GEA Bock HGX2 CO2 T Series Setup guide

Repair instruction electric motor
Series: HGX2 CO2T, HGX34 CO2T, HGX46 CO2T
HGX34 CO2THGX2 CO2T
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Translation of the original instructions

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Contents
1 Liability and Warranty ......................................................................................................................2
2 Additional Safety Information............................................................................................................2
3 Disassembly .......................................................................................................................................4
4 Assembly ..........................................................................................................................................10
1 Liability and Warranty
Liability and the manufacturer‘s warranty are excluded if
• Alterations and functional modications have been carried out,
• no original replacement parts have been used.
2 Safety Information
Target group for this repair information
¾Work on the compressor may only be carried out by persons whose technical training, skills and
experience along with their knowledge of pertinent regulations and documentation means that
they are capable of assessing the work to be carried out and detecting any possible dangers.
¾A specialist can mean a refrigeration technician for example. Note that electrical work may only
be carried our by a qualied electrician. Alternatively, on a country-specic basis, persons who
have undergone electrotechnical instruction and who have proof of their qualication are also
permitted to carry out the work.
• DANGER! This symbol refers to instructions for avoiding direct severe
dangers to persons or plant by electrical current.
• DANGER! This symbol refers to instructions for avoiding direct severe
dangers to persons.
• WARNING! This symbol is used to indicate that inaccurate compliance or
total failure to comply with the instructions could cause injury to persons or
damage to the compressor or refrigerating machine.
• This symbol is used to indicate that parts with refrigeration oils (for oil types see
compressor name plate) should be moistened prior to installing.
• This symbol indicates the permitted tightening torque for the screw.
60 Nm
• INFO! Important information or tips on simplifying work.

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Safety Information
Important prerequisites
DANGER
Risk of electric shock.
XBefore you carry out any repair work, disconnect the compressor from the electricity network.
XTurn the main switch to „O“ (OFF).
XSecure the main switch against an unauthorised restart.
WARNING
The heavy weight of the compressor can be potentially dangerous.
Use all the seals included in the kit.

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Disassembly
3 Disassembly
WARNING
Ensure that the compressor is depressurised before starting work.
3.1 Draining the oil
NOTE
Do not dispose of oil in domestic waste.
XDispose of the old oil in accordance with the environmental regulations and observe national regulations
¾Remove the screw plug (M22, AF19) and the seal ring.
HGX34 CO2T / HGX46 CO2THGX2 CO2T
¾Remove the screw plug (M26, AF24) and the seal ring.

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Disassembly
3.2 Disconnecting the electrical connections and the components
XDo not damage any cables and components.
Damaged parts must be repaired or replaced immediately.
¾Remove the connection of the oil sump heater at the terminal box, the oil sump heater can remain in the compressor
housing.
¾Remove the terminal box cover (4 hexagon head screws, if available).
¾Loosen the electrical connections on the terminal board and on the motor protection device.
¾Remove the terminal box (4 hexagon head screws M6, AF10).
¾Remove the terminal board (8 cylinder head screws M10, AF8).
¾Remove the electrical lines from the underside of the terminal board (6 hexagon head screws M6, AF10).

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3.3 Disassemble the motor cover
WARNING
The heavy weight of the compressor and parts can potentially be dangerous;
risk of falling, danger of crushing.
XATTENTION! The residual oil ows out when the motor cover is removed.
XLay an absorbent material under the area and dispose of it in accordance with the environmental regulations.
HGX2 CO2T
¾Loosen the hexagon head screws (M12, AF19).
¾Remove the motor cover with the seal ring.
Disassembly

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HGX34 CO2T / HGX46 CO2T
¾Loosen the cylinder head screws (M12, AF10).
¾Remove both grub screws (M10).
¾The motor cover must be pushed off the compressor housing.
For this purpose, screw two suitable screws (M10) evenly into both threads on the opposite side in order to squeeze off
the motor cover. The at gasket is destroyed in the process!
¾Take off the motor cover with the seal and the O-ring.
XCarefully clean the sealing surface from old at gasket material.
Disassembly

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3.4 Disassemble the stator
WARNUNG
The heavy weight of the stator can potentially be dangerous; risk of falling, danger of crushing.
XUse a suitable hoist for the removal.
XTake the measures required to safely remove the stator, by screwing two round rods of the correct height
in two holes opposite one another of the motor housing.
Prevent inadvertent rolling of the removed stator.
¾Carefully pull the stator out of the compressor housing and pay attention to the cable!
¾Loosen the threaded pin of the stator protection (M8, AF4).
¾The threaded pin is glued in. For easier disassembly, warm up the threaded pin with an hot air blower.
XProtect the electrical lines from heat!
max.
75kg
Disassembly

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3.5 Disassemble the rotor
Disassembly
¾Loosen the rotor srew (M12, AF19).
¾Pull off rotor from crankshaft. In case of stiffness, use take-off device.

