Danfoss EM-PMI540-T4000 User Manual
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Danfoss EM-PMI540-T4000 User Manual

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Summary of Contents for Danfoss EM-PMI540-T4000

  • Page 1 User Guide Motor / Generator EM-PMI540-T4000 www.danfoss.com...
  • Page 2 User Guide EM-PMI540-T4000 Revision history Table of revisions Date Changed April 2023 Minor modifications and improvements 0202 © Danfoss | April 2023 BC265857716810en-000202...

  • Page 3: Table Of Contents

    Connection diagram................................35 Cable gland assembly and power line connection....................36 Low voltage connections...............................41 Grounding connections................................. 44 Anti-condensation heater connections..........................47 Operation Operation conditions..................................51 Condition monitoring during operation..........................51 Recommended lubricants................................51 Recommended coolants................................52 Emergency operation...................................52 © Danfoss | April 2023 BC265857716810en-000202 | 3...
  • Page 4 User Guide EM-PMI540-T4000 Contents Maintenance Regular maintenance................................... 54 Cleaning......................................55 Bearings and lubrication................................56 Cooling system maintenance..............................58 Dismounting Troubleshooting Aftersales Service policy....................................62 Service parts.....................................62 Disposal Storage, installation and maintenance checklists © Danfoss | April 2023 BC265857716810en-000202...

  • Page 5: General Information

    User Guide EM-PMI540-T4000 General information This user guide is the installation, operation and maintenance user guide for the EM-PMI540-T4000 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

    IEC 60034-5:2001/A1:2007 Rotating electrical machines - Part 5: Degrees of protection provided by the integral design of rotating electrical machines (IP code) - Classification IEC 60034-6:1991 Rotating electrical machines - Part 6: Methods of cooling © Danfoss | April 2023 BC265857716810en-000202...

  • Page 7: Warranty

    Directive 2006/42/EC, when the EM-PMI electric machines are fitted into machinery. 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 | April 2023 BC265857716810en-000202 | 9...

  • Page 10: Personal Protective Equipment

    The electric machine has 12 x PT100 temperature sensors in the windings. The temperature signals can be read out from the measurement connector of the electric machine. You can connect any of the 10 | © Danfoss | April 2023 BC265857716810en-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 | April 2023 BC265857716810en-000202 | 11...

  • Page 12: Product Overview

    The electric machines have several frame models (sizes) to be the optimal solutions for several applications. They also have options for shaft type, attachment interface, bearings, connection box attachment, rotation sensors and temperature sensors. 12 | © Danfoss | April 2023 BC265857716810en-000202...

  • Page 13: Intended Use Of The Electric Machine

    Using cables that cannot withstand the maximum currents of the electric machine. Used technology The electric machine is a Synchronous Reluctance assisted Permanent Magnet (SRPM) machine. This technology has several benefits compared to standard permanent magnet (PM) technology and © Danfoss | April 2023 BC265857716810en-000202 | 13...

  • Page 14: 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 for converting from traditional to hybrid electric (HEV) or electric vehicle (EV) solutions. Danfoss technology saves fuel and lowers emission and noise levels.

  • Page 15: Connections And Interfaces

    Air ventilation plug. • Vibration sensor connection points. Electrical interfaces: • Power connections through the connection box. • Measurement signal connectors. • Anti-condensation heater connections (+HEAT2 option). • Bearing temperature connectors (+BTMP1 option). © Danfoss | April 2023 BC265857716810en-000202 | 15...

  • Page 16: Rating Plate

    The rating values in the Figure below are not correct for this machine. See the rating plate on the machine and data sheets for the correct values. 16 | © Danfoss | April 2023 BC265857716810en-000202...
  • Page 17 Rotation Direction of rotor rotation with default phase order. Observed facing the D-end. Max n Maximum rotation speed Insul. class Temperature rating (class) of insulation of the electric machine according to IEC60034-1 © Danfoss | April 2023 BC265857716810en-000202 | 17...

  • Page 18: Tightening Torques

    Mounting bolts for foot mounting 200 Nm Connection box mounting screws 7 Nm Connection box cover plate screws 4 Nm Cable lug 15 Nm Tightening torques to use unless otherwise noted 10.9 12.9 Thread 18 | © Danfoss | April 2023 BC265857716810en-000202...

  • Page 19: 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 | April 2023 BC265857716810en-000202 | 19...

  • Page 20: 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 21: 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 22: Shaft Alignment And Load

    With angular misalignment, the shafts are at an angle to each other. Figures below illustrate the parallel and angular misalignment. 22 | © Danfoss | April 2023 BC265857716810en-000202...
  • Page 23 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 | April 2023 BC265857716810en-000202 | 23...
  • Page 24 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 24 | © Danfoss | April 2023...

