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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. 

 
 

 

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. 

 
 
 

Summary of Contents for AZ 108

Page 1: ...AZ MOTOR INSTRUCTIONS FOR BEARINGS REPLACEMENT Edition 4 June 2014 ...

Page 2: ...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 ...

Page 3: ...ngs 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 ...

Page 4: ...er 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 ...

Page 5: ...mbly 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 ...

Page 6: ... 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 ...

Page 7: ...tions 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 39 5 3 AZ 150 6 5 25 5 51 5 4 AZ 220 6 5 30 5 61 5 ...

Page 8: ...th 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...

Page 9: ...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...

Page 10: ...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 i...

Page 11: ...AZ motor Edition 4 Instructions for bearings replacement 11 2 3 Main motor parts 2 3 1 Parts of motor AZ 84 Picture 3 Main motor parts AZ 84 ...

Page 12: ...e 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 ...

Page 13: ...AZ motor Edition 4 Instructions for bearings replacement 13 2 3 2 Parts of motors AZ 108 AZ 150 AZ 220 ...

Page 14: ...AZ motor Edition 4 Instructions for bearings replacement 14 Picture 4 Main motor parts AZ 108 AZ 150 AZ 220 ...

Page 15: ...otor 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 ...

Page 16: ...IC 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 C...

Page 17: ...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 touc...

Page 18: ...ent 18 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 ...

Page 19: ...r 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 ...

Page 20: ... 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 t...

Page 21: ...ns for bearings replacement 21 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 ...

Page 22: ...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 ...

Page 23: ...rew M6x16 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 so...

Page 24: ...t 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 pr...

Page 25: ... 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 MOTORS AZ 108 AZ 150 AZ 220 Unscrew the bonding screws pos 19 and remove bonding screws with washers pos 20 Use INBUS hexagonal tool 5 mm e MOTOR AZ 8...

Page 26: ...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 ...

Page 27: ... 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 suppor...

Page 28: ...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 ...

Page 29: ...stator support MOTORS AZ 108 AZ 150 AZ 220 MOTOR AZ 84 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 ...

Page 30: ...Z 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 ro...

Page 31: ...he 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 w...

Page 32: ...ols 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 ...

Page 33: ... 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 inductiv...

Page 34: ...ion 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 an...

Page 35: ...rter 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 fixi...

Page 36: ...e 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 MOTORS AZ 108 AZ 150 AZ 220 ...

Page 37: ...ll 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 ...

Page 38: ... 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 ...

Page 39: ... 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 torqu...

Page 40: ...rmissible 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 addition...

Page 41: ...n the stator support with assembly paste Apply only a thin layer of assembly paste Install the new rear bearing PICTURE A MOTORS AZ 108 AZ 150 AZ 220 MOTOR AZ 84 PICTURE B MOTORS AZ 108 AZ 150 AZ 220 MOTOR AZ 84 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 ...

Page 42: ...lling 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 p...

Page 43: ...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 wash...

Page 44: ...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 installatio...

Page 45: ... 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 1...

Page 46: ...rectly 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 MOTORS AZ 108 AZ 150 AZ 220 MOTOR AZ 84 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 y...

Page 47: ...ding 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...

Page 48: ...AZ motor Edition 4 Instructions for bearings replacement 48 PICTURE A PICTURE B PICTURE C 17 torx T20 21 22 19 18 ...

Page 49: ...rical 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 assem...

Page 50: ... 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...

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