, bearings, and damper
linkage access. Clearance must meet or exceed
applicable local and national codes.
Panel Removal
To remove access panels, loosen the four retaining
screws and lift the panel off. Alternately, lift off the
hinges with quick turn fasteners.
General Piping
All pipe connections need to be supported
independently from the header; failure to do so may
cause cracking at the headers.
All piping must be in accordance with local codes and
follow accepted industry standards. Before mounting
the Thermostatic Expansion Valve (TXV), you must
remove the Direct Expansion (DX) coil distributor cap
for testing and nitrogen charging. All coil connections
are stubbed out of the cabinet panel with the exception
of the refrigerant (DX) coils. Field penetration of panels
is required for liquid line piping.
Condensate Drain
All condensate drains must have a trap installed to
prevent excessive condensate buildup and/or
condensate overflow. To ensure that the trap remains
sealed, 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.
Figure 8: Condensate Drain Trap
7
Electrical Installation 4. Check the tightness of sheave setscrews and/or
To wire the unit, perform the following steps: capscrews. Check the alignment of fan and motor
sheaves and belt tension.
1. Verify that the electrical service to the fan is
compatible to the rated voltage on the motor 5. Rotate the shaft manually to make sure it is free.
nameplate and is in accordance with local codes. 6. Start the fan and observe its rotation. If the fan is
2. On isolated units, connect the fan segment’s metal operating backward, disconnect the power and
casing to the building’s electrical ground. reverse the two legs of the three-phase supply
power.
3. Review the wiring diagram and make any
necessary connections. 7. To ensure that water connections and joints are
tight, leak test the piping systems.
Notes:
8. Check that condensate drain is trapped.
• Door electrical interlock is not offered.
• Some motors have internal automatic reset Startup
overload protection. Alternating Current (AC) power current imbalance
must not exceed 2%. Observe the following guidelines:
• Thermal motor protection is external to the unit.
Thermal protection and a disconnect switch are • AC power is within 10% of rate voltage with
provided by others. frequency (see the equipment nameplate for
ratings).
Pre-startup • AC power is within 5% of rated frequency with
voltage.
IMPORTANT: Before entering the fan section,
make sure that the fan electrical power source is • a combined variation in voltage and frequency of
disconnected and locked in the OFF position. 10% (the sum of absolute values) of rated values,
provided the frequency variation does not exceed
Perform the following steps prior to starting the unit: 5% of rated frequency
1. Check that the unit is completely and properly
installed with ductwork connected. Check that all
construction debris is removed and filters are
cleaned.
2. Check that all electrical work is finished and
properly terminated. Check that all electrical
connections are tight and that the proper voltage is
connected.
Note: Motor and ball bearings on the fan shaft are
prelubricated and do not need grease before
startup.
3. Check the tightness of the setscrews in the
bearings and fan wheel(s). If retightening is
needed, make certain the fan wheel(s) are
positioned accordingly and that setscrews are
torqued appropriately. See Table 1 for torque
settings.

! CAUTION: Equipment damage due to loose

setscrews or fasteners represents improper startup
and equipment abuse. It is not covered by the
warranty.

