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Related Manuals for Danfoss EM-PMI540-T1500
Summary of Contents for Danfoss EM-PMI540-T1500
- Page 1 User Guide Motor / Generator EM-PMI540-T1500 www.danfoss.com...
- Page 2 User Guide EM-PMI540-T1500 Revision history Table of revisions Date Changed July 2021 Updated user guide 0201 © Danfoss | July 2021 BC265856800806en-000201...
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Page 3: Table Of Contents
Connection diagram................................40 Cable gland assembly and power line connection....................41 Low voltage connections...............................46 Grounding connections................................. 50 Anti-condensation heater connections..........................53 Operation Operation conditions..................................56 Condition monitoring during operation..........................56 Recommended lubricants................................56 Recommended coolants................................57 Emergency operation...................................57 © Danfoss | July 2021 BC265856800806en-000201 | 3... - Page 4 User Guide EM-PMI540-T1500 Contents Maintenance Regular maintenance................................... 59 Cleaning......................................60 Bearings and lubrication................................61 Cooling system maintenance..............................63 Dismounting Troubleshooting Aftersales Service policy....................................67 Service parts.....................................67 Disposal Storage, installation and maintenance checklists © Danfoss | July 2021 BC265856800806en-000201...
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Page 5: General Information
User Guide EM-PMI540-T1500 General information This user guide is the installation, operation and maintenance user guide for the EM-PMI540-T1500 electric machine. Intended use of the user guide This user guide contains instructions necessary to safely and properly handle, install, operate and maintain the electric machine. - Page 6 PT100 in bearings Plug-in connector Anti-condensation heaters None +HEAT1 One anti-condensation 230VAC/130W heater Marine classification No marine classification +CL1 ABS American Bureau of Shipping +CL2 BV Bureau Veritas +CL3 +CL4 LR Lloyd’s Register +CL5 RINA © Danfoss | July 2021 BC265856800806en-000201...
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Page 7: Conformity According To Standards
56 mm and higher - Measurement, evaluation and limits of vibration severity. Warranty Danfoss offers warranty against defects in workmanship and materials for its products for a period of twelve (12) months from commissioning or eighteen months (18) from delivery (Incoterms-EXW), whichever occurs first. -
Page 8: Responsibility Of The Manufacturer
Duty type according to the IEC60034; Duty with non-periodic load and speed variations Responsibility of the manufacturer Danfoss is responsible for the safety, reliability and performance of the electric machine only if: • Handling, mounting, installation, operation and maintenance are done by qualified and authorized personnel. -
Page 9: Safety Information
It indicates a hot device that could cause burns to a person. The symbol also indicates that the device should be placed and installed so that contact with its potentially hot surface is not possible. © Danfoss | July 2021 BC265856800806en-000201 | 9... -
Page 10: Personal Protective Equipment
The electric machine has at least one PT100 temperature sensor in the windings. The amount of the sensors depend on the options chosen. The temperature signal(s) can be read out from the measurement 10 | © Danfoss | July 2021 BC265856800806en-000201... -
Page 11: Electromagnetic Compatibility (Emc)
It is the responsibility of the installer to make sure that the equipment or system into which the product is incorporated complies with the EMC legislation of the country of use. Within the European Union, equipment into which this product is incorporated must comply with the EMC Directive 2014/30/EU. © Danfoss | July 2021 BC265856800806en-000201 | 11... -
Page 12: Product Overview
Machine structure designed to be able to produce high starting torques (instant torque to non- moving wheel). • Optimized speed range to meet most common gear ratios used in heavy mobile machinery. 12 | © Danfoss | July 2021 BC265856800806en-000201... -
Page 13: Intended Use Of The Electric Machine
The electric machine is intended to be powered and controlled with an inverter or inverters capable of supplying three-phase alternating current and that is capable of controlling the electric machine. The electric machine is not suitable for direct online use. © Danfoss | July 2021 BC265856800806en-000201 | 13... -
Page 14: Used Technology
The permanent magnets of the rotor are of salient-pole design, having embedded permanent magnets in the rotor structure. This structure makes the electric machine mechanically more stable and capable of 14 | © Danfoss | July 2021 BC265856800806en-000201... -
Page 15: System Introduction
Permanent magnets in the rotor System introduction Danfoss provides electric drive trains for applications in heavy mobile work machines, marine vessels and buses. The drive trains include all essential components from converting from traditional to hybrid electric (HEV) or electric vehicle (EV) solutions. Danfoss technology saves fuel and lowers emission and noise levels. -
Page 16: Connections And Interfaces
Power connections through the connection box. • Measurement connector (connection through the connection box). • Anti-condensation heater connection (+HEAT1 option) (through the connection box). • Bearing temperature connectors (+BTMP1 option). • Leakage sensor connectors. 16 | © Danfoss | July 2021 BC265856800806en-000201... - Page 17 17 Grease escape connections, D-end (+BHS option dependent). One axial plug and four radial plugs in 90º angles around the flange in the D-end. 18 D-end flange mounting (12 connection bores around the flange). © Danfoss | July 2021 BC265856800806en-000201 | 17...
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Page 18: Rating Plate
Number of magnetic pole pairs of the machine Rated coolant liquid input temperature °C Mounting Allowed mounting position according to IEC60034-7 Mass Mass of the electric machine Duty Defined rotating electric machine duty cycles by IEC60034-1 standard 18 | © Danfoss | July 2021 BC265856800806en-000201... -
Page 19: Tightening Torques
Connection box mounting screws 7 Nm Connection box cover plate screws 4 Nm Cable lug 15 Nm Additional attachment points (M10 8.8.) 47 Nm Tightening torques to use unless otherwise noted 10.9 12.9 Thread © Danfoss | July 2021 BC265856800806en-000201 | 19... - Page 20 User Guide EM-PMI540-T1500 Product overview 20 | © Danfoss | July 2021 BC265856800806en-000201...
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Page 21: Design Principles
The value of the insulation lifetime expectancy is a calculated value and it is not tested in practice. The insulation of the electric machine has the following lifetime expectancy. © Danfoss | July 2021 BC265856800806en-000201 | 21... -
Page 22: Inverter
If the electric machine is driven with an inverter from a supplier other than Danfoss Editron, the electric machine performance may differ from rated values. The optimum performance of the electric machine is obtained with Danfoss Editron inverters. -
Page 23: Mounting Structure
AUX DC - The main machine power driving parameters are shown in the machine rating plate. For more information, contact Danfoss representative. You can connect one of the temperature signals (from the low voltage connector) to the temperature surveillance pin in the inverter and make sure that the inverter has the machine temperature protection feature activated. -
Page 24: Shaft Alignment And Load
With angular misalignment, the shafts are at an angle to each other. Figures below illustrate the parallel and angular misalignment. 24 | © Danfoss | July 2021 BC265856800806en-000201... - Page 25 Maximum angular misalignment values Non flexible coupling Flexible coupling mm / 100 mm mm / 100 mm 0-1000 0,06 0,10 1000-2000 0,05 0,08 2000-3000 0,04 0,07 3000-4000 0,03 0,06 4000-6000 < 0,03 0,05 © Danfoss | July 2021 BC265856800806en-000201 | 25...
- Page 26 For more information, see document DOC-000454. Calculate the relevant values with the help of the document. Contact Danfoss service at https://danfosseditron.zendesk.com/hc/en-gb or send email to editron.service@danfoss.com to obtain the document. External shaft forces of the electric machine 26 | © Danfoss | July 2021...
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Page 27: Transportation And Storage
Do not touch the electrical terminals when the rotor is rotated. The electrical terminals have dangerous voltage during rotation. Contact Danfoss representative if the rotor can not be rotated. Remove the transportation supports of the electric machine. - Page 28 See the electric machine rating plate for weight information. Lift the electric machine using the correct lifting lugs/eyes only. Do not go under a lifted load. Lifting slings cannot touch the electric machine during the lifting. 28 | © Danfoss | July 2021 BC265856800806en-000201...
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Page 29: Storage
Do not touch the electrical terminals when the shaft is rotated. The electrical terminals have dangerous voltage during rotation. Keep the electric machine on a correct base. Support the electric machine to prevent accidental turning and falling. © Danfoss | July 2021 BC265856800806en-000201 | 29... -
Page 30: Extended Storage
Rotate the shaft of the electric machine once a month. Keep the electric machine in its installation position while in storage. For example, vertically installed electric machines should be stored in vertical position. 30 | © Danfoss | July 2021 BC265856800806en-000201... -
Page 31: Installation
Only trained and qualified personnel familiar with the relevant safety requirements can work with the electric machine. Use correct personal protective equipment when you are near the electric machine. Read the instructions in this user guide before you install the electric machine. © Danfoss | July 2021 BC265856800806en-000201 | 31... -
Page 32: Required Tools
If the electric machine is in continuous use, it is recommended to do the insulation resistance test three or four times a year. The reference value of 150 MΩ must be exceeded in room temperature. Contact Danfoss representative if the reference value is not exceeded. Reference value of 150 MΩ should not be exceeded at reference ambient temperature 25°C (measured with 500 V... - Page 33 It is in some cases possible to make an exception from the limitations of the mounting positions. Document Allowed bearing loads for EM-PMI machines DOC-000454 gives more information about this. Contact Danfoss to obtain the document. The electric machine can be installed horizontally or vertically. See Figures below for the allowed installation angles in each case.
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Page 34: Mounting The Electric Machine
Do not exceed the maximum axial and radial forces calculated for the shaft. Document Allowed bearing loads for EM-PMI machines DOC-000454 gives more information about this. Contact Danfoss to obtain the document. Do not use the N-end of the electric machine for mounting the electric machine. - Page 35 Mounting foot rails (see Main dimension drawing). Mounting bolts (12 pcs of DIN912 M12 socket head). Not included in the delivery. Vertical assembly In vertical assembly, follow the Steps given in the previous Section Horizontal assembly. © Danfoss | July 2021 BC265856800806en-000201 | 35...
- Page 36 The electric machine can be equipped with the foot mounting option (+FM1). For the installation of the electric machine, use 8 pieces of mounting bolts (M16 EN-ISO 4014 / 4017 M16 10.9 bolts and washers) that are tightened to 280 Nm. See the Figure below. 36 | © Danfoss | July 2021 BC265856800806en-000201...
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Page 37: Cooling Connections
It is recommended to use coolant connector equipped with o-ring seal or to use sealing washer (for example Usit or Bonded seals) in the connection. In addition, it is recommended to use thread sealant © Danfoss | July 2021 BC265856800806en-000201 | 37... -
Page 38: Electrical Installation
The Figure below shows the components of the high voltage connection box assembly. 1. Remove the cover of the terminal box. 2. Install the power cables. 3. Install the cover of the terminal box back. 38 | © Danfoss | July 2021 BC265856800806en-000201... - Page 39 (winding temperature, bearing temperature and resolver) from the low voltage connectors as well as the anti- condensation heater connector. For further information, see Chapters Low voltage connections page 46 and Anti-condensation heater connections on page 53. © Danfoss | July 2021 BC265856800806en-000201 | 39...
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Page 40: Connection Diagram
The amount of inverters depends on the electric machine and converter current ratings. For an electric machine with option DUAL (two connection boxes each containing one three-phase system), the electrical connection principles from the inverters are shown in the Figure below. 40 | © Danfoss | July 2021 BC265856800806en-000201... -
Page 41: Cable Gland Assembly And Power Line Connection
Blueglobe cable gland tightening torques Metric thread Nominal torque M10x1,0 3,0 Nm M12x1,5 5,0 Nm M16x1,5 8,0 Nm M20x1,5 10,0 Nm M25x1,5 15,0 Nm M32x1,5 15,0 Nm M40x1,5 20,0 Nm M50x1,5 30,0 Nm © Danfoss | July 2021 BC265856800806en-000201 | 41... - Page 42 (which ever is closer), is 10 mm. Do not remove the cable sheath completely at this point and do not cut the braid screen of the cable! Cut length of the cable sheath 42 | © Danfoss | July 2021 BC265856800806en-000201...
- Page 43 5. Cut a piece of length D of the inner sheath shown below in the Figure Cutting the inner sheath. The length D must equal to the length of the cable lug body. © Danfoss | July 2021 BC265856800806en-000201 | 43...
- Page 44 This is done to keep the braid screen in place and for extra insulation. The shrink tube must be specified for operating temperature range from -40 ºC to 150 ºC. Self gluing shrink tube is recommended. 44 | © Danfoss | July 2021 BC265856800806en-000201...
- Page 45 Tighten from the body of the cable gland with the correct torque. Then tighten the cap of the cable gland manually, but so that the insulation does not come out of the joint. 10. Tighten the cable lug. Use tightening torque of 15 Nm. © Danfoss | July 2021 BC265856800806en-000201 | 45...
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Page 46: Low Voltage Connections
Recommended cable types for low voltage connections Application Cable type Resolver cabling Shielded cable (twisted pair) Temperature measurement (PT100) Shielded cable (twisted pair) Location of the low voltage connectors in the connection box (N-end) 46 | © Danfoss | July 2021 BC265856800806en-000201... - Page 47 Temperature 8 Temperature 8, PT100 (P), windings, option TEMP5 Temperature 8, PT100 (N), windings, option TEMP5 Temperature 9 Temperature 9, PT100 (P), windings, option TEMP5 Temperature 9, PT100 (N), windings, option TEMP5 © Danfoss | July 2021 BC265856800806en-000201 | 47...
- Page 48 Resolver, EXCP, in-built non contacting Resolver shield Resolver, SHIELD/GROUND, in-built non contacting Bearing temperature measurement connector (optional), both ends of electric machine PT100 pin PT100 pin PT100 ground pin PT100 ground pin 48 | © Danfoss | July 2021 BC265856800806en-000201...
- Page 49 Heater, ground / protective earth, M5 screw inside connection box Reserve Reserve Temperature 1, PT100 (P), windings Temperature 1, PT100 (N), windings Temperature 2, PT100 (P), windings Temperature 2, PT100 (N), windings Temperature 3, PT100 (P), windings © Danfoss | July 2021 BC265856800806en-000201 | 49...
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Page 50: Grounding Connections
Ground the electric machine from its frame to make sure it functions correctly and safely. Ground the cable shields of the power cables to make sure the electric machine functions correctly and safely. 50 | © Danfoss | July 2021 BC265856800806en-000201... - Page 51 The grounding points on the frame of the electric machine are for safety grounding, and signal cables and power cable shields have their own grounding points. The machine enclosure grounding point, safety grounding © Danfoss | July 2021 BC265856800806en-000201 | 51...
- Page 52 User Guide EM-PMI540-T1500 Installation Low voltage cable grounding points Power cable grounding through the cable gland Testing the power cable shield grounding (earthing) 52 | © Danfoss | July 2021 BC265856800806en-000201...
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Page 53: Anti-Condensation Heater Connections
The installed anti-condensation heater must be supplied with 230 Vac power. The heater connector is inside the connection box, in the lower part if it. The anti-condensation heater cable has an inlet (cable gland) next to the low voltage signal connector. See Figure below. © Danfoss | July 2021 BC265856800806en-000201 | 53... - Page 54 Connect the measurement device between the heater terminals. The resistance should be around 1 kΩ. Measuring no value, or zero value, indicates a possible failure in the heater element. If the electric machine has an anti-condensation heater and failure is suspected, contact Danfoss representative. 54 | ©...
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Page 55: Operation
Use sufficient personal protective equipment when you are near the electric machine. Read the instructions in this user guide before you install the electric machine. © Danfoss | July 2021 BC265856800806en-000201 | 55... -
Page 56: Operation Conditions
Coolant liquid must be water- glycol mixture with maximum of 50 % glycol content. See Chapter Recommended coolants. If electric machine operation limits are exceeded, please contact Danfoss representative. Condition monitoring during operation Supervise the electric machine during operation to make sure that the electric machine operates correctly and has a designed lifetime. -
Page 57: Recommended Coolants
(1/2) of the rated speed and maximum 20 % of the nominal torque may be used. In such case, the electric machine may be operated for maximum one hour. Repair the cooling system as soon as possible. For further information, contact Danfoss representative. The temperature measurement of the electric machine fails The operation temperature of the electric machine is measured by PT100 temperature sensors in the electric machine windings. - Page 58 This gives more correct estimation of the inner temperature of the electric machine. In case of the temperature measurement failure and using additional temperature sensor, replace the electric machine as soon as possible, but no later than in two months. Danfoss service contact information Contact Danfoss service at https://danfosseditron.zendesk.com/hc/en-gb or send email to editron.service@danfoss.com.
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Page 59: Regular Maintenance
Regular maintenance Inspect the electric machine at regular intervals. Use the Storage, installation and maintenance checklists on page 70. © Danfoss | July 2021 BC265856800806en-000201 | 59... -
Page 60: Cleaning
Bolt tightness. Tighten to proper value if necessary. Applies to bolts and screws that are discussed in this user guide. See Chapter Tightening torques. Bearings Listen to any unusual noise or vibration. If exists, contact Danfoss. Enclosure and Check cleanliness. Clean if necessary. See Chapter Cleaning. connected parts Shaft seals Check the wear. -
Page 61: Bearings And Lubrication
Make sure that the automatic greasing and the oil lubrication function correctly after you start the electric machine. The bearing type of the electric machine can be found on the rating plate of the electric machine. © Danfoss | July 2021 BC265856800806en-000201 | 61... - Page 62 The information of bearing lifetime and bearing grease lifetime are estimations only to provide a magnitude of them. The bearing lifetime and bearing grease lifetime in customer application may vary. Danfoss is not responsible for the actual bearing lifetime in use. For further information, contact Danfoss representative.
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Page 63: Cooling System Maintenance
The quality of the coolant must be checked yearly. The mixture of water and glycol as well as the type of the glycol used must be as specified. See Chapter Recommended coolants. © Danfoss | July 2021 BC265856800806en-000201 | 63... -
Page 64: Dismounting
3. If force is required, use the bores in D-end flange to push the electric machine out from the mating structure, or use some other method that does not damage the electric machine. 4. Lift the electric machine off. Support the electric machine when lifting. 64 | © Danfoss | July 2021 BC265856800806en-000201... -
Page 65: Troubleshooting
Leakage in the cooling system. Check the cooling system circuit and connections. Rigid particle inside the machine cooling Try pulsating coolant to open the channels. Contact Danfoss. channel. Wrong machine parameters in the Check and correct the machine parameters from the inverter. - Page 66 Temperature measurement failure The PT100 sensor is faulty. Measure the resistance of the PT100 sensor, see Chapter voltage connections. If the sensor is faulty, read out the signal from another sensor. Contact Danfoss. See Chapter Emergency operation. 66 | ©...
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Page 67: Aftersales
The recommended service parts are listed in this Section. Quantity describes the number of components in a single electric machine. Maintenance procedures not described in this user guide require special tools and instructions. Contact Danfoss for more information and purchasing. Recommended service parts... - Page 68 Plug for grease escape hole (both in D-end M16 x 1.5 , VSTI16X1.5SED71 and in N-end) (horizontal and radial holes) 10358 Ventilation plug PMF 100444 Metal Vent The bearing type depends on the Bearing insulation option selected. 68 | © Danfoss | July 2021 BC265856800806en-000201...
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Page 69: Disposal
User Guide EM-PMI540-T1500 Disposal Dispose of the electric machine and any of its parts by appropriate means in accordance with local laws and regulations. © Danfoss | July 2021 BC265856800806en-000201 | 69... -
Page 70: Storage, Installation And Maintenance Checklists
Electric machine enclosure grounding connected ☐ ☐ ☐ Low voltage cable shield grounding connected ☐ ☐ ☐ Power cable shield connection resistances to ground ☐ ☐ ☐ (electric machine enclosure) measured and valid 70 | © Danfoss | July 2021 BC265856800806en-000201... - Page 71 N.A = Procedure not applicable PASS = Procedure passed FAIL = Procedure failed Electric machine weekly maintenance checklist PASS FAIL General construction Noise or vibration during operation ☐ ☐ ☐ in general Cooling system © Danfoss | July 2021 BC265856800806en-000201 | 71...
- Page 72 Cooling system Functioning of the cooling system in ☐ ☐ ☐ general Tightness of the ventilation plug ☐ ☐ ☐ 72 | © Danfoss | July 2021 BC265856800806en-000201...
- Page 73 ☐ ☐ Coolant quality as specified ☐ ☐ ☐ Used coolant: Functioning of the cooling system in general ☐ ☐ ☐ Tightness of the tubing and connections (no leakages) ☐ ☐ ☐ © Danfoss | July 2021 BC265856800806en-000201 | 73...
- Page 74 60. Used service parts Part description Part type Quantity Item (order) number Notes: • • • • • • • • • • • • Date: Signature: Electric machine storage checklist Date: 74 | © Danfoss | July 2021 BC265856800806en-000201...
- Page 75 Date Storage base as specified (vibration free) Storage temperature and humidity as specified Electric machine type and serial number is correct Electric machine supported correctly Shaft rotated as specified (10 rotations monthly) © Danfoss | July 2021 BC265856800806en-000201 | 75...
- Page 76 Phone: +86 21 2080 6201 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed.
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