Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

Atlas Copco Airpower n.v.

AII

Maintenance Instruction For Fan Rebearing Kit

Note Date Intr./Appd
Modified from

Name: Maintenance Instruction For Date 15-jun-06

Fan Rebearing
Detail Print date
Secr. Class 1102 K/ 2-Controlled distribution only (default)

Project title Project nr

Written by Andries De Owner AII

Bock
Edition 00 Compare 9820451700
00.00 Designation

Status Approved Replaces 9820451700 9820451700

00.00
Sheet 1(12)

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Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

Maintenance Instruction

for

Rebearing kit for compressor fan

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Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

Technical plotting for maintenance instruction:

201 202 203

Fig. 2

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Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

303

304

301 302

Fig. 3 305

Bar extractor 401 402

404 405 403

Fig. 4

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Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

501 502
Bar extractor Extractor sleeve

Fig. 5

602
Pres in sleeve

501 601
Fig. 6

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Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

Press in sleeve 404

Fig. 7

Please see description on the following pages

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Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

1 General:

These maintenance type refer to external rotor asynchronous motors MK…, motorised impellers
with free running impeller types 2CF..1NA.Z, with forward curved impeller design and fans with
housing design.

Maintenance is necessary if a fault occurs either in the bearings or in the winding or if the grease
consumption period has expired.

Safety Information:

These special fans are electrical equipment for the use in compressor units of Industrial
Air. It is strongly recommended that the maintenance work is done only by trained
personnel (VDE 105 or IEC 364). Pay attention to the safety information’s about
maintenance, service and commissioning according to the Operating Instructions which
belong to the product.

2 Removal radial fan of Atlas Copco compressor applications:

• Take off the compressor roof or open the housing on the side to have access to the fan, see
compressor operating instructions.
• Disconnect the motor power supply in the control cabinet of the compressor.
• Loose connection of the power cable (101 on Fig. 1) and tear it out of the cubicle box
carefully.
• Mark one side of the motor support and mounting plate so identical reassembly is
guaranteed. (This necessary because of symmetrical design)
• Remove the screws (102 on fig. 1) of the mounting plate and motor support or housing and
remove the impeller-motor-support-unit (103 on Fig. 1) carefully.

ATTENTION:

¾ Handle with care.

¾ Don’t throw the unit.
¾ Avoid shock and deforming of the impeller!

• Mark the motor support and the motor-impeller-unit so identical reassembly is garanteed.
• Remove the bolts (104 on Fig. 1) of the motor-impeller-unit to the support (103 on Fig. 1)
and take it off.

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Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

3 Disassembly of Motorised impeller / motor:

• Remove any dirt from the outside of the motorised impeller before disassembly.

ATTENTION:

¾ Do not use high pressure cleaner equipment!

¾ Do not disassemble the fan impeller or rebalancing is necessary!

• Lay down the impeller-motor unit to get free access to motor from the top.
• Remove sealing disk (201 / 202 on Fig. 2) or in case of version with separate stator flange,
loose bolt (301 / 302 on Fig. 3).
• In case of version with connection cable, loose additional connector (303 on Fig. 3) and
remove the stator flange (304 on Fig. 3).
• Remove circlip (305 on Fig. 3)
• Separate stator (401 on Fig. 4) and rotor (402 on Fig. 4) using the bar extractor1
delivered with the toolkit.
• Note position and number of washers (403 on Fig. 4) for later assembly.
• Remove the first ball bearing (404 on Fig. 4) by touching lightly e.g. using a hammer stick.
• Avoid distortion, because the bearing seat in the stator will be damaged.

• Remove circlip (405 on Fig. 4),

• Remove the second ball bearing (501 on Fig. 5) using bar extractor and extractor sleeve2
(Fig. 4/5).

• In case of version with nilos ring, remove also Nilos ring (601 on Fig. 6) between ball
bearing (501 on Fig. 6) and rotor hub (602 on Fig. 6).

ATTENTION:

¾ Shaft (502 on Fig. 5) cannot be removed!

¾ Removed ball bearings must not be reused!
¾ Carefully remove dirt from winding and metal surfaces.
¾ Do not use water solvents e.g. nitro.
¾ In case of a fault in the winding or damage of the bearing seat in the stator, exchange
of the complete stator is necessary.

1,2
The bar extractor and extractor sleeve belongs to a tool kit, see section 8 “Toolkit for fan rebearing”

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Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

4 Assembly of the motor:

• In case of version with Nilos ring (601 on Fig. 6), check the Nilos ring for damage.
• Apply moisture-resistant grease (Atlas Copco Heavy duty grease 2901 0338 02:
Klüberquiet BQH72-102; 8 gram3) to grease groove and push it on the shaft with grease
groove in direction of bearings (501 on Fig. 6)
• Continue assembly by following disassembly steps in reverse order.
• Apply grease to bearing seats.
• Press-in the first new ball bearing4 (501 on Fig. 6) using press in sleeve5.

ATTENTION:

¾ Avoid any pressure on the impeller

¾ Underlay rotor front side!

• Ensure that position and number of washers (403 on Fig. 4) are identical to position and
number before disassembly.
• Join stator (401 on Fig. 4) and rotor (402 on Fig. 4).
• Install circlip (405 on Fig. 4)
• Press-in the second new ball bearing (404 on Fig. 7) using press in sleeve.