8 Indoor Air Handling Unit (Model AMI) Installation Instructions

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

Indoor Air Handling Unit (Model AMI) Installation Instructions 9

Periodic Maintenance and Service
The following checklist is provided as an abbreviated
guide to periodic maintenance. Detailed procedural
information is given after this checklist.
After 48 Hours of Operation
Belts will achieve their permanent stretch and will
require readjustment; be sure not to overtighten the
belt.
Weekly
Observe the unit weekly for any changes in running
condition and unusual noise.
Monthly
Observe the following monthly guidelines:
• Check air filters; clean or replace if they are
clogged or dirty.
• Relubricate fan bearings if operating conditions
include high speeds, moist or dirty air, or high
temperatures.
• Relubricate motor bearings in accordance with the
motor manufacturer's recommendations if
operating conditions include high speed, moist or
dirty air, or high temperatures (see the motor label
for more information).
• Check and adjust the fan belt tension.
Every 3 to 6 Months
Observe the following quarterly and semi-annual
guidelines:
• check the fan bearing grease line connections; the
lines should be tight to the bearings
• relubricate fan bearings
• check motor lubrication; recommendations are
provided on the motor label
• check bearing and motor bracket bolt torque
Note: See Table 1 for torque settings.
• align fan and motor sheaves; 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
Yearly
Observe the following annual guidelines:
• Inspect the unit casing for corrosion; if damage is
found, clean and paint the surface with a
rust-resistant primer and vinyl chlorinated lacquer.
• Clean the fan wheel and fan shaft; remove any
rust with an emery cloth and apply a coat of
heavy-duty rust inhibitor.
• Clean the coils; using a fin comb, straighten any
bent fins.
• Inspect the condensate pan and drain line; remove
sludge or foreign materials that might obstruct
proper drainage.
• Remove obstructions from the unit.
• Check damper linkages, set screws and blade
adjustment; clean, but do not lubricate, the nylon
damper rod bushings.
• Clean the damper operators.
• Inspect control and power box wiring for secure
connections and insulation.
• Rotate the fan wheel and check for obstructions in
the fan housing; the wheel should not rub on the
fan housing.
• Adjust the fan wheel to center if necessary and
tighten wheel setscrews to the proper torque.
• Check the condition of gasketing and insulation
around the unit, door, and dampers; repair or
replace as necessary.
• Examine flex connections for cracks or leaks;
repair or replace damaged material.
 Drain Pan
Table 1: Minimum Hex Head Bolt Torque in
Foot lbs. (Grade 5 Bolt) Inspecting and Cleaning Drain Pans
Size Thread Minimum If evidence of standing water or condensate overflow
(inches) Designation Torque exists, identify and remedy the cause immediately. If
microbial growth (mold) in the drain pan is observed,
1/4 – 20 UNC 6
clean the pan immediately.
5/16 – 18 UNC 14
Perform the following steps to inspect and clean drain
5/16 – 24 UNF 16
pans:
3/8 – 16 UNC 24
3/8 – 24 UNF 28
1. Disconnect all electrical power to the unit, and tag
and lock out the power source.
7/16 – 14 UNC 42
7/16 – 20 UNF 45 2. Put on appropriate personal protective equipment.
1/2 – 13 UNC 69 3. Remove all standing water.
1/2 – 20 UNF 83 4. Use a scraper or other tool to remove any solid
9/16 – 12 UNC 99 matter. Remove solid matter with a vacuum device
9/16 – 18 UNF 118 that uses High-Efficiency Particulate Air (HEPA)
5/8 – 11 UNC 150 filters with a minimum efficiency of 99.97% at
0.3-micron particle size.
5/8 – 18 UNF 176
3/4 – 10 UNC 254 5. Thoroughly clean the contaminated area with mild
bleach and water solution or an Environmental
3/4 – 16 UNF 301
Protection Agency (EPA)-approved sanitizer
7/8 – 9 UNC 358 specifically designed for Heating, Ventilating, and
7/8 – 14 UNF 422 Air Conditioning (HVAC) use. Carefully follow the
1-8 UNC 500 sanitizer manufacturer’s instructions regarding the
1-14 UNF 602 use and the disposal of their product.
6. 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.
7. Allow the unit to dry thoroughly before putting the
system back into service.
8. Determine and correct the cause of the microbial
contamination.
9. Be careful that the contaminated material does not
contact other areas of the unit or building.
Properly dispose of all contaminated materials
and cleaning solution.

IMPORTANT: Standing water in drain pans

can promote microbial growth (mold) that may cause
unpleasant odors and serious health-related indoor
air quality problems. If mold is found, it must be
removed immediately and that portion of the unit
properly cleaned and sanitized.

Indoor Air Handling Unit (Model AMI) Installation Instructions 11

 Fan Bearings
Air Filters
Refer to the Indoor Air Handling Unit (Model AMI) Aligning Bearing Setscrews
Product Bulletin (LIT-1201834) for information on air Align bearing setscrews. See Table 1 for bearing
filter size, type, and quantity. setscrew torque.

Throwaway Filters Lubricating Fan Bearings

To replace throwaway filters, install new filters with the
directional arrows pointing in the direction of airflow.
Fans
Inspecting and Cleaning Fans
Fan sections or air handlers should be inspected every
six months at a minimum, or more frequently if the unit
operating experience dictates another inspection.
Accumulated dirt and organic matter on the interior
surfaces of fans should be cleaned immediately.
Perform the following steps to lubricate fan bearings:
1. Disconnect all electrical power to the unit, and tag
and lock out the power source.
2. Check grease lines for tight connections at the
grease fitting.
3. Using a manual low-pressure grease gun, add
grease until a light bead appears at the bearing
grease seal. Turn the fan wheel manually while
adding grease.

