AZ MOTOR - Swegon

1 AZ MOTOR INSTRUCTIONS FOR BEARINGS REPLACEMENT Edition 4 (June 2014) AZ MOTOR Edition 4 Instructions for bearings replacement 2 1. ABOUT INSTRUCTIONS FOR BEARINGS REPLACEMENT In this document there are presented steps for safe bearings replacement in AZ motors. Every step is described with text and pictures so that any kind of misunderstanding is minimized to a low level. Before any kind of MOTOR disassembly you should read the instructions for bearings replacement first. During the bearings replacement you will need some standard and specially adjusted tools. The list of tools is described in chapter Some parts of the MOTOR must not be used again. The list of new MOTOR parts is described in chapter All pictures in this document are symbolic. Domel is not responsible for any kind of equipment damage, MOTOR or EC controller failure or any kind of personal injuries or material damage that were caused because of not following the instructions for bearings replacement.

2 Explanation of safety signs and safety messages Bellow there is presented the explanation of safety signs which are used in these instructions. For your safety and safety of your equipment you should always follow safety signs. DANGER indicates a hazardous situation with a high level of risk. WARNING indicates a hazardous situation with a medium level of risk. CAUTION indicates a hazardous situation with a low level of risk. NOTE. Notes, additional information and instruction tips. AZ MOTOR Edition 4 Instructions for bearings replacement 3 List of tools and accessories for bearings replacement In table 1 there are presented tools that you should use for safe bearings replacement. Table 1. List of tools for bearings replacement Tool marking Name of tool Picture of tool (a) TORX T20 screwdriver or tool (b) TORX T30 screwdriver or tool (c) retaining ring pliers (d) Heavy duty pliers (e) INBUS (hexagonal) tool 5 mm for M6 screw (f) three M6 eye bolts (AZ 84) OR two M8 eye bolts (AZ 108 and AZ 150) OR two eye bolts with thread M14x1,5 (AZ 220) or or (g) small flat screwdriver AZ MOTOR Edition 4 Instructions for bearings replacement 4 (h) pliers (i) 2 or 3 handed puller We recommend to use the puller from KUKKO manufacturer ( ) with small pulling arms.

3 (j) inductive heater (k) special tools for front bearing installation We recommend using bearing fitting tool kit TMFT 36 from SKF manufacturer ( ). (l) centring tube (picture 1) (m) torque wrench AZ MOTOR Edition 4 Instructions for bearings replacement 5 (n) assembly grease (o) adjusted press ring (picture 2) (p) sharp knife (r) rubber hammer (s) tool for fan wheel installation (t) Wrench 19 mm Dimensions for centring tube are described on picture 1 and in table 2. Dimensions for adjusted press ring are described on picture 2 and table 3. AZ MOTOR Edition 4 Instructions for bearings replacement 6 Picture 1. Tube (tube provide concentric between rotor (shaft) and the stator support) Table 2. Centring tube dimensions No. MOTOR type A[mm] B[mm] C[mm] x/y [mm/ ] y [ ] 1 AZ 108 26,65 24,65 100 45 2 AZ 150 34,75 29,75 150 1 60 3 AZ 220 54,7 34,7 150 4 60 Dimension C can be longer if needed.

4 AZ MOTOR Edition 4 Instructions for bearings replacement 7 Picture 2. Adjusted press ring dimensions Table 3. Adjusted press ring dimensions No. MOTOR type d[mm] D[mm] E[mm] 1 AZ 84 6,5 16 34,5 2 AZ 108 4,5 18 3 AZ 150 6,5 4 AZ 220 6,5 AZ MOTOR Edition 4 Instructions for bearings replacement 8 List of new MOTOR parts In table 4 there is presented list of new MOTOR parts. Which bearing type must be used according to MOTOR size is described in table 5. Table 4. List of new MOTOR parts 2 pieces of new bearing according to table 5. 1 piece of new wave spring washer according to table 5 Grounding brush support with brushes Dimensions: 54x15x11,3 for motors ( MOTOR size AZ 150) 64x15x11,6 for motors ( MOTOR size AZ 220) New larger press ring For motors ( MOTOR size AZ 150) For motors ( MOTOR size AZ 220) Table 5: Bearing types and wave spring washer according to MOTOR sizes MOTOR Code MOTOR size Bearings type Size of wave spring washer (d1 x d2 x s x h)

