az motor - swegon motor edition 4 instructions for bearings replacement 8 1.3. list of new motor...

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 1.2. Some parts of the motor must not be used again. The list of new motor parts is described in chapter 1.3. All pictures in this document are symbolic. Domel d.o.o 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.

1.1 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.

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1.2. 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

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(h) pliers

(i) 2 or 3 handed puller

We recommend to use the puller from KUKKO manufacturer (www.kukko.com) with small pulling arms.

(j) inductive heater

(k) special tools for front

bearing installation We recommend using bearing fitting tool kit TMFT 36 from SKF manufacturer (www.skf.com).

(l) centring tube

(picture 1)

(m) torque wrench

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(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.

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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 0.25 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.

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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 39.5 3 AZ 150 6,5 25.5 51.5 4 AZ 220 6,5 30.5 61.5

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1.3. 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 748.3.xxx motors (motor size AZ 150) 64x15x11,6 for 749.3.xxx motors (motor size AZ 220)

New larger press ring For 748.3.xxx motors (motor size AZ 150)

For 749.3.xxx 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)

Shaft end Not shaft

end

C3E D EA3S NSK

C3E D EA3S NSK

746.3.392 AZ 84-50 6202 ZZ 6202 ZZ 28x34,5x0,6x3 747.3.192 AZ 108-30 6204 DDU 6203 DDU 33x39,1x0,5x2,9 747.3.194 AZ 108-30 6204 DDU 6203 DDU 33x39,1x0,5x2,9

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747.3.392 AZ 108-55 6204 DDU 6203 DDU 33x39,1x0,5x2,9 747.3.397 AZ 108-55 6204 DDU 6203 DDU 33x39,1x0,5x2,9 748.3.292 AZ 150-45 6205 ZZ 6205 ZZ 42x51x0,5x3,4 748.3.492 AZ 150-70 6205 ZZ 6205 ZZ 42x51x0,5x3,4 748.3.496 AZ 150-70 6205 ZZ 6205 ZZ 42x51x0,5x3,4 749.3.392 AZ 220-55 6206 ZZ 6206 ZZ 51x61x0,5x3,7 749.3.393 AZ 220-55 6206 ZZ 6206 ZZ 51x61x0,5x3,7 749.3.692 AZ 220-100 6206 ZZ 6206 ZZ 51x61x0,5x3,7 749.3.694 AZ 220-100 6206 ZZ 6206 ZZ 51x61x0,5x3,7 749.3.695 AZ 220-100 6206 ZZ 6206 ZZ 51x61x0,5x3,7

749.3.901 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. 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

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2. ABOUT AZ MOTORS

2.1. 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.

2.2. 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. 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.

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2.3. Main motor parts: 2.3.1. Parts of motor AZ 84

Picture 3. Main motor parts – AZ 84

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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

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2.3.2. Parts of motors AZ 108, AZ 150, AZ 220

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Picture 4: Main motor parts – AZ 108, AZ 150, AZ 220

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Table 7. 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

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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.

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.

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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.

RISK OF ELECTRIC SHOCK. Before service intervention, ensure that motor controller is disconnected by the mains voltage and that motor does not rotate. The fan, mounted on the motor shaft, could rotate due to influence of the overpressure in the air channel or wind. The rotation of the fan causes the rotation of the motor. In such case the motor generates electrical voltage. And a touch of the non-insulated wires of the connection cable can lead to serious injuries.

RISK OF INJURY BECAUSE OF FLYING OBJECTS. During the service intervention protecting glasses and protective gloves should be used.

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Step 1: Removing the fan frame with motor Remove the fan frame with motor from AHU. Motor controller must be disconnected from mains.

Step 2: Removing the wheel Remove the inlets, fan wheel screw and wheel from motor shaft (Inter dismantle front profile).

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Step 3: Disconnecting motor cable from motor controller You will need a TORX T20 screwdriver (a) and a small flat screwdriver (g) for this step Open the cover of motor controller and disconnect the motor cable from motor controller.