Perform the following steps to inspect and clean fans: Table 2: Recommended Greasing Intervals – Fan
1. Disconnect all electrical power to the unit, and tag Bearings
and lock out the power source. Operating -20 to 140°F 140 to 200°F
2. Put on appropriate personal protective equipment. Conditions
3. Use a portable vacuum with HEPA filtration to Clean, Dry 3 – 6 months 1 – 3 weeks
remove the loose dirt and organic matter. The filter Dirty, Dry 1 – 3 months 1 – 4 weeks
should be 99.97% efficient at 0.3-micron particle Dirty, Wet, 1 – 4 weeks 1 – 14 days
size. High Humid
a. If no microbial growth (mold) exists, thoroughly
clean the fan and associated components with
an industrial cleaning solution. Carefully follow Table 3: Recommended Greases for Various
the cleaning solution manufacturer’s Operating Ranges
instructions regarding the use and the disposal
Recommended Recommended Operating
of their product.
Greases Range
b. If microbial growth (mold) is present, remove
Texaco™ Multifak® #2 -20°F to 250°F
the contamination and thoroughly clean the
affected area with an EPA-approved sanitizer Shell™ Alvania® #2 -20°F to 250°F
specifically designed for HVAC use. Carefully Mobil™ Mobilux® #2 -20°F to 250°F
follow sanitizer manufacturer instructions. Exxon™ Unirex #2 -20°F to 250°F
4. Rinse the affected surfaces thoroughly with fresh Exxon™ Beacon -65°F to 250°F
water and a fresh sponge to prevent potential
corrosion of metal surfaces.
5. Allow the unit to dry thoroughly before putting the Table 4: Fan Bearing Maximum Grease Capacity
system back into service.
Shaft Size (inches) Capacity (fluid ounces)
6. Be careful that the contaminated material does not 1/2 – 3/4 1/8
contact other areas of the unit or building.
Properly dispose of all contaminated materials 7/8 – 1 3/16 3/8
and cleaning solution. 1 1/4 – 1 1/2 5/8
1 11/16 – 1 15/16 7/8
IMPORTANT: If microbial growth (mold) was 2 – 2 7/16 1 1/4
found, the cause of the contamination must be 2 1/2 – 2 15/16 2
determined and action taken to ensure it does not
Note: Lubricate fan bearings with a lithium base grease
reoccur.
conforming to National Lubricating Grease Institute (NLGI)
Number 2 for consistency.