5 Shaft end Not shaft end C3E D EA3S NSK C3E D EA3S NSK AZ 84-50 6202 ZZ 6202 ZZ 28x34,5x0,6x3 AZ 108-30 6204 DDU 6203 DDU 33x39,1x0,5x2,9 AZ 108-30 6204 DDU 6203 DDU 33x39,1x0,5x2,9 AZ MOTOR Edition 4 Instructions for bearings replacement 9 AZ 108-55 6204 DDU 6203 DDU 33x39,1x0,5x2,9 AZ 108-55 6204 DDU 6203 DDU 33x39,1x0,5x2,9 AZ 150-45 6205 ZZ 6205 ZZ 42x51x0,5x3,4 AZ 150-70 6205 ZZ 6205 ZZ 42x51x0,5x3,4 AZ 150-70 6205 ZZ 6205 ZZ 42x51x0,5x3,4 AZ 220-55 6206 ZZ 6206 ZZ 51x61x0,5x3,7 AZ 220-55 6206 ZZ 6206 ZZ 51x61x0,5x3,7 AZ 220-100 6206 ZZ 6206 ZZ 51x61x0,5x3,7 AZ 220-100 6206 ZZ 6206 ZZ 51x61x0,5x3,7 AZ 220-100 6206 ZZ 6206 ZZ 51x61x0,5x3,7 AZ 220-55-100 6206 ZZ 6206 ZZ 51x61x0,5x3,7 Sufficient bearings life time is guaranteed just with bearings specified in table 5. These bearings are filled with special grease that ensures appropriate life time.

6 Using other bearing types can lead to shorter MOTOR life time and Domel cannot guarantee for these bearings. Explanation of bearing designation: 6205 ZZ C3 E D EA3 S NSK Bearing producer Grease quantity S - standard (35% of free bearing space) Type of special grease Production location Noise level mark E quiet bearing Radial internal clearance C3 - 6202, 6203 (11-25 m) 6204, 6205, 6206 (13-28 m) Bearing sealing ZZ shields on both sides DDU contact rubber seals on both sides Bearing geometry number Other data important for new bearing selection: Consider ambient temperatures expected for MOTOR operation (Motors are designed for long term operation at temperatures from -40 C to +52 C). Max. long term bearing operating temperature can reach 80 C Grease viscosity must prevent grease leakage from bearing AZ MOTOR Edition 4 Instructions for bearings replacement 10 2.

7 ABOUT AZ MOTORS MOTOR introduction External rotor MOTOR types AZ are electronically commutated motors with high efficiency at all operating area and low level of noise. The high efficiency is reflected in low MOTOR heating. The motors can operate between -40 and +52 C ambient temperature. AZ motors are designed in four lamination diameters of stator: 84 mm (AZ 84), 108 mm (AZ 108), 150 mm (AZ 150) and 220 mm (AZ 220). They are made in degree of protection IP54 (closed housing). The motors are equipped with connecting cables and can be easily connected with MOTOR controllers. Electronically commutated MOTOR must be always used together with a MOTOR controller. MOTOR cannot operate without controller. MOTOR must not be connected directly to voltage supply. Purpose of usage AZ motors are designed as standard industrial motors. On the MOTOR shaft it is possible to mount different types of fans used for all kind of purposes.