Step 4: Positioning the motor in vertical direction

RISK OF INJURY. For larger motor sizes use lift and be careful not to injury yourself. Be careful not to damage fan housing, motor or motor cables.

Place the fan housing with motor in vertical direction as shown on picture bellow.

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Step 5: Fixing the motor shaft

In this step you must fix motor shaft so that it cannot move axially. Avoid forces in axial or radial direction that are pulling the shaft out or pressing the shaft in. You can damage wave spring washer. For fixing the shaft you can use e.g. a plastic tie as shown on picture bellow. Be careful not to damage the shaft.

Fix the motor shaft.

Step 6: Removing terminal box and disconnection of cable You will need a TORX T20 screwdriver (a) and a small flat screwdriver (g) for this step.

Be careful not to damage motor wires, connector and connecting cable. Be careful not to damage terminal box seal.

MOTOR AZ 84 Unscrew four motor fixation bolts and remove motor from frame – PICTURE A. Untighten cable gland nut and release the connecting cable (pos. 18). Unscrew four M4 screws (pos. 17) and gently pull out the terminal box (pos. 21) with seal (pos. 22). Use TORX T20 screwdriver (a). You will have to push the connecting cable into cable gland to slide inside. When you get enough place to disconnect the cable, stop to pull. Disconnect the connecting cable (pos. 18) from connector (pos. 19). Use a small flat screwdriver (g) with pressing the pins of connector – PICTURE B. Unscrew ground screw and screw for cable screen connection and remove connection cable together with terminal box

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PICTURE A: PICTURE B: Fix motor back on frame that next steps will be easier to perform. Gently tighten motor fixation bolts – you do not need to tighten with high torque – PICTURE C.

17 torx T20

21

22

19

18

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PICTURE C:

Step 7: Removing the motor cover You will need a TORX T20 screwdriver (a) or TORX T30 screwdriver (b) for this step. MOTORS AZ 108, AZ 150, AZ 220 Unscrew two M4 screws (pos. 18) and remove the cover (pos. 17). Use TORX T20 screwdriver (a). MOTOR AZ 84 Unscrew three M6 screws (pos. 15) and remove the stator support cover (pos. 14). Use TORX T30 screwdriver (b).

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MOTORS AZ 108, AZ 150, AZ 220 MOTOR AZ 84

Step 8: Removing rear bearing fixation elements and preload elements You will need a TORX T20 screwdriver or tool (a) or TORX T30 screwdriver or tool (b), retaining ring pliers (c) and heavy duty pliers (d) for this step. Table 8: Rear bearing fixation elements and preload elements on motors

AZ 108 AZ 150, AZ 220 AZ 84 Rear bearing fixation elements

Press ring (pos. 12) Screw M4x16 (pos. 13)


Bearing fixation washer (pos.11) Screw M6x16 (pos. 12)

Preload elements Wave spring washer (pos. 9) Shim washer (pos. 10) Retaining ring (pos. 11)

Wave spring washer (pos. 9) Distance ring (pos. 10)

When unscrewing the screw in shaft, hold the motor shaft at the other side if you are not able to unscrew the screw since the shaft will rotate. Protect the shaft e.g. with a cotton cloth or soft metal or some plastic. Then use e.g. heavy duty pliers, hold the shaft and unscrew screw with screwdriver or tool. Be careful not to damage the motor shaft. See picture A for additional information. Avoid forces in axial or radial direction that are pulling the shaft out of the motor.

18 (torx T20)

17

15 (torx T30)

14

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RISK OF INJURY BECAUSE OF FLYING OBJECTS. When removing retaining ring secure it e.g. with your hand because it can fly away since it is compressed. Safety glasses must be used. Pay attention to the screw and make sure that it does not fall inside of the motor.

MOTORS AZ 108, AZ 150, AZ 220

Unscrew the screw (pos. 13) from the shaft and remove the press ring (pos. 12). Use the retaining ring pliers and carefully remove retaining ring (pos. 11). Then remove shim washer (pos. 10) and wave spring washer (pos. 9). See picture B for additional information.