12 Indoor Air Handling Unit (Model AMI) Installation Instructions

Motor
General Inspection
Inspect the motor at regular intervals, approximately
every 500 hours of operation or every 3 months,
whichever occurs first. Operating conditions vary the
frequency of inspection and lubrication. Keep the
motor clean and the ventilation opening clear.
Perform the following steps to inspect the motor:
1. Check that the motor is clean. Check that the
interior and exterior of the motor is free of dirt, oil,
grease, and water, which can accumulate and
block motor ventilation. If the motor is not properly
ventilated, overheating can occur and can cause
early motor failure.
2. Periodically use the megger to ensure that the
integrity of the winding insulation has been
maintained; record megger readings. Immediately
investigate any significant drop in insulation
resistance.
3. Check all electrical connectors to verify that they
are tight.
4. Check that all mechanical fasteners are properly
tightened.
Table 5: Recommended Motor Greasing Schedule
Average Daily Maximum Ambient Average
Operating Hours Temperature Environment
8 – 16 40°C Clean and dry
12 – 24 50°C Moderate dirt or
moisture
Any >50°C or Class H Severe (very dirty or
insulation high temperatures)
Lubricating the Motor with the Grease Outlet Plug
Perform the following steps to lubricate the motor:
1. Clean the grease fitting.
2. Remove the grease outlet plug.
3. Add grease to the motor.
a. If the motor is stopped, add the recommended
amount of grease.
b. If greasing the motor while it is running, slowly
add a slightly greater quantity of grease until
the new grease appears at the shaft hole in
the endplate or purge outlet plug.
4. Reinstall the grease outlet plug.
Indoor Air Handling Unit (Model AMI) Installation Instructions
Lubrication and Bearings
Bearing grease loses its lubrication ability over time,
not suddenly. The lubricating ability of grease (over
time) depends primarily on the type of grease, the size
of the bearing, the speed at which the bearing
operates, and the severity of the operating conditions.
The recommended lubrication interval for an
1,800 RPM motor, up to and including National
Electrical Manufacturers Association (NEMA) frame
215T, is every 12,000 hours of operation. It is
important to remember that this recommendation is
based on average use.
When lubricating the motor, use a high-grade ball or
roller bearing grease. The motor is factory installed
with Chevron® SRI with a polyurea base.
IMPORTANT: Ensure that the grease you are
adding to the motor is compatible with the grease
already in the motor. Consult your factory
representative if grease other than the
recommended type is to be used.
! CAUTION: To avoid damage to motor
bearings, grease must be kept free of dirt.
.25 to 7.5 hp Motors 10 hp Motors
Every 5 years Every 3 years
Every 2 years Yearly
Every 6 months Every 3 months
Lubricating the Motor without the Grease Outlet
Plug
Perform the following steps to lubricate the motor:
1. Disassemble the motor.
2. Add the recommended amount of grease to the
bearing and bearing cavity.
Note: The bearing should be about 1/3 full of
grease and the outboard bearing cavity should be
about 1/2 full of grease.
3. Assemble the motor.
To relubricate the motor, consult the maintenance tag
provided on the motor. See Table 1 for torque settings.
13
Drives
Mounting Straight Bore Sheaves
To mount straight bore sheaves, perform the following
steps:
1. Make sure there are no nicks or burrs on the key,
keyway, and shaft. If there are, remove them using
the appropriate methods.
2. Check the key size with both the shaft and the
sheave.
3. Verify that all straight bore sheaves are mounted
on the motor or driver shaft with the setscrew (A)
toward the motor (see Figure 9). The sheave
should be as close to the motor as possible with
setscrew (A) in full contact with the key.
4. Ensure that the driver and driven sheaves are in
alignment and that the shafts are parallel. The
centerline of the driver sheave must line up with
the centerline of the driven sheave. Angle A
cannot exceed 1/2º (see Figure 10).
5. Insert the key (D, Figure 9) between the sheave
and the shaft and tighten the setscrew
(A, Figure 9) in place using the torque value from
Table 1.
6. Put on the belts and adjust the belt tension
properly. For more information, see the Adjusting
Belt Tension section in this document.
7. Verify that all keys are in place. Make sure all
setscrews and capscrews are torqued properly
before starting the drive. Check the setscrew and
belt tension after 24 hours of service.

! WARNING: If the setscrew is not fully in

contact with the key, the sheave assembly could
come off.

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

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

Indoor Air Handling Unit (Model AMI) Installation Instructions 15

Adjusting Variable Pitched Sheaves (Motor Only) Belts
To adjust variable pitched sheaves, see Figure 9 and
Adjusting Belt Tension
perform the following steps:
To adjust belt tension, perform the following steps:
1. Slack off all belt tension by moving the motor
towards the blower shaft until the belts are free of 1. To measure the belt span, lay a tape measure
the groove(s). For easier adjustment, remove the along the top of the belt and measure between the
belts from the groove(s). points at which the outside of the belt meets the
outside of the sheaves. Use the following formula
2. Loosen the setscrew (B) in the outer locking ring. to calculate the belt span, where:
3. Loosen, but do not remove, the capscrew. C = center distance to the drive shaft
4. Remove the key (D). D = driver sheave (large sheave) pitch diameter
Note: This key projects a small amount to provide d = driver sheave (small sheave) pitch diameter
a grip for removal.
5. Adjust the pitch diameter by opening or closing the
movable flange(s) by a half- or full-turn. Opening
the flange(s) decrease the blower speed; closing
the flange(s) increases blower speed.
Figure 12: Calculating Span
Note: Two groove sheaves are supplied with both
grooves set at the same pitch diameter. Both
movable flanges must be rotated the same
number of turns to ensure the same pitch diameter
for satisfactory operation.

! WARNING: Do not open the sheaves more

than five turns for the A belt or six turns for the B
belt. Doing so may cause the belts to sit improperly
and cause the flanges to detach while in service.

6. Replace the key (D).

7. Tighten the setscrew (B) in the outer locking ring
and the capscrew (C) with a torque wrench. See
Table 1 for torque settings.
8. Put on the belt and adjust the belt tension
properly. For more information, see the Adjusting
Belt Tension section in this document.
9. Verify that all keys are in place. Make sure all
setscrews and capscrews are torqued properly
before starting the drive. Check the setscrew and
belt tension after 24 hours of service.
Figure 13: Belt Tension
2. Calculate deflection (Deflection = Span ÷ 64).
3. Using a spring scale, apply force at a right angle to
the midpoint of the belt span.
4. Check the tension at least twice during the first
day of operation, and periodically thereafter.