ATTENTION:

¾ Canting and impacts may damage the ball bearings.

¾ Install ball bearings only with in due form press in sleeves.

• Install circlip (305 on Fig. 3), ensure that the circlip is fitted correctly to the shaft groove.
• Depending on the design either press in sealing disk (201 on Fig. 2) with O-ring by hand or
pull in a separate O-ring (203 on Fig. 2) in the frontal groove of the stator flange and screw
on sealing disk (202 on Fig. 2). Ensure that the O-ring is without damage.
• Pass through connection cable, attach the new DUBO circlip (302 on Fig. 3) to the screws
(301 on Fig. 3)

Tightening torques for motor screws (301 on Fig. 3):

¾ M6 = min. 9Nm / max. 12 Nm

¾ M8 = min. 15Nm / max. 20 Nm

• Insert connector (303 on Fig. 3) of connection cable.

3,4
The grease and ball bearings are delivered with the rebearing kit, see section 7 “Fan rebearing kit”
5
The press-in sleeve belongs to a tool kit, see section 8 “Toolkit for fan rebearing”
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Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

5 Assembly of the fan:

• Mount impeller-motor-unit to support unit (103 on fig. 1).
• Align motor cable to be tightened to the support by cable grip.
• Fix motor with bolts (104 on fig. 1) and fixing elements and tighten with correct tightening
torque. Make sure that you use the new fixing elements delivered with the fan rebearing kit.

Tightening torques for motor screws (104 on Fig. 1) on motor support (103 on Fig. 1):

¾ M6 = max. 9,5 Nm
¾ M8 = max. 43 Nm
¾ M12 = max. 77 Nm

• Position impeller-motor-support unit to the holes in base plate.

• The nozzle of the base plate and the impeller are to be aligned to get an even gap all round.
Check even gap by turning impeller by hand.
• After Fixing the bolting (102 on Fig. 1), check the gap again.
• Insert motor power cable into the control cabinet and fix it.
• Make electrical connection according to wiring diagram and compressors manual.

6 Commissioning:
• When powering up for the first time, check correct sense of rotation. It is shown by arrow on
the rating plate.
• In case of wrong rotation, stop the compressor immediately. Check and correct wiring of the
fan.
• After inspection, put back compressor roof or side plates according to compressor manual.

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Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

7 Fan Rebearing Kit

There are 3 different rebearing kits which correspond with the specific motor used in the compressor fan.
In the table below you will find the contents of the kits and the corresponding compressor type.

Fan rebearing kit

2901 1632 00 2901 1633 00 2901 1634 00
(AC-nr.)
Atlas Copco GA11, GA15, GA30C GA55, GA75, GA55+,
Compressor type GA18, GA22 (since 11-2000) GA75+, GA55VSD,
(since 11-2000) GA75VSD
GA30, GA37, GA45, (since 07-1998)
GA30+, GA37+, GA45+
(since 09-1998) GA90C, GA90,
GA90VSD (since 11-
2000)

GA50VSD (since 09-

1998)
2 x Ball bearing DIN625 DIN625 DIN625
with 6002-2z.C3 6002-2z.C3 6002-2z.C3
Atlas Copco heavy grease: Klüberquiet grease: Klüberquiet grease: Klüberquiet
duty grease BQH72-102 BQH72-102 BQH72-102
1 DUBO circlip DUBO M8-PAG
- SN60320 NT60701- -
48

Remark: only the kits have Atlas Copco numbers. The contents data refer to Siemens codes.

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Maintenance Instruction for Fan Rebearing Kit 9820 4517 00

8 Toolkit for fan rebearing:

There is a toolkit for each fan rebearing kit, see table below:

Fan rebearing kit (AC-nr.) 2901 1632 00 2901 1633 00 2901 1634 00
Corresponding toolkit (AC-nr.) 2903 0054 00 2903 0055 00 2903 0056 00
Contents of toolkit
Bar extractor 2CY2 416 2CY2 419 2CY2 419
Extractor sleeve 2CY2 417 2CY2 420 2CY2 423
Press in sleeve 2CY2 418 2CY2 421 2CY2 424
Necessary bolts and washers 2x hex screw 2x hex screw 2x hex screw
M6x30 M10x40 M12x40 ISO4017-
ISO4017-8.8- ISO4017-8.8- 8.8-A3X: NT60100-
A2X: A3X: 69
NT60007-06 NT60100-61
2x washer A13
2x hex screw 2x washer DIN125-140HV-
M6x40 A10,5 A3X: NT60700-47
ISO4017-8.8- DIN125-
A2X: 140HV-A3X: 2x hex screw
NT60100-31 NT60700-45 M10x125 ISO4014-
8.8-A3X: NT60108-
2x washer 2x hex screw 02
A6,4 DIN125- M6x40
140HV-A3X: ISO4017-8.8- 2x hex screw
NT60700-42 A2X: M10x50 ISO4017-
NT60100-31 8.8-A3X: NT60100-
(for GA30C) 62

2x hex screw 2x washer A10,5

M6x70 DIN125-140HV-
ISO4014-8.8- A3X: NT60700-45
A2X:
NT60101-00
(for GA30-45)

2x washer
A6,4 DIN125-
140HV-A3X:
NT60700-42

Remark: only the kits have Atlas Copco numbers. The contents data refer to Siemens codes.

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