Removed press ring will not be used again on motors 748.3.xxx (motor size AZ 150) and motors 749.3.xxx (motor size AZ 220). It will be changed with new one according to table 4 at page 8 of these instructions. Motors 747.3.xxx (motor size AZ 108) will use the existing press ring during motor assembling back.

Removed wave spring washer must be replaced with new one according to table 5 at pages 8 and 9 of these instructions because during motor disassembly there is a risk of its deformation and consequently motor bearings preload will not be sufficient.

MOTORS AZ 84

Unscrew the M6 screw (pos. 12) from the shaft and remove bearing fixation washer (pos. 11). Then remove distance ring (pos. 10) and wave spring washer (pos. 9). See picture B for additional information.

Removed wave spring washer must be replaced with new one according to table 5 at pages 8 and 9 of these instructions because during motor disassembly there is a risk of its deformation and consequently motor bearings preload will not be sufficient.

PICTURE A:

SHAFT

HOLDING WITH PLIERS

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PICTURE B:


Step 9: Removing bonding screws You will need INBUS (hexagonal) tool 5 mm for M6 screw head (e) or TORX T30 screwdriver or tool (b) for this step

RISK OF DAMAGE IF WASHERS FALL INSIDE. Every bonding screw on motors AZ 108, AZ 150, AZ 220 has a washer under the head of the screw. Pay attention to these washers and make sure that they do not fall inside of the motor. If the washer falls inside and you forget to take it out then it is possible that motor will damage when you power it on.


Unscrew the bonding screws (pos. 19) and remove bonding screws with washers (pos. 20).

Use INBUS (hexagonal) tool 5 mm (e).

MOTOR AZ 84

Unscrew the bonding screws (pos. 16) and remove it.

Use TORX T30 screwdriver or tool (b).

13 (torx T30 or torx T20)

12

11

10

9

10

12 (torx T30)

9

11

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Step 10: Removing stator support with stator For motor sizes AZ 84 you will need three M6 eye bolts (f) for this step. For motor sizes AZ 108 and AZ 150 you will need two M8 eye bolts (f) for this step. For motor sizes AZ 220 you will need two eye bolts with thread M14x1,5 for this step. You can also use other hook designs with specified thread. You will also need a thin item e.g. a small screwdriver (g) for this step.

You will need to increase the gap between the stator support and motor housing with a thin item, e.g. a screwdriver, on both sides (see picture A for this step). Between motor housing and flange on motors AZ 108, AZ 150 and AZ 220 there is O-ring. Be careful not to damage it. Be careful not to damage the motor housing or stator support. Especially take care of mating surfaces that must not be damaged. Damaged mating surfaces can lead to bearings misalignment and shorter life of motor bearings. For removing the stator you must use moderate force. The pulling force must act exactly in the direction of the axis. Too high force can damage stator support with stator.

19 (INBUS 5 mm)

20

16 (torx T30)

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By removing stator support with stator you also remove rear bearing from bearing seat on shaft. Sometimes rear bearing does not leave bearing seat on shaft easily so you need to use puller tool to easier disassembling. Pay attention to not to lift the fan housing with motor because it will fall down when rear bearing will release from bearing seat on shaft. If rear bearing does not leave shaft please use other tools such as three handed puller. Place the hands of the puller in the gap between the stator support and housing and pull the stator support with stator up. Be careful not to damage the shaft, stator wires, bearing seat in stator support or any other part. For additional information see picture B. When stator support with stator is released put it on a clean, soft and non-abrasive surface to prevent stator winding to any kind of damage.

RISK OF INJURY. For heavier motors (e.g. AZ 220) you should use lift because parts are heavy and magnetic force, holding the stator and rotor, is strong, so you can hurt yourself when trying to lift by hands.

Increase the gap between the stator support and housing with e.g. a small screwdriver. Disassemble the stator support with stator (pos. 1) from the rest of the motor. For this purpose use designed threaded holes in stator support. On motors AZ 108, AZ 150 in AZ 220 stator support has threaded holes in two of four holes (holes for bonding screws). In these two threads eye bolts can be fitted and by these two eye bolts we can pull up the stator support with stator.