  • Page 25: 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 26 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. 26 | © Danfoss | April 2023 BC265857716810en-000202...

  • Page 27: Storage

    Rotate the shaft of the electric machine by hand monthly at least ten revolutions to prevent grease migration. If necessary, use a tool, for example a spanner. Do not damage the shaft in any case. © Danfoss | April 2023 BC265857716810en-000202 | 27...

  • Page 28: 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. 28 | © Danfoss | April 2023 BC265857716810en-000202...

  • Page 29: 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 | April 2023 BC265857716810en-000202 | 29...

  • Page 30: 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 has to be exceeded at reference ambient temperature 25°C (measured with 500 V...
  • Page 31 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 must be installed horizontally. The standard horizontal mounting option (MDH) is the only possible mounting option.

  • Page 32: 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 33: Cooling Connections

    To prevent damage to the cooling connectors, refer to the documentation of the manufacturer for the correct tightening torque of the cooling liquid nipples. When selecting cooling liquid nipples, choose nipples that can resist galvanic corrosion. © Danfoss | April 2023 BC265857716810en-000202 | 33...

  • Page 34: Electrical Installation

    The Figure below shows the components of the high voltage connection box assembly. You are allowed to open only the nuts and bolts that are specified here. Only Danfoss professionals are allowed to open other nuts and bolts in the terminal box.

  • Page 35: Connection Diagram

    Connection diagram The electric machines are intended to be powered and controlled by three-phase alternating current, supplied by an inverter or inverters. The electric machine is not suitable for direct online use. © Danfoss | April 2023 BC265857716810en-000202 | 35...

  • Page 36: Cable Gland Assembly And Power Line Connection

    If you are not using the recommended cable lugs, select cable lugs that leave 10 mm gap between each and every cable lug on the same connection plate. The pictures are schematic, and the actual components can look different. 36 | © Danfoss | April 2023 BC265857716810en-000202...
  • Page 37 Measure with the cable lug that is used and cut to suitable length. Install two layers of copper tape on the cable so that the distance B is covered. Use 3M ™ Copper Foil Tape 1181 or similar. © Danfoss | April 2023 BC265857716810en-000202 | 37...
  • Page 38 (cover) from 10 mm (distance C) from the gland bottom as shown in Figure below. Make sure that the cable gland spring is against the cable sheath (that is protected with copper tape) before cutting the braid screen. 38 | © Danfoss | April 2023 BC265857716810en-000202...
  • Page 39 6. Make sure that the conducting strands of the cable are completely free of silicone and other impurities. Put the cable inside the cable lug body, and crimp the cable lug twice in different places. See Figure below. © Danfoss | April 2023 BC265857716810en-000202 | 39...
  • Page 40 Make sure that there is at least 10 mm air gap between the cable lug and other metallic structures including the braid of the cable. If the air gap is smaller, use extra insulation shrink tube to cover the lug. 40 | © Danfoss | April 2023 BC265857716810en-000202...

  • Page 41: Low Voltage Connections

    For more information about the options, refer to Chapter Product naming convention on page 5. © Danfoss | April 2023 BC265857716810en-000202 | 41...
  • Page 42 3 Bearing temperature measurement sensor connector in the D-end of the machine. Type: M12 Male 4-pin, A-coded connector. Low voltage connector details Deutsch HD34-24-47PE connector has two kinds of mating pins: 1 mm and 1.5 mm in diameter. 42 | © Danfoss | April 2023 BC265857716810en-000202...
  • Page 43 Resolver, RES_COS_N, in-built non contacting Resolver COS_P Resolver, RES_COS_P, in-built non contacting Resolver SIN_N Resolver, RES_SIN_N , in-built non contacting Resolver SIN_P Resolver, RES_SIN_P , in-built non contacting Resolver EXCN Resolver, EXCN, in-built non contacting © Danfoss | April 2023 BC265857716810en-000202 | 43...

  • Page 44: Grounding Connections

    Ground the cable shields of the instrumentation cables to make sure the electric machine functions correctly and safely. It is recommended to perform a ground bond test after installing the electric machine to make sure the electric machine is correctly grounded. 44 | © Danfoss | April 2023 BC265857716810en-000202...
  • Page 45 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 | April 2023 BC265857716810en-000202 | 45...
  • Page 46 The power cable shields are grounded (earthed) through the cable glands to the connection box and further to the electric machine enclosure. After the cable gland assembly and power cable installations, and any time when needed, make sure that the grounding (earthing) connections are correct. 46 | © Danfoss | April 2023 BC265857716810en-000202...