8 Beside fans drive they can be used for drive of water pumps, air compressors and all kind of industrial machines, where precise speed regulation is needed. AZ MOTOR Edition 4 Instructions for bearings replacement 11 Main MOTOR parts: Parts of MOTOR AZ 84 Picture 3. Main MOTOR parts AZ 84 AZ MOTOR Edition 4 Instructions for bearings replacement 12 Table 6. Main MOTOR parts MOTOR AZ 84 Number Component part 1 Stator support 2 Stator 3 Housing 4 O ring (in the bearing seat of the Housing pos. 3) 5 Rotor (with magnets) 6 Shaft 7 Bearing, front 8 Bearing, rear 9 Wave spring washer 10 Distance ring 11 Bearing fixation washer 12 Screw M6 13 Parallel Key 14 Stator support cover 15 Screw M6 16 Bonding screw M6 17 Screw M4 18 Connecting cable 19 Connector for MOTOR connection 20 Connector insulation 21 Terminal box 22 Terminal box seal AZ MOTOR Edition 4 Instructions for bearings replacement 13 Parts of motors AZ 108, AZ 150, AZ 220 AZ MOTOR Edition 4 Instructions for bearings replacement 14 Picture 4: Main MOTOR parts AZ 108, AZ 150, AZ 220 AZ MOTOR Edition 4 Instructions for bearings replacement 15 Table 7.

9 Main MOTOR parts AZ 108, AZ 150, AZ 220 Number Component part 1 Stator support 2 Stator 3 Housing 4 Flange 5 Rotor (with magnets) 6 Shaft 7 Bearing, front 8 Bearing, rear 9 Wave spring washer 10 Shim washer 11 Retaining ring 12 Press ring 13 Screw 14 O ring (on the Stator support pos. 1 and on the Flange pos. 4) 15 O ring (in the bearing seat of the Flange pos. 4) 16 Parallel Key 17 Cover 18 Screw 19 Bonding screw 20 Washer 21 Ground screw 22 Connecting cable 23 Identification label 24 Eye Nut AZ MOTOR Edition 4 Instructions for bearings replacement 16 3. SAFETY INSTRUCTIONS AND WARNINGS THE OPERATING AND INSTALLATION INSTRUCTIONS MUST BE READ BEFORE THE INSTALLATION OF THE MOTOR , IT'S USAGE AND IT'S MAINTENANCE! INSTRUCTIONS FOR BEARINGS REPLACEMNET MUST BE READ BEFORE ANY KIND OF MOTOR MAINTENANCE! RISK OF ELECTRIC SHOCK. ELECTRICAL CONNECTION HAS TO BE PERFORMED ONLY BY QUALIFIED PERSON! RISK OF ELECTRIC SHOCK. ELECTRICAL CONNECTION IS ALLOWED TO BE PERFORMED ONLY IF THE VOLTAGE SUPPLY IS DISCONNECTED.

10 RISK OF ELECTRIC SHOCK. MOTOR MUST NOT BE CONNECTED IF ELECTRICAL CABLE IS DAMAGED! RISK OF ELECTRIC SHOCK. ANY KIND OF MAINTENANCE OF THE MOTOR IS ALLOWED ONLY IF VOLTAGE SUPPLY IS DISCONNECTED AND THE MOTOR SHAFT NOT ROTATED! RISK OF INJURY. BEFORE STARTING THE MOTOR FASTENING OF THE MOTOR HAS TO BE CHECKED. POTENTIAL FALL OF THE MOTOR . MOTOR SHAFT MUST NOT BE USED FOR THE TRANSPORT OF THE MOTOR . POTENTIAL FALL OF THE MOTOR . ELECTRICAL CABLE MUST NOT BE USED FOR TRANSPORT OF THE MOTOR ! MOTOR CABLE DAMAGE IS POSSIBLE. AZ MOTOR Edition 4 Instructions for bearings replacement 17 4. SERVICING OF THE MOTOR FOR BEARINGS REPLACEMENT Replacement of the MOTOR bearings is an example of service intervention. Any service intervention should be performed by a qualified person. Disturbing noise from fan MOTOR ! Check by spinning the wheel by hand and listen for noise from the bearings. Establish the replacement of bearings if noise from bearings is detected.