On motors AZ 84 use three threaded M6 holes designed for stator support cover (pos.14) fixation. Fit eye bolts in all holes and pull up the stator support with stator. Make sure that connector insulation (pos. 20) stays on PCB.

For additional information see picture C.

PICTURE A:

GAP

GAP

1

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PICTURE B:

PICTURE C:


Step 11: Removing the rear bearing

If the rear bearing cannot be removed from stator support by hands, you can turn around stator support with stator and push it through the hole in the stator support. Be careful not to damage stator winding, wires and cables, bearing seat or any other part. Rear bearing must not be used again.

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Disassemble rear bearing (pos. 8) from the stator support.


Step 12: Removing the fixation of the motor shaft

Be careful not to damage the shaft. Avoid forces in axial or radial direction that are pulling the shaft out of the motor.

Remove plastic tie or other fixation that you used for motor shaft fixation.

8

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Step 13: Removing the parallel key You will need pliers (h) for this step.

Be careful not to damage the motor shaft. You can protect motor shaft with cotton cloth or soft metal or plastic.

Remove parallel key (pos.13 on AZ 84 and pos. 16 on AZ 108, AZ 150, AZ 220) from motor shaft (pos. 6).

Step 14: Removing rotor with shaft

The pulling force must act exactly in the direction of the axis. Be careful not to damage the shaft, rotor or flange. Avoid touching the rotor magnets. When you remove rotor with shaft from flange the front bearing will stay on the shaft. For rotor and flange disassembly you must not use shocking force e.g. by using a hammer.

Remove rotor with shaft from the flange. Pull rotor axially from flange.

6

16 on AZ 108, AZ, 150 AZ 220

13 on AZ 84

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Step 15: Removing the front bearing You will need 2 or 3 handed puller (i) for this step. We recommend using the puller from KUKKO manufacturer (www.kukko.com) with small pulling arms.

The pulling force must act exactly in the direction of the axis. Be careful not to damage the bearing seat on the shaft, shaft end, the thread in the shaft or rotor with magnets. Front bearing must not be used again.

RISK OF INJURY. If you use other tools for bearing removal, secure the bearing e.g. by sticking it with tape or inserting parallel key. It is possible that by applying the force bearing will suddenly fly away and injury you. When removing front bearing press only on the shaft. Do not press on the ring where magnets are placed. It can damage the rotor.

Place rotor with shaft on a flat surface. Disassemble the front bearing (pos. 7) from the shaft (pos. 6) with the appropriate instrument, e.g. a puller.

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Step 16: Installing the new front bearing You will need inductive heater (j) or special tools for front bearing installation (k) and new bearing for this step. We recommend using bearing fitting tool kit TMFT 36 from SKF manufacturer (www.skf.com).

The bearing has to be new, according to specifications. The installation of the bearing can be done by using force or with the preliminary heating of the bearing. Use the appropriate tool or device for this purpose and follow producer’s instructions for use. Only tools that bearings producers recommend are suitable for this operation. Force for bearing installation has to be applied on inner bearing ring or inner and outer bearing ring at the same time. Force just on outer bearing ring must not be applied. The force for the bearing installation should act exactly in the direction of the axis of the shaft. You must not use shocking force for bearing installation, e.g. hitting the bearing with hammer. In case of installation of the bearing with preliminary heating, the heating temperature of the bearing should be 100 °C to 110 °C. After heating, assemble the bearing on the bearing seat on the shaft immediately. Otherwise the bearing will cool down and the bearing assembly could not be possible. Pay attention not to strike the bearing on the shaft e.g. by dropping it.

7

6

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Bearing must not be heated over 110°C because higher temperature influence bearing grease which can lead to shorter bearing life time. Ensure that the bearing is installed up to the level on the shaft (bearing seat). Otherwise the distances between the components will not be appropriate. Because of that the bearing will be overloaded which lead to shorter life time or the assembly of the motor will not be possible. Appropriate support for bearing installation is just shaft end. You cannot support rotor on the rotor ring because forces during bearing installation can influence the magnets and rotor ring which can lead to rotor damages and shorter motor life time.