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4 Assembly
We recommend cleaning the inside of the case before the installation.
There must not be any particles and dirt in the compressor.
To assemble, reverse the order of the steps. Note any particular features such as observance of different torques.
4.1 Connecting the stator to the motor housing
¾Align the stator so that the cable harness is positioned upwards and the feather key is aligned with the groove of the
stator.
XDo not damage any cables and components.
WARNING
The heavy weight of the stator can potentially be dangerous; risk of falling, danger of crushing.
XUse a suitable hoist for the removal.
XNote the direction of the feather key — stator.
You must align the parts in order to install them.
¾Assembly instructions for HGX46 CO2 T up to design key A053, see page 13.
Assembly

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Assembly instructions for HGX2 CO2T and HGX34 CO2T up to design key A053
¾Push the stator with the cables leading into the motor housing up until the dimension X (see table, page 12).
At the same time, carefully pull the cables upwards through the terminal board opening.
Motors without dimension X are inserted up to the stop into the compressor housing.
¾For the threaded pin for securing the stator, a countersink has to be provided.
XFor this purpose use a drill with Ø 6.8 mm and a drill tip of 90°.
¾Bore a hole into the stator by observing the dimension Y, but only use a drill with cone tip.
XCarefully remove the chips (e.g. with a vacuum cleaner).
max.
75kg
Y
Dimension Y:
HGX2 CO2 T= 52,0 -0,5
HGX34 CO2 T= 52,7 -0,5
¾Screw in the new threaded pin, see page 15.
Assembly

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Dimension and view of the dimension X
Description X in mm
Distance CH-stator
for the 11 kW motor 32,8 (±1,5)
Distance CH-stator
for the 15 kW motor 30,8 (±1,5)
CH = compressor housing
HGX34 CO2THGX2 CO2T
X
X
Description X in mm
Distance CH-stator
for the 9 kW motor 60 (±1,5)
Distance CH-stator
for the 11 kW motor 45 (±1,5)
Distance CH-stator
for the 15 kW motor 65 (±1,5)
Distance CH-stator
for the 18,5 kW motor 49 (±1,5)
CH = compressor housing
Assembly

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Assembly instructions for HGX46 CO2T up to design key A053
¾Insert the feather key.
¾Align the stator so that the cable harness is positioned upwards and the feather key is aligned with the groove of the
stator.
XDo not damage any cables and components. Push the stator with the cables leading, into the motor housing until
the stop. At the same time, carefully pull the cables upwards through the terminal board opening.
¾For the threaded pin (2) (M8x16), a countersink has to be provided.
XFor this purpose use a drill with Ø 6.8 mm and a drill tip of 90°.
¾Bore a hole into the stator by observing the dimension Y = 62,4 -0,5 mm, but only use a drill with cone tip.
XCarefully remove the chips (e.g. with a vacuum cleaner).
WARNING
The heavy weight of the stator can potentially be dangerous; risk of falling, danger of crushing.
XUse a suitable hoist for the removal.
XNote the direction of the feather key — stator.
You must align the parts in order to install them.
Y
¾For clamping the feather key to the stator, a threaded pin (1) (M8x20) without tip is used (see gure).
¾Screw in the new threaded pins, see page 15.
Threaded pin (2) for stator protection
Threaded pin (1) for clamping the feather key
max.
75kg
Assembly

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max.
75kg
¾Align the stator so that the cable harness is positioned upwards and the feather key is aligned with the groove of the
stator.
XDo not damage any cables and components. Push the stator with the cables leading into the motor housing up
until the dimension X (see table, page 12). Motors without dimension Xare inserted up to the stop into the compressor
housing.
XAt the same time, carefully pull the cables upwards through the terminal board opening.
¾Align the stator so that the countersink for the threaded pin in the stator is aligned with the countersink of the female
thread in the compressor housing.
Assembly instructions for HGX2 CO2T, HGX34 CO2T and HGX46 CO2T from design key A054
Assembly

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10+1 Nm
¾Install the terminal board, see page 16.
¾Degrease the threaded hole for the threaded pin (e.g. with brake cleaner spray).
XScrew in the new threaded pins.
INFO
XThe hardening time of the thread coating is 6 hours. The threaded pin is coated and may only be
used once.
XObserve the tightening torques!
Assembly

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4.2 Assembling the terminal board
¾Connect the electrical connections as per the illustration on page 17.
¾Install the terminal board and the seal with 8 cylinder head screws M10x30.
60 Nm
INFO
XObserve the tightening torques!
Assembly

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4.3 Connecting the electrical connections on the terminal board
Terminal assignment on the terminal board
Standard part winding
Terminal assignment on the terminal board
Star delta
WARNING
XMake sure that you use the correct connection on the cable harnesses!
NOTE
The drawings show the underside of the terminal board.
3
2
1
Connections for
PTC sensors
1U11V1 1W1
7
8
9
2U1 2V1 2W1
blue
black
red
U1 V1 W1
blue
red
black
W2 U2 V2
Part winding 1
Part winding 2
Cable loom 1
Cable loom 2
Connections for
PTC sensors
Assembly

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4.4 Assembling the rotor
¾Push the rotor on the crankshaft.
XScrew in the new screw M12x70 with the disk.
65 Nm
INFO
XNote the direction of the feather key — rotor.
You must align the parts in order to install them.
XThe screw is adhesive-coated and must only be used once!
XObserve the tightening torques!
Assembly

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4.5 Assembling the motor cover
HGX34 CO2T / HGX46 CO2T
XSlightly oil the new O-ring.
¾Insert the O-ring and place it into the groove on the motor cover.
¾Install the motor cover and the new at gasket with 24 cylinder head screws M12x40.
HGX2 CO2T
XSlightly oil the new O-ring.
¾Install the motor cover and the O-ring with 24 hexagon head screws M12x45.
130 Nm
130 Nm
INFO
XObserve the tightening torques!
Assembly

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4.6 Assembling the terminal box
¾Install the terminal box with the seal.
¾Fasten the connections to the terminal board and the motor protection device.
XInstall the terminal box cover. Make sure that the sealing lip is not damaged!
¾Connect the oil sump heater on the terminal box.
8,5 Nm
15 Nm
INFO
XMount all cable screws to the terminal box with care, so the the IP protection type continues
to be guaranteed.
XObserve the tightening torques!
Assembly