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Repair Instructions

CEIGL 80 and CEIGL 132 compact drive

Motorentechnik

These instructions are supplementary to the repair instructions for ATB motors and describe how to repair the components that constitute a compact drive in addition to the basic motor. The preliminary remarks in the repair instructions for ATB motors (Safety Instructions and Explosion Protection) must also be observed when repairing the compact drive. 1. The compact drive The compact drive essentially consists of the following components: - Three-phase motor - Explosion-proof housing for additional components - Lenze frequency converter The type of compact drive must be established before performing any troubleshooting:
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Power supply:

Model designation CEIGL...TN, version for TN mains Model designation CEIGL...IT, version for IT mains

Converter output: Model designation CEIGL 80 1.5 TN, converter output 1.5 kW Function module: Wiring diagram Version with contactor and posistor triggering device: Wiring diagram

2. Troubleshooting Faults in the compact drive can be determined using the associated manual terminal (keypad). Attention! The manual terminal is not approved for use in potentially explosive areas. Connect the plug of the manual terminal to the test connectors of terminals 5-6-15-16. Fault messages and error messages are then displayed on the terminal. Information and possibly remedial measures concerning the error and fault messages can be found in the Lenze assembly instructions or the Lenze operating instructions for the frequency converter. If motor damage is indicated, see 3. If the fault cannot be remedied using the manual terminal, a repair is needed. See section 4. If no display appears on the manual terminal, the power supply of the frequency converter must be checked. The supply voltage must be present at input terminals L1, L2 and L3. The supply voltage must also be present at terminals L/+ and N/- in the version with contactors and a posistor triggering device with separate feed. The contactor and the posistor triggering device are fault-free if voltage is present at terminals 14 and 2N with the contactor switched on. The version with the contactor, the posistor triggering device and a shared feed contains a protective 230V, 1A fuse in a cable fuse housing in the contactor supply cable. The hexagon screw plug W/F 67 pos. 9 must be undone to check this fuse. If the fuse is defective, it must be replaced with a 5 x 20 mm 1A TR fuse. If no voltage is present at 14 and 2N, the contactor or the posistor triggering device is defective (or both are defective).

3. Motor repairs Motor repairs are carried out as described in the three-phase motor repair instructions. With the CEIGL 80. compact drive (motor size 80 112) the frequency converter motor coil must be removed before carrying out a repair, see section 5. 4. Contactor and posistor triggering device Defective contactor or posistor triggering devices must be replaced. These devices must always be replaced with equipment with equivalent performance data. Only ATEX-approved posistor triggering devices must be used. The frequency converter has to be dismantled to replace these devices, see section 5. 5. Repairing and replacing the frequency converter If troubleshooting reveals that the frequency converter or the functional module has to be repaired or replaced, the pressure-proof housing of the compact drive must be opened. The general principles for assembling explosion-proof electrical equipment must be observed: No chips or wire ends must get into the device Explosion-proof surfaces must not be damaged or coated with paint. Insulation must not be damaged. Cables must be routed in such a way as to prevent damage from occurring during operation. Tighten clamping screws with an adequate amount of torque. No wire ends must protrude from the rear of the wire end ferrules Opening the pressure-proof housing: - Place in the motor in a stable position (securing equipment must be used for motors without feet). - Remove hexagon screw plug pos. 9 W/F 67. - Remove hexagon bolts pos. 4 and open pressure-proof housing cover pos. 3 with two M 8 diagonally opposite jacking screws. Replacing the functional module: - Mark assignment of leads to terminals and disconnect. Release functional module as described in Lenze assembly instructions and replace, then connect leads. Removing the frequency converter: - Release functional module as described in Lenze assembly instructions and swivel to side with connecting cable. - For frequency converter with output of 4kW and above, slacken clamping screws. Remove M6 converter securing bolts and lift converter using the M6 jacking screw. Disconnect cable plug and lift converter. Unscrew posistor temperature sensor from heat sink on underside of frequency converter. Remove heat conducting paste from converter heat sink and cooling surface of housing. - The frequency converter is installed with electrical insulation in the CEIGL..IT version. The underside of the heat sink contains a 0.05 mm thick layer of Kapton insulating foil. This insulating foil usually has to be replaced after the frequency converter has been removed. Repairing the frequency converter: - The frequency converter can be repaired by Lenze or ATB Motorentechnik. - A replacement frequency converter can be purchased from ATB Motorentechnik.
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Frequency converter installation: - Screw posistor temperature sensor into heat sink on underside of frequency converter. - a) CEIGL ... TN: The frequency converter is fitted to the cooling surface of the converter housing with heat conducting paste. Check cleanliness of heat sink surface and cooling surface of converter housing and clean if necessary. Apply an even coating of Electrolube HTSP heat conducting paste to the heat sink with a serrated spatula. - b) CEIGL ... IT: The frequency converter is fitted with a piece of self-adhesive 0.05 mm Kapton foil. Clean underside of frequency converter heat sink, and stick on film without bubbles. Check cleanliness of cooling surface of converter housing and clean if necessary. Apply an even coating of Electrolube HTSP heat conducting paste to the cooling surface of the converter housing with a serrated spatula. The coating thickness of the heat conducting paste should be approx. 0.1. The required quantity is approx. 1.5 cm3 for the 1.5 kW and 2.2 kW converters, 2.5 cm3 for the 4.0 kW and 5.5 kW converters and 3.0 cm3 for the 7.5 kW and 11 kW converters. A strip of paste from the tube about 8 cm in length corresponds to approx. 1 cm3. Insert the converter into the housing and cover as much of the surface as possible with heat conducting paste by making circular movements and applying gentle pressure. Check this work operation by ensuring that the converter cannot be pulled from the contact surface by hand. - With CEIGL ... IT the electric strength of the Kapton foil must be tested with 500V no flashover must occur. - Connect leads as per wiring diagram. The leads must not be in the vicinity of the gap surface *risk of damage when fitting the cover). With the CEIGL 80 compact drive, insert a 90x30 piece of laminated insulating material (Evitherm 0.3 or equivalent insulating material) at the marked position to insulate the connector connecting cable at the G side. Closing the pressure-proof housing: - Coat contact surfaces of explosion-proof cover with anticorrosive grease and fit cover. Tighten M6 hexagon bolts with 10 Nm. - Fit hexagon screw plug pos. 9 W/F 67. Completing the repair: - Perform function test. - After removing a frequency converter with nominal output of 5.5 kW and above and with CEIGLIT it is strictly advisable to check the heat transfer from the frequency converter to the housing. The internal temperature of the frequency converter can be read off using the keypad by entering code no. 61. This value must not exceed the ambient temperature plus 45 C at the nominal output in a thermally stable condition under any circumstances.