RISK OF INJURY. In case of installation of the bearing with preliminary heating be careful not to burn your hands because bearing surface is hot. Do not use any other kind of bearing heating except the inductive heater.

Place rotor with shaft on a flat, soft and clean surface. Remove any tape or parallel key if you placed it on a shaft in previous step. Ensure that the bearing seat on the shaft is without any dirtiness or mechanical particles. Install the new bearing.

FORCE ON INNER RING

FORCE ON INNER RING

SUPPORT DURING BEARING INSTALLATION

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Step 17: Lubricating and installing rotor with shaft back into flange You will need assembly grease (n) for this step.

Be careful not to damage the motor shaft. Be careful not to assemble rotor with shaft suddenly because the strike could damage the new bearing and magnets. The installation of the rotor must be done exactly in the direction of the axis. Assembly paste is used to prevent the corrosion between two materials (between bearing and bearing seat in the flange) and to ensure easy assembly (O-ring lubrication in the flange). Please ensure that front bearing is fully placed into bearing seat in flange. Avoid touching the rotor magnets.

Before installation ensure that front bearing is cooled down on a room temperature (if you heated it in previous step). You must also lubricate bearing seat and O-ring in the flange with assembly paste. Apply only a thin layer of assembly paste. Make sure that O-ring is in correct position in bearing seat groove. Place rotor with shaft into flange slowly to the end position.


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Step 18: Installing the parallel key

You will need pliers (h) for this step.

Be careful not to damage the motor shaft. You should protect motor shaft with cotton cloth, soft metal or plastic. Do not hit key with hammer or other tools because strikes can damage bearings which can lead to shorter bearings life time.

Install parallel key (pos.13 on AZ 84 and pos. 16 on AZ 108, AZ 150, AZ 220) into motor shaft (pos. 6). Ensure that parallel key is installed to the end position.

Step 19: Fixation of motor shaft

In this step you must fix motor shaft so that it cannot move axially. Avoid forces in axial or radial direction that are pulling the shaft out because you can damage new front bearing. For fixing the shaft you can use e.g. a plastic tie as shown on picture bellow. Be careful not to damage the shaft.

6 16 on AZ 108, AZ, 150 AZ 220

13 on AZ 84

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Fix the motor shaft.

Step 20: Inserting centering tube You will need centering tube (l) for this step. Only for motors AZ 108, AZ, 150 and AZ 220. Motor AZ 84 do not need centering tube. Insert centering tube on the rotor shaft slowly to the end position.


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Step 21: Installing stator support with stator into motor housing

RISK OF INJURY. Secure the fan housing with rotor and flange so the magnetic forces between rotor magnets and stator will not pull everything up and eventually squeeze your hands. When inserting hold the stator only by the eye bolts and not by the stator. For heavier motors (motor type AZ 150 and AZ 220) please use lift because you will not be able to insert stator support with stator and housing slowly due to strong magnetic forces which will pull the rotor and stator suddenly together. Again secure the fan housing with rotor and flange. Be careful not to damage motor wires and cable. Be careful not to damage O-ring on stator support. Check the position of connector insulation on motor AZ 84. PCB must lie in the connector insulation groove and must be inserted to the end position. There is a risk of electric shock if connector insulation is not in right position.

Insert stator support with stator and housing on rotor and flange slowly. Be careful to assemble it in right position. Make sure that there is no gap between motor housing and flange when finished. On motor AZ 84 additionally check that connector insulation is on the right position.

MOTORS AZ 108, AZ 150, AZ 220 Correct position of stator support

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MOTOR AZ 84 Correct position of stator support

Correct position of connector insulation

Step 22: Removing centering tube and installing bonding screws You will need INBUS (hexagonal) tool 5 mm for M6 screw head (e) or TORX T30 screwdriver or tool (b) and torque wrench (m) for this step.