  • Page 47: Anti-Condensation Heater Connections

    The installed anti-condensation heater must be supplied with 230 Vac power. The heater connector used is HUMMEL Twilock connector, illustrated in Figure below. © Danfoss | April 2023 BC265857716810en-000202 | 47...
  • Page 48 The electric cables for the heater warming element are connected to the pins 1 and 2, see Figure below. The heater connector ground pin (marked with the grounding symbol) is connected to the electric machine enclosure. Connection of the heater element 48 | © Danfoss | April 2023 BC265857716810en-000202...
  • Page 49 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. ©...

  • Page 50: 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. 50 | © Danfoss | April 2023 BC265857716810en-000202...

  • Page 51: 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 52: 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 53 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.

  • Page 54: Regular Maintenance

    Read the instructions in the user guide before you start to work with the electric machine. To make sure that the operation of the electric machine is safe and reliable, obey the maintenance instructions. Regular maintenance Inspect the electric machine at regular intervals. 54 | © Danfoss | April 2023 BC265857716810en-000202...

  • Page 55: 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 Detect any unusual noise or vibration. If exists, contact Danfoss. Enclosure and connected Check cleanliness. Clean if necessary. See Chapter Cleaning. parts Shaft seals Check the wear.

  • Page 56: Bearings And Lubrication

    Beware of rotating parts. Do not touch the electric machine during operation. The surface of the electric machine can be hot. Use correct protective equipment (heat resistant gloves) when you handle the electric machine. 56 | © Danfoss | April 2023 BC265857716810en-000202...
  • Page 57 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.

  • Page 58: Cooling System Maintenance

    (sediment) accumulating to the cooling system. The quality of the coolant must be checked yearly. The mixture of coolant fluid must be according to specification. See Chapter Recommended coolants. 58 | © Danfoss | April 2023 BC265857716810en-000202...

  • Page 59: 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. © Danfoss | April 2023 BC265857716810en-000202 | 59...

  • Page 60: Troubleshooting

    DC resistance meter and compare to manufacturer specifications. Replace the electric machine if necessary. Inverter switching frequency too low. If other than a Danfoss Editron inverter is used, ensure that the switching frequency is at least equal to the required minimum switching frequency of the motor.
  • Page 61 The heater element is faulty. Measure the resistance of the heater element. See Chapter Anti-condensation heater connections on page 47. If the heater is faulty, contact local Danfoss representative. Temperature measurement The PT100 sensor is faulty. Measure the resistance of the PT100 sensor, see Chapter...

  • Page 62: 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 63 10451 Seal, O-ring 184.5 X 3 NBR70 10349 Plug for grease escape hole (D-end and M16 x 1.5 , VSTI16X1.5SED71 N-end) 10358 Ventilation plug PMF 100444 Metal Vent © Danfoss | April 2023 BC265857716810en-000202 | 63...

  • Page 64: Disposal

    User Guide EM-PMI540-T4000 Disposal Dispose of the electric machine and any of its parts by appropriate means in accordance with local laws and regulations. 64 | © Danfoss | April 2023 BC265857716810en-000202...

  • Page 65: Storage, Installation And Maintenance Checklists

    (to the bus bar) Connection box cover bolts 4 Nm ☐ ☐ ☐ tightening torque Grounding Electric machine enclosure grounding connected ☐ ☐ ☐ Low voltage cable shield grounding connected ☐ ☐ ☐ © Danfoss | April 2023 BC265857716810en-000202 | 65...
  • Page 66 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 66 | © Danfoss | April 2023 BC265857716810en-000202...
  • Page 67 Encoder mounting ☐ ☐ ☐ Cooling system Functioning of the cooling system in ☐ ☐ ☐ general Tightness of the ventilation plug ☐ ☐ ☐ © Danfoss | April 2023 BC265857716810en-000202 | 67...
  • Page 68 (to the bus bar) Connection box cover bolts 4 Nm ☐ ☐ ☐ tightening torque Cooling system Coolant flow direction changed and connection checked ☐ ☐ ☐ Coolant quality as specified ☐ ☐ ☐ 68 | © Danfoss | April 2023 BC265857716810en-000202...
  • Page 69 For cleaning instructions, refer to Chapter Cleaning on page 55. Used service parts Part description Part type Quantity Item (order) number Notes: • • • • • • • • • • • • Date: Signature: © Danfoss | April 2023 BC265857716810en-000202 | 69...
  • Page 70 Electric machine type and serial number is correct Electric machine supported correctly Corrosion protection of non-painted surfaces (for example shaft-end and grounding points) Shaft rotated as specified (10 rotations monthly) 70 | © Danfoss | April 2023 BC265857716810en-000202...
  • Page 71 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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