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Summary of Contents for Danfoss EM-PMI540-T2000
- Page 1 User Guide Motor / Generator EM-PMI540-T2000 www.danfoss.com...
- Page 2 User Guide EM-PMI540-T2000 Revision history Table of revisions Date Changed July 2021 Updated user guide 0202 © Danfoss | July 2021 BC265857530809en-000202...
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Page 3: Table Of Contents
Connection diagram................................38 Cable gland assembly and power line connection....................39 Low voltage connections...............................44 Grounding connections................................. 48 Anti-condensation heater connections..........................51 Operation Operation conditions..................................54 Condition monitoring during operation..........................54 Recommended lubricants................................54 Recommended coolants................................55 Emergency operation...................................55 © Danfoss | July 2021 BC265857530809en-000202 | 3... - Page 4 User Guide EM-PMI540-T2000 Contents Maintenance Regular maintenance................................... 57 Cleaning......................................58 Bearings and lubrication................................59 Cooling system maintenance..............................61 Dismounting Troubleshooting Aftersales Service policy....................................65 Service parts.....................................65 Disposal Storage, installation and maintenance checklists © Danfoss | July 2021 BC265857530809en-000202...
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Page 5: General Information
User Guide EM-PMI540-T2000 General information This user guide is the installation, operation and maintenance user guide for the EM-PMI540-T2000 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: Conformity According To Standards
+CL4 LR Lloyd’s Register +CL5 RINA Conformity according to standards The electric machine has been designed to be in conformity with the following directives and to meet the requirements specified in the following standards: © Danfoss | July 2021 BC265857530809en-000202... -
Page 7: Warranty
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 BC265857530809en-000202 | 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 BC265857530809en-000202... -
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 BC265857530809en-000202 | 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 BC265857530809en-000202... -
Page 13: Intended Use Of The Electric Machine
Disregarding the obligation to comply with the user guide, safety signs and rating plate of the electric machine. • Using the electric machine, making adjustments and maintenance without first reading this user guide. © Danfoss | July 2021 BC265857530809en-000202 | 13... -
Page 14: Used Technology
This structure makes the electric machine mechanically more stable and capable of higher speed operations. See Figure below illustrating the magnet topology of the electric machine. The Figure shows the principle only, and is not an exact illustration of the structure. 14 | © Danfoss | July 2021 BC265857530809en-000202... -
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 BC265857530809en-000202... - Page 17 One leakage connector in both ends. 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. 19 Shaft connection. © Danfoss | July 2021 BC265857530809en-000202 | 17...
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Page 18: Rating Plate
Allowed mounting position according to IEC60034-7 Mass Mass of the electric machine Duty Defined rotating electric machine duty cycles by IEC60034-1 standard Rated ambient temperature °C IP rating Enclosure class according to IEC60034-5 18 | © Danfoss | July 2021 BC265857530809en-000202... -
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 BC265857530809en-000202 | 19... -
Page 20: 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. 20 | © Danfoss | July 2021 BC265857530809en-000202... -
Page 21: 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 22: 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 23: Shaft Alignment And Load
With angular misalignment, the shafts are at an angle to each other. Figures below illustrate the parallel and angular misalignment. © Danfoss | July 2021 BC265857530809en-000202 | 23... - Page 24 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 24 | © Danfoss | July 2021 BC265857530809en-000202...
- Page 25 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 © Danfoss | July 2021 BC265857530809en-000202 | 25...
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Page 26: 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 27 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. © Danfoss | July 2021 BC265857530809en-000202 | 27...
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Page 28: 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. 28 | © Danfoss | July 2021 BC265857530809en-000202... -
Page 29: 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. © Danfoss | July 2021 BC265857530809en-000202 | 29... -
Page 30: 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. 30 | © Danfoss | July 2021 BC265857530809en-000202... -
Page 31: 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 32 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 33: 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 34 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. 34 | © Danfoss | July 2021 BC265857530809en-000202...
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Page 35: Cooling Connections
For more information, see Chapter Recommended coolants and product data sheet. Rated values can be found in the electric machine rating plate. © Danfoss | July 2021 BC265857530809en-000202 | 35... -
Page 36: 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. 36 | © Danfoss | July 2021 BC265857530809en-000202... - Page 37 (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 44 and Anti-condensation heater connections on page 51. © Danfoss | July 2021 BC265857530809en-000202 | 37...
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Page 38: 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. 38 | © Danfoss | July 2021 BC265857530809en-000202... -
Page 39: 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 BC265857530809en-000202 | 39... - Page 40 (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 40 | © Danfoss | July 2021 BC265857530809en-000202...
- Page 41 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 BC265857530809en-000202 | 41...
- Page 42 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. 42 | © Danfoss | July 2021 BC265857530809en-000202...
- Page 43 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 BC265857530809en-000202 | 43...
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Page 44: 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) 44 | © Danfoss | July 2021 BC265857530809en-000202... - Page 45 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 BC265857530809en-000202 | 45...
- Page 46 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 46 | © Danfoss | July 2021 BC265857530809en-000202...
- Page 47 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 BC265857530809en-000202 | 47...
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Page 48: 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. 48 | © Danfoss | July 2021 BC265857530809en-000202... - Page 49 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 BC265857530809en-000202 | 49...
- Page 50 User Guide EM-PMI540-T2000 Installation Low voltage cable grounding points Power cable grounding through the cable gland Testing the power cable shield grounding (earthing) 50 | © Danfoss | July 2021 BC265857530809en-000202...
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Page 51: 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 BC265857530809en-000202 | 51... - Page 52 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. 52 | ©...
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Page 53: 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 BC265857530809en-000202 | 53... -
Page 54: 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 55: 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 56 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 57: Regular Maintenance
Regular maintenance Inspect the electric machine at regular intervals. Use the Storage, installation and maintenance checklists on page 68. © Danfoss | July 2021 BC265857530809en-000202 | 57... -
Page 58: 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 59: 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 BC265857530809en-000202 | 59... - Page 60 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 61: 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 BC265857530809en-000202 | 61... -
Page 62: 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. 62 | © Danfoss | July 2021 BC265857530809en-000202... -
Page 63: 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 64 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. 64 | ©...
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Page 65: 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 66 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. 66 | © Danfoss | July 2021 BC265857530809en-000202...
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Page 67: Disposal
User Guide EM-PMI540-T2000 Disposal Dispose of the electric machine and any of its parts by appropriate means in accordance with local laws and regulations. © Danfoss | July 2021 BC265857530809en-000202 | 67... -
Page 68: 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 68 | © Danfoss | July 2021 BC265857530809en-000202... - Page 69 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 BC265857530809en-000202 | 69...
- Page 70 Cooling system Functioning of the cooling system in ☐ ☐ ☐ general Tightness of the ventilation plug ☐ ☐ ☐ 70 | © Danfoss | July 2021 BC265857530809en-000202...
- Page 71 ☐ ☐ Coolant quality as specified ☐ ☐ ☐ Used coolant: Functioning of the cooling system in general ☐ ☐ ☐ Tightness of the tubing and connections (no leakages) ☐ ☐ ☐ © Danfoss | July 2021 BC265857530809en-000202 | 71...
- Page 72 58. Used service parts Part description Part type Quantity Item (order) number Notes: • • • • • • • • • • • • Date: Signature: Electric machine storage checklist Date: 72 | © Danfoss | July 2021 BC265857530809en-000202...
- Page 73 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 BC265857530809en-000202 | 73...
- Page 74 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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