RISK OF DAMAGE IF WASHERS FALL INSIDE. Every bonding screw of motors AZ 108, AZ 150 and AZ 220 has a washer under the head of the screw. Pay attention to these washers and make sure that they do not fall inside of the motor. If the washers fall inside remove the washers from the motor by applying steps for motor disassembly which are needed to get the washers out. If you forget to take them out then it is possible that motor will damage when you power it on.

20

PCB

PCB lies in connector insulation groove

NO GAP between PCB and connector insulation

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All bonding screws of motors AZ 108, AZ 150 and AZ 220 have to be secured against the unscrewing with appropriate glue. It is recommended to use glue Loctite 243. Apply the glue on bonding screw thread.

When screwing bonding screws you should screw them diagonally.

Remove centering tube from rotor shaft. Remove two eye bolts from the stator support. Fasten the stator support, motor housing and flange with 4 bonding screws (pos. 19 for motors AZ 108, AZ 150 and AZ 220 or pos. 16 for motors AZ 84). Under the screw head the washer (pos. 20) has to be mounted (for motors AZ 108, AZ 150, AZ 220). Screw the bonding screws with sufficient tightening torque by using torque wrench (m). Tightening torque for bonding screws (pos. 19 - AZ 108, AZ 150, AZ 220) is 6 Nm while tightening torque for bonding screws (pos. 16 - AZ 84) is 13 Nm.

19 (INBUS 5 mm)

20

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MOTOR AZ 84

Step 23: Installing the new rear bearing

You will need assembly paste (n), new bearing, adjusted press ring (o) and screw M4x30 or M6x35 for this step.

Ensure that the bearing seat on the shaft is without any dirtiness or mechanical particles. The bearing has to be new, according to the manufacturer's specifications. The force for the bearing installation has to be equable and it has to act on the inner and outer ring of the bearing at the same time. Permissible forces for rear bearing installation are described in table 9. The bearing seat is designed to mount the rear bearing manually. If manual rear bearing installation is not possible, use e.g. adjusted press ring and M6 screw (motors AZ 84, AZ 150 and AZ 220) or M4 screw (motor AZ 108) and slowly screw the screw into thread in the shaft to get the right position of bearing. See picture B for additional information. When done remove the adjusted press ring and screw. The installation of rear bearing must be done exactly in the direction of the axis. Ensure that the bearing is installed up to the level on the shaft (bearing seat). Otherwise the distances between the components will not be appropriate. Because of that the bearing will be

16 (torx T30)

AZ motor Edition 4


overloaded which will lead to shorter life time or the assembly of the motor will not be possible.

You must first lubricate bearing seat in the stator support with assembly paste. Apply only a thin layer of assembly paste. Install the new rear bearing. PICTURE A:


PICTURE B:


Table 9. Permissible forces for rear bearing installation

Motor type Max. force for rear bearing assembly [N]

746.3.xxx (AZ 84) 80 747.3.xxx (AZ 108) 100 748.3.xxx (AZ 150) 200 749.3.xxx (AZ 220) 300

AZ motor Edition 4


Step 24: Installing back rear bearing fixation elements and preload elements You will need a TORX T20 screwdriver or tool for M4 screw head (a) or TORX T30 screwdriver or tool for M6 screw head (b), torque wrench (m), heavy duty pliers (d) and retaining ring pliers (c) for this step. Table 10: Rear bearing fixation elements and preload elements on motors

AZ 108 AZ 150, AZ 220 AZ 84 Rear bearing fixation elements



Bearing fixation washer (pos.11) Screw M6x16 (pos. 12)

Preload elements Wave spring washer (pos. 9) Shim washer (pos. 10) Retaining ring (pos. 11)

Wave spring washer (pos. 9) Distance ring (pos. 10)

RISK OF INJURY BECAUSE OF FLYING OBJECTS. When installing retaining ring secure it e.g. with your hand because it can fly away since it is compressed. Safety glasses must be used. Pay attention to the screw because it can fall inside of the motor. If this happens, remove the screw from the motor by applying steps for motor disassembly which are needed to get the screw out. If you forget to take it out then it is possible that motor will damage when you power it on.

Screw M4 or M6 has to be secured against the unscrewing with glue for protection against unscrewing. It is recommended to use glue Loctite 243. When screwing the M4 or M6 screw you should hold the motor shaft because you will not be able to screw since the shaft will rotate. Protect the shaft e.g. with a cotton cloth or soft metal or some plastic. Then use e.g. heavy duty pliers, hold the shaft and screw the screw with torque wrench. Be careful not to damage the motor shaft. Be careful not to damage stator winding or motor wires and cable or motor connector.

AZ motor Edition 4


MOTORS AZ 108, AZ 150, AZ 220 Install new wave spring washer (pos. 9) according to table 5 on pages 8 and 9 and shim washer (pos. 10). Use retaining ring pliers and carefully install retaining ring (pos. 11). Check that retaining ring lies correctly in the groove. On motors 747.3.xxx (motor size AZ 108) install the previous press ring you removed in step 8 while on motors 748.3.xxx (motor size AZ 150) and 749.3.xxx (motor size AZ 220) install the new press ring (pos. 12) from table 4 on page 8 and screw the M4 or M6 screw (pos. 13) by using torque wrench. Tightening torque of screw M4 is 5 Nm and for M6 is 6 Nm. Hold the shaft with heavy duty pliers. Use glue for screw fixation. Previous press ring on motors 748.3.xxx and 749.3.xxx cannot be used because mating surface for grounding brushes will be too small and also gap between press ring and brush support will be too small and brush effectiveness and life time will not be sufficient. MOTOR AZ 84 Install distance ring (pos. 10) and new wave spring washer (pos. 9) according to table 5 on pages 8 and 9 in the groove of distance ring. Be careful for the right orientation of distance ring (look at the picture below). Install bearing fixation washer (pos. 11) and screw the M6 screw (pos. 12) by using torque wrench. Tightening torque of screw is 6 Nm. Hold the shaft with heavy duty pliers. Use glue for screw fixation.


13 (torx T30 or torx T20)

12

11

10

9

12 (torx T30)

11

9

10

AZ motor Edition 4


Step 25: Installing the grounding brush (only motors 748.3.xxx – motor size AZ 150 and 749.3.xxx – motor size AZ 220) You will need a rubber hammer (r) for this step.

Only the rubber hammer is allowed to be used. If you use hard hammer (steel, plastic) the hits can damage motor bearings and other parts and motor life time can be shorter.

Push grounding brush into the bearing seat to the end position. Edge on grounding brush must touch the top of bearing seat. Grounding brush orientation is important. It has to be aligned along the virtual line that connects two M4 holes in stator support for cover fixation (look at the picture below). If brush is assembled that way cover will be able to support the brush after installation and prevent the brush moving out from the bearing seat in stator support.

Grounding brush orientation along the virtual line that go through holes for motor cover fixation

AZ motor Edition 4


Step 26: Installing the motor cover You will need a TORX T20 screwdriver or tool for M4 screw head (a) or a TORX T30 screwdriver or tool for M6 screw head (b), torque wrench (m) and sharp knife (p) for this step.

Be careful not to damage motor cables, wires or connector. Be careful not to injury yourself with knife. Be careful not to damage rubber seal under motor cover. It has also function of electric insulation. Damaged rubber seal can lead to shorter motor life time and there is also a risk of electric shock at motor operation.

FOR MOTORS OF CODE 748.3.XXX (MOTOR AZ 150) AND 749.3.XXX (MOTOR AZ 220):

Cut the hole into rubber seal of motor cover. It has to be approximately on the middle of motor cover. Hole diameter for motors 748.3.xxx (motor AZ 150) is approximately 50 mm and for motors 749.3.xxx (motor AZ 220) approximately 60 mm. Remove the inner seal part.

FOR MOTORS OF CODE 747.3.XXX (MOTOR AZ 108)

For motors 747.3.xxx (motor AZ 108) use the existing cover without any modifications.

Mount the cover (pos. 17) on the stator support (pos. 1) and fasten it with two screws (pos. 18) by using torque wrench. Tightening torque of screws (pos. 18) is 2.5 Nm. Make sure that cover is in right position and sealing on the edge is ensured.

Code of motor Hole diameter D [mm]

748.3.xxx (motor size AZ 150) 50

749.3.xxx (motor size AZ 220) 60

D

AZ motor Edition 4


FOR MOTORS OF CODE 746.3.XXX (MOTOR AZ 84)

Mount the cover (pos. 14) on the stator support (pos. 1) and fasten it with three screws (pos. 15) by using torque wrench. Tightening torque of screws is 5 Nm. Make sure that cover is in right position and sealing is ensured. Also take care that wave spring washer lies correctly in the groove of distance ring. If wave spring washer is not positioned correctly it can lead to insufficient motor bearings preload and shorter lifetime.


Step 27: Removing the fixation of the motor shaft

Be careful not to damage the shaft. Avoid pulling the shaft down because you can damage new front bearing. Avoid pushing the shaft in the motor because you can damage new rear bearing and wave spring washer.

Remove plastic tie or any other fixation that you used for motor shaft fixation.

18 (torx T20)

17

15 (torx T30)

14

AZ motor Edition 4


Step 28: Installing the terminal box and cable connection You will need a TORX T20 screwdriver (a), a small flat screwdriver (g), wrench 19 mm (t) and torque wrench (m) for this step.

Be careful not to damage motor wires, connector and connecting cable. Be careful not to damage terminal box seal.

MOTOR AZ 84 Disassemble motor from frame. Be careful not to hit the shaft. Connect the connecting cable according to signs on cables and on motors (letters U, V and W on cable must match U, V and W on motor). Use a small flat screwdriver (g) to press the pins of connector. Connect the ground ring connector and connect cable screen with cable clamp. Use TORX T20 screwdriver (a). Tightening torque of screws is 2.5 Nm. Install terminal box and tighten four M4 screws. Use TORX T20 screwdriver (a). Tightening torque of screws is 2.5 Nm – PICTURE A. Tighten the cable gland nut. Nut is tightened enough when the gap between cable gland nut and the neighbour hexagonal part of cable gland is approximately 2 mm – PICTURE B. Use wrench 19 mm (t). Assemble the motor back to frame – PICTURE C.

AZ motor Edition 4


PICTURE A: PICTURE B:

PICTURE C:

17 torx T20

21

22

19

18

AZ motor Edition 4


Step 29: Connecting motor cable to motor controller You will need a TORX T20 screwdriver (a) and a small flat screwdriver (g) for this step.

RISK OF ELECTRIC SHOCK. Before connecting the motor cable to motor controller ensure that motor controller is disconnected by the mains voltage and that motor does not rotate. The fan, mounted on the motor shaft, could rotate due to different influences in the air channel. The rotation of the fan causes the rotation of the motor. In such case the motor generates electrical voltage. And a touch of the non-insulated wires of the connection cable can lead to serious injuries.

Connect the motor cable to motor controller. Be careful that signs on controller match signs on cable. Connect also the cable screen. Place the cover on motor controller.

Step 30: Installing the wheel You will need a tool for fan wheel installation (s) and suitable wrench for this step.

Too high assembly force can damage motor bearings and wave spring washer which can lead into shorter bearings life time. Axial force for fan assembly must not exceed permissible force defined in table 11.

Table 11. Permissible force for wheel installation

Motor type Max. force for fan assembly [N]

746.3.xxx (AZ 84) 80 747.3.xxx (AZ 108) 100 748.3.xxx (AZ 150) 200 749.3.xxx (AZ 220) 300

AZ motor Edition 4


Mount fan wheel on motor shaft with very low force. There is no need that wheel is mounted to the end position, just position fan wheel on shaft. Install the tool for fan wheel installation (s) into shaft threaded hole. With screwing the nut of tool for fan wheel installation push the fan wheel to the end position. Uninstall the tool for fan wheel installation. Screw the wheel screw. Install the inlets.

Step 31: Install the fan in AHU Install the fan housing with motor to the final place and test first with hand and make sure that everything seems normal. The wheel should spin quietly.

az motor - swegon motor edition 4 instructions for bearings replacement 8 1.3. list of new motor...

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