16 Indoor Air Handling Unit (Model AMI) Installation Instructions

Table 6: Deflection Force

Belt Belt Deflection Force

Smallest Sheave
Cross RPM Range
Diameter Range
Section
Used Belt New Belt
400 – 2500 3.7 5.5
3.0 - 3.6"
2501 – 4000 2.8 4.2

400 – 2500 4.5 6.8

A 3.8 - 4.8"
2501 – 4000 3.8 5.7

400 – 2500 5.4 8.0

5.0 - 7.0"
2501 – 4000 4.7 7.0

860 – 2500 5.3 7.9

4.4 - 5.6"
2501 – 4000 4.5 6.7
B
860 – 2500 6.3 9.4
5.8 - 8.6"
2501 – 4000 6.0 8.9

Increasing Belt Life Coils

Observe the following guidelines to ensure longer belt
life:
• Keep sheaves and belts clean; abrasive dust, rust,
oils, and acids reduce service life.
• Give drives clearance; never let belts run against
the belt guards or other obstructions.
• Never force belts; move the motor on the
adjustment base so the belts go on easily.
• Eliminate slack. Adjust the motor and tighten the
belts in position. Slack belts wear excessively,
causing slippage and less air delivery.
• Use matched belts. Matched belts run more
smoothly and last longer because the load is
evenly distributed. Never partially replace a set of
belts.
• Mount belts straight. The shaft must be parallel
and the sheave grooves must be in alignment to
prevent unnecessary belt wear.
• Do not overload the belt; belts have a specific
horsepower rating that must not be exceeded.
The frequency of required coil cleaning is dependent
on system operating hours, filter maintenance and
efficiency, and dirt load.
IMPORTANT: Coils may become externally
fouled as result of normal operation. Dirt on the
surface of the coil reduces its ability to transfer heat
and can result in reduced performance and
increased operating energy costs. If the dirt on the
surface of the coil becomes wet, which commonly
occurs with cooling coils, microbial growth (mold)
can result, in turn causing unpleasant odors and
serious health related indoor air quality problems.
! CAUTION: Fin edges are sharp and fragile;
care must be exercised to avoid damaging fins.

Indoor Air Handling Unit (Model AMI) Installation Instructions 17

Steam, Hot Water, and Chilled Water Coils
Steam, hot water, and chilled water coils should be
kept clean to maintain maximum performance. If fins
become dirty, clean them with steam and detergent,
hot water spray and detergent, or one of the
commercially available chemical coil cleaners. Rinse
coils thoroughly after cleaning.
Perform the following steps to clean water coils:
1. Disconnect all electrical power to the unit, and tag
and lock out the power source.
2. Put on appropriate personal protective equipment.
3. Access the coil section of the unit.
4. Use a soft brush to remove loose debris from the
sides of the coil.
5. Using a steam-cleaning machine, start from the
top of the coil and work downward. Clean the
leaving airside of the coil first, then the entering
airside. Use a block-off to prevent steam from
blowing through the coil and into the dry sections
of the unit. Repeat as necessary.
6. Confirm that the drain line is open.
7. Enable the unit to dry thoroughly before putting the
system back in service.
8. Using a fin comb, straighten any coil fins that may
have been damaged during the cleaning process.
9. Replace all panels and parts and restore electrical
power to the unit.
10. Be careful that any contaminated material does
not contact other areas of the unit or building.
Properly dispose of all contaminated materials
and cleaning solution.
18 Indoor Air Handling Unit (Model AMI) Installation Instructions
Refrigerant Coils
Refrigerant coils should be kept clean to maintain
maximum performance. If fins become dirty, clean
them with cold water and detergent or one of the
commercially available chemical coil cleaners. Rinse
coils thoroughly after cleaning.
Perform the following steps to clean refrigerant coils:
1. Follow Steps 1 – 4 in the Steam, Hot Water, and
Chilled Water Coils section.
2. Mix a high quality coil cleaning detergent with
water according to the manufacturer’s instructions.
Note: If the detergent is strongly alkaline after mixing
(pH 8.5 or higher), it must contain an inhibitor.
Carefully follow the detergent manufacturer’s
instructions regarding use of the product.
3. Place the mixed solution in a garden sprayer or
high-pressure sprayer. If a high-pressure sprayer
is used, note the following:
a. Maintain a minimum nozzle spray angle of 15
degrees.
b. Spray perpendicular to the coil face.
c. Protect other areas of the air handler and
internal controls from contact with moisture or
the cleaning solution.
d. Keep the nozzle at least six inches from the
coil.
e. Do not exceed 600 psi.
4. Spray the leaving airside of the coil first, then the
entering airside. Use a block-off to prevent spray
from going through the coil and into the dry
sections of the unit and/or system ductwork.
Carefully follow the cleaning solution
manufacturer’s instructions regarding use of the
product.
5. Thoroughly rinse both sides of the coil and the
drain pan with cool, clean water.
6. Repeat Steps 4 and 5 as necessary.
7. Using a fin comb, straighten any coil fins that may
have been damaged during the cleaning process.
8. Confirm that the drain line is open.
9. Replace all panels and parts and restore electrical
power to the unit.
10. Be careful that any contaminated material does
not contact other areas of the unit or building.
Properly dispose of all contaminated materials
and cleaning solution.
Winterizing Water Coils
Due to air stratification and the failure of outdoor air
dampers and/or preheat controls, coil freeze-up can
occur. Scheduled draining of water cooling coils for
winter shutdown cannot be depended upon as
insurance against interior tube freeze-up. Freeze-up
will result in severe coil damage. It is recommended
that all coils be drained as thoroughly as possible and
then treated.
Perform the following steps to winterize water coils:
1. Using a small circulating pump, fill each coil
independently with an antifreeze solution.
Note: Check the freezing point of the anti-freeze
before proceeding to the next coil.
2. Thoroughly drain each coil.
IMPORTANT: Due to a small amount of water
always remaining in each coil, there will be a diluting
effect. The small amount of anti-freeze solution
remaining in the coil must be sufficient to prevent
freeze-up.
! WARNING: Carefully read the instructions
for mixing anti-freeze. Some products have a higher
natural state freezing point than when mixed with
water.
Operating Guidelines
Periodic Service and Maintenance
Check all moving parts for wear every 6 months, and
check the bearing collar, sheave, and wheel hub
setscrews, sheave capscrews, and bearing hold-down
bolts for tightness every 6 months.
Indoor Air Handling Unit (Model AMI) Installation Instructions
Vibration Levels
Each unit that is shipped has been trim-balanced to
function properly, although factory requirements are
much tighter to ensure satisfactory operation after the
rigors of shipping and installation.
Table 7: Vibration Levels
Fan Speed Vibration
(RPM)
800 or less 5 mils maximum displacement
801 or greater .20 inches/section maximum velocity
Note: Excessive vibration from any cause contributes
to premature fan and motor bearing failure. Overall,
vibration levels should be monitored every six months of
operation. An increase in levels is an indication of
potential trouble.
Vibration Causes
Causes of vibration include:
1. Wheel imbalance
a. Dirt or debris on the wheel blades.
b. Loose setscrews in the wheel hub or
bearing-to-shaft.
c. The wheel is distorted from over-speed.
d. The wheel balance weight is missing.
2. Bent blower shaft
3. Faulty drive
a. Variable pitch sheaves – axial and radial
run-out of flanges; uneven groove spacing or
out of balance. There may be a similar fault in
the driven sheave.
b. Bad V-belts; lumpy, or mismatched belts
c. Belt tension too tight or loose
4. Bad bearings; loose bearing hold-down bolts
5. Motor imbalance
6. The fan section is not supported evenly on the
foundation.
7. The fan shaft is not parallel with the motor shaft.
Operating Limits
Do not exceed the operating limits in Table 8. A fan
wheel that is operated beyond the RPM and
temperature limits shown in the table may suffer
permanent damage or failure.
19
Table 8: Forward Curve Fan Data
Diameter 9x4 9x6 10 x 7 12 x 9 12 x 12 15 x 11 18 x 13 18 x 18
Maximum RPM Class I 4800 3600 2800 2300 2000 1600 1200 1200
Maximum RPM Class II n/a n/a n/a n/a n/a 1700 1475 1450
Note: The maximum air temperature through the fan section is 225°F (107°C).

Coil Applications Direct Expansion (DX) Coils

General
When designing and installing piping, follow the
design, size, and installation information presented in
the American Society of Heating, Refrigerating and
Air-Conditioning Engineers (ASHRAE) Fundamentals
Handbook. In addition, observe all local codes and
industry standards.
Water Cooling Coils
To design and install water cooling coils, perform the
following steps:
1. Label water supply, water return, drain and vent
connections on the end panel.
2. Check the water supply and water return
connections.
To design and install DX coils, perform the following
steps:
1. 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.
2. DX coils are shipped capped and sealed with a
20 psig holding charge of dry nitrogen. Remove
the nitrogen charge from the coil by depressing
the Schraeder stem prior to cap removal.
3. Check the nozzle in the distributor for proper
tonnage.
4. When a thermostatic expansion valve is supplied
with the unit, it will be shipped loose and you will
need to field install it to the distributor.

3. Avoid undue stress to the connection extending
through the unit panel. Use a backup pipe wrench
to avoid breaking the weld between the coil
connection and the header.
4. Follow the recommendations of the control
manufacturer regarding type, size, and installation
of control valves.
5. Do not apply heat to the body or thermal element
of the expansion value; wrap it in a wet rag while
brazing.
6. The thermostatic expansion valve must be the
same tube type as the external equalizer. Connect
the 1/4-inch diameter external equalizer tube
provided on the coil to the connection on the
expansion valve.
7. Exercise care when piping up the system to
ensure all joints are tight and all lines are dry and
free of foreign material.

20 Indoor Air Handling Unit (Model AMI) Installation Instructions

Steam Coils (Maximum Steam Pressure 15 psig)
To design and install steam coils, perform the following
steps:
1. 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.
2. When installing couplings, do not apply undue
stress to the connection extending through the unit
panel. Use a backup pipe wrench to avoid
breaking the weld between the coil connection and
the header.
3. Support the piping independently of coils and
provide adequate piping flexibility. Stresses
resulting from expansion of closely coupled piping
can cause serious damage.
4. Do not reduce the pipe size at the coil return
connection; carry the return connection size
through the dirt pocket, making the reduction at
the branch leading to the trap.
5. Install vacuum breakers on all applications to
prevent condensate retention in the coil.
Generally, the vacuum breaker is connected
between the coil inlet and the return main, and the
vacuum breaker should be open to the
atmosphere and the trap design should enable the
venting of large quantities of air.
6. Do not drip supply mains through the coil.
7. Do not attempt to lift the condensate when using
the modulating or on/off control.
8. Size traps in accordance with manufacturer
recommendations. Ensure that the required
pressure differential is always available; do not
undersize.
9. Float and thermostatic or bucket traps are
recommended for low-pressure steam.
Thermostatic traps should be used only for air
venting.
10. Locate traps at least 12 inches below the coil
return connection.
11. For multiple coil installations:
a. Each coil or group of coils that is individually
controlled must be individually trapped.
b. For coils in series, separate traps are required
for each coil or bank of coils.
c. For coils in parallel, a single trap may be used,
but an individual trap for each coil is preferred.
Indoor Air Handling Unit (Model AMI) Installation Instructions
12. For coils arranged for series airflow, a separate
control is required on each back or coil in the
direction of airflow.
13. Size modulating valves properly; do not
undersize.
14. For freezing conditions (entering air temperature
below 35ºF):
a. 5 psi steam must be supplied to coils at all
times.
b. Modulating valves are not recommended;
control should be via face and bypass
dampers.
c. Consideration should be given to the use of
two- or three-coils in series with two-position
steam control valves on the coil or coils that
are handling 35ºF (or colder) air. The desired
degree of control can be obtained with a
modulating valve on the downstream coil.
d. Provision should always be made to
thoroughly mix fresh air and return air before it
enters the coil. In addition, temperature control
elements must be properly located to obtain
true air mixture temperatures.
e. As additional protection against freeze-up, 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.
f. Estimate 3 feet for each psi of trap differential
required.
g. On startup, admit steam to the coil 10 minutes
before admitting outdoor air.
h. Provision must be made to close the fresh air
dampers if the steam supply pressure falls
below the specified minimum.
21
Water Heating Coils
To design and install water heating coils, perform the
following steps:
1. Extend the water supply and water return
connections through the end panel of the coil
section. Label all connections on the end panel.
2. Water supply and water return connections are
male NPT copper pipe.
3. When installing couplings, do not apply undue
stress to the connection extending through the unit
panel. Use a backup pipe wrench to avoid
breaking the weld between the coil connection and
the header.
4. Follow the recommendations of the control
manufacturer regarding type, size, and installation
of control valves.
5. Hot water coils are not recommended for use with
entering air below 40ºF.
6. If fresh air and return air are to be heated by a hot
water coil, consider the design of the system to
ensure thorough mixing before air enters the coil.

22 Indoor Air Handling Unit (Model AMI) Installation Instructions

Troubleshooting
Table 9: AMI Troubleshooting Guide
Problem Possible Cause Solution

Bearing is excessively hot.
First start after relubrication (grease Allow the machine to cool down and
distribution) restart it.
Over-lubrication Clean surfaces of grease and purge.
Over-tensioned belts Adjust belt tension.
No lubrication Apply lubricant; check the bearing for
damage.

Misaligned bearing Correct alignment; check shaft level.

Motor fails to start. Blown fuse or open circuit breaker Replace fuse or reset circuit breaker.

Overload trip Check and reset overload.

Improper wiring connections Check wiring with diagram supplied on

unit.
Improper current supply Compare the actual supply power with
the motor nameplate recommendations.
Contact the power company for
adjustments.
Mechanical failure Check that the motor and drive rotate
freely; check the bearing lubricant.

Motor stalls. Open phase Check line for an open phase.

Overloaded motor Reduce load or replace with larger

Excessive Vibration
motor.
Low line voltage Check voltage across the AC line.
Correct voltage if possible.
Poor alignment Align bearing setscrews. Loosen and
retighten bearing setscrew.
Shipping spacers not removed Remove shipping spacers and/or bolts.

Over-tensioned belts Adjust belt tension.

Misaligned drive Align drive.

Motor runs and then dies down.
Motor does not come up to speed.
Motor overheats.
Continued on next page . . .
Partial loss of line voltage
Stator shorts when motor warms up
Low voltage at motor terminals
Line wiring to motor is too small
Overloaded motor
Motor fan is clogged with dirt,
preventing ventilation.
Temperature leaving the heating
section is too high.
Check for loose connections. Determine
adequacy of main power supply.
Replace the motor.
Check voltage across the AC line and
correct voltage loss if possible.
Replace with larger sized wiring.
Reduce load or replace with a larger
motor.
Remove fan cover, clean fan, and
replace cover.
Increase airflow volume, reduce hot
water inlet temperature, and turn
thermostat down.

Indoor Air Handling Unit (Model AMI) Installation Instructions 23

Problem (Cont.)
Excessive Motor Noise
Rapid Motor Bearing Wear
Loose Fan Belt
Short Belt Life
Bearing Noise
Low Coil Capacity (Chilled Water)
Low Coil Capacity (Refrigerant)
Drain pan is overflowing.
Standing water in drain pan or mold
inside the air handler.
Excess dirt in unit.
24 Indoor Air Handling Unit (Model AMI) Installation Instructions
Possible Cause
Motor mounting bolts loose
Rigid coupling connections
Worn motor bearings
Fan rubbing on fan cover
Excessive overhung load due to
over-tensioned drive
Excessive overhung load due to a
small diameter motor sheave
Motor is poorly positioned
Worn or damaged belts
Worn sheaves
Worn sheaves
Misaligned belt
Grease or oil on belts
Belt slipping
Belts rubbing
Poor alignment
Inadequate lubrication
Air is bypassing coil
Coil tubes are blocked
Incorrect airflow
Incorrect GPM
Incorrect water temperature
Air is bypassing coil.
Coil tubes are blocked.
Incorrect airflow
Expansion valve not operating.
Poor refrigerant distribution
Plugged drain line
Unit not level
Improper trap design
Missing filters
Filter bypass
Solution
Tighten motor mounting bolts.
Replace with flexible connections.
Replace bearings and seals.
Remove interference in motor fan
housing.
Check belt tension and overhung load.
Replace sheave with larger one.
Adjust belt tension.
Replace belt or belt set. Check sheave
alignment.
Replace sheaves.
Replace sheaves.
Realign drive with MVP sheave set at
mean pitch diameter.
Check for leaky bearings. Clean belts
and sheaves.
Adjust tension.
Remove obstruction of realign drive for
clearance.
Loosen bearing setscrews and realign
them.
Grease bearing(s).
Prevent bypass with block-offs.
Clean and unblock tubes.
Check fan operating conditions.
Check water pumps, valves, and lines
for obstructions
Provide proper water temperature.
Prevent bypass with block-offs.
Clean and unblock tubes.
Check fan operating conditions.
Check sensing bulb location and TXV
operation.
Check for blockage in distributor and
tubes.
Clean drain line.
Level unit.
Design trap for unit.
Replace filters.
Reduce filter bypass.
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, fittings, and grilles as required
Proper supply and return grille type and size used
Control outside air for freeze protection
Insulate all ductwork as required
Controls Group
507 E. Michigan Street
P.O. Box 423
Milwaukee, WI 53201
Indoor Air Handling Unit (Model AMI) Installation Instructions
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
Published in U.S.A.
www.johnsoncontrols.com
25