Danfoss EM-PMI300-T310 User Manual
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Danfoss EM-PMI300-T310 User Manual

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Summary of Contents for Danfoss EM-PMI300-T310

  • Page 1 User Guide Motor / Generator EM-PMI300-T310 www.danfoss.com...
  • Page 2 User Guide EM-PMI300-T310 Revision history Table of revisions Date Changed April 2023 Minor modifications and improvements 0202 © Danfoss | April 2023 BC265858156812en-000202...

  • Page 3: Table Of Contents

    Connection diagram................................35 Cable gland assembly and power line connection....................35 Low voltage connections...............................40 Grounding connections................................. 44 Anti-condensation heater connections..........................46 Operation Operation conditions..................................48 Condition monitoring during operation..........................48 Recommended lubricants................................48 Recommended coolants................................49 Emergency operation...................................49 © Danfoss | April 2023 BC265858156812en-000202 | 3...
  • Page 4 User Guide EM-PMI300-T310 Contents Maintenance Regular maintenance................................... 51 Cleaning......................................52 Bearings and lubrication................................53 Cooling system maintenance..............................56 Dismounting Troubleshooting Aftersales Service policy....................................60 Service parts.....................................60 Disposal Storage, installation and maintenance checklists © Danfoss | April 2023 BC265858156812en-000202...

  • Page 5: General Information

    User Guide EM-PMI300-T310 General information This user guide is the installation, operation and maintenance user guide for the EM-PMI300-T310 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

    RINA +CL6 CCS China Classification Society 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 | April 2023 BC265858156812en-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 BC265858156812en-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 depends on the options chosen. The temperature signal(s) can be read out from the 10 | © Danfoss | April 2023 BC265858156812en-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 BC265858156812en-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. EM-PMI300-T310 The electric machine can be delivered for different speed and torque applications. 12 | © Danfoss | April 2023 BC265858156812en-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 BC265858156812en-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. Electrical interfaces: • Power connections through the connection box. • Measurement connections. • Anti-condensation heater(s) connector (+HEAT1). • Power grounding connection. • Low voltage (measurement signal) grounding connection. © Danfoss | April 2023 BC265858156812en-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 BC265858156812en-000202...
  • Page 17 °C IP rating Enclosure class according to IEC60034-5 Cooling Cooling method according to IEC60034-6 Rotation Direction of rotor rotation with default phase order. Observed facing the D-end. Max n Maximum rotation speed © Danfoss | April 2023 BC265858156812en-000202 | 17...

  • Page 18: Tightening Torques

    Add suitable lubrication, for example Wuerth HSP 1400, to prevent excess friction. Connection Torque Mounting bolts for D-end attachment 40 Nm Connection box cover plate screws 5 Nm Cable lug 15 Nm Tightening torques to use unless otherwise noted 10.9 12.9 Thread 18 | © Danfoss | April 2023 BC265858156812en-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 BC265858156812en-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 BC265858156812en-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 BC265858156812en-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 Lifting slings cannot touch the electric machine during the lifting. Lifting lugs/eyes/points for lifting slings and lifting position of the electric machine 1 Lifting eye type of ANSI B18.15.1M M10x16 is recommended in M10 bores. Not included in the delivery. 26 | © Danfoss | April 2023 BC265858156812en-000202...

  • Page 27: 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 | April 2023 BC265858156812en-000202 | 27...

  • Page 28: 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. 28 | © Danfoss | April 2023 BC265858156812en-000202...

  • Page 29: 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 30 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 uses the mounting option 1 with the standard bearing option, but with the grease lubricated bearings it uses the mounting option 2.

  • Page 31: 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 32 1 Bores for the lifting eyes, N-end. 2 D-end flange (SAE4) mounting bolts (12 pcs of DIN912 M10). Not included in the delivery. 3 Shaft of the electric machine; spline structure of the shaft (DIN5480W50x2x24x8f). 32 | © Danfoss | April 2023 BC265858156812en-000202...

  • Page 33: Cooling Connections

    Electrical installation Power connections High voltage connection Risk of electric shock when connection box is open. When you work with power connections make sure that electricity is disconnected and shaft rotation is prevented. © Danfoss | April 2023 BC265858156812en-000202 | 33...
  • Page 34 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

    Table below. Cable gland assembly instruction can also be found from PFLITSCH gland catalog available from http://www.pflitsch.de. Use correct type of gland for different cable diameters. These are shown in the Table below. © Danfoss | April 2023 BC265858156812en-000202 | 35...
  • Page 36 Copper Foil Tape 1181 or similar. The maximum distance between the copper tape or the shield (braid) of the cable and the cable lug or the conductor (which ever is closer), is 10 mm. 36 | © Danfoss | April 2023 BC265858156812en-000202...
  • Page 37 (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. © Danfoss | April 2023 BC265858156812en-000202 | 37...
  • Page 38 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. 38 | © Danfoss | April 2023 BC265858156812en-000202...
  • Page 39 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. © Danfoss | April 2023 BC265858156812en-000202 | 39...

  • Page 40: Low Voltage Connections

    For more information about the options, refer to Chapter Product naming convention on page 5. Recommended cable types for low voltage connections Application Cable type Resolver cabling Shielded cable (twisted pair) Temperature measurement (PT100) Shielded cable (twisted pair) 40 | © Danfoss | April 2023 BC265858156812en-000202...
  • Page 41 Connector type: TE 115645201 • Pin type of connector: TE 9642703 (gold plated) • Mating female connector type: TE 117036391 • Pin type for the mating connector: TE 12413813 (use gold plated pins) © Danfoss | April 2023 BC265858156812en-000202 | 41...
  • Page 42 Resolver, EXCN Temperature, PT100, windings Temperature, PT100, windings Temperature, PT100, windings Resolver, RES_COSP Resolver, RES_SINP Resolver, EXCP GND, Temperature, PT100, windings (corresponds to pin4 PT100) GND, Temperature, PT100, windings (corresponds to pin5 PT100) 42 | © Danfoss | April 2023 BC265858156812en-000202...
  • Page 43 Temperature 5, PT100 (N), windings (+TEMP4 option) Temperature 6, PT100 (P), windings (+TEMP4 option) Temperature 6, PT100 (N), windings (+TEMP4 option) Heater, phase, 230 V Heater, neutral Heater, ground / protective earth, M4 screw inside connection box © Danfoss | April 2023 BC265858156812en-000202 | 43...

  • Page 44: Grounding Connections

    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. 44 | © Danfoss | April 2023 BC265858156812en-000202...
  • Page 45 4. Change the measurement device terminal(s) to the shield of different power cable and repeat the measurement until all cables have been measured. Testing the low voltage (measurement signal) cable shield grounding (earthing) © Danfoss | April 2023 BC265858156812en-000202 | 45...

  • Page 46: 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. Connection of the heater element If the electric machine has an anti-condensation heater and failure is suspected, contact Danfoss representative. 46 | ©...

  • Page 47: 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 | April 2023 BC265858156812en-000202 | 47...

  • Page 48: 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 49: 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 50 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 51: 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. © Danfoss | April 2023 BC265858156812en-000202 | 51...

  • Page 52: 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 53: Bearings And Lubrication

    The mechanical bearing lifetime (grease relubricable bearings) of the electric machine is shown below. It depends on the bearing operation temperature and rotation speed. © Danfoss | April 2023 BC265858156812en-000202 | 53...
  • Page 54 Bearing lifetime with greased for life bearings, horizontal mounting 54 | © Danfoss | April 2023 BC265858156812en-000202...
  • Page 55 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 56: 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. 56 | © Danfoss | April 2023 BC265858156812en-000202...

  • Page 57: 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 BC265858156812en-000202 | 57...

  • Page 58: 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 59 The heater element is faulty. Measure the resistance of the heater element. See Chapter Anti-condensation heater connections on page 46. 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 60: 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 61 10348 Connection box cover plate gasket 10358 Ventilation plug PMF 100444 Metal Vent 10323 Bearing, N-end, Deep groove ball SKF 6211 2RS1 C3 WT (non insulated in N-end, BI0 option, BGL) © Danfoss | April 2023 BC265858156812en-000202 | 61...

  • Page 62: Disposal

    User Guide EM-PMI300-T310 Disposal Dispose of the electric machine and any of its parts by appropriate means in accordance with local laws and regulations. 62 | © Danfoss | April 2023 BC265858156812en-000202...

  • Page 63: Storage, Installation And Maintenance Checklists

    ☐ ☐ (to the bus bar) The phase connections order is correct (U, V, W -> L1, L2, ☐ ☐ ☐ Connection box cover bolts 4 Nm ☐ ☐ ☐ tightening torque © Danfoss | April 2023 BC265858156812en-000202 | 63...
  • Page 64 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 64 | © Danfoss | April 2023 BC265858156812en-000202...
  • Page 65 Encoder mounting ☐ ☐ ☐ Cooling system Functioning of the cooling system in ☐ ☐ ☐ general Tightness of the ventilation plug ☐ ☐ ☐ © Danfoss | April 2023 BC265858156812en-000202 | 65...
  • Page 66 ☐ ☐ torque (to the box) Cable lug tightening torque 15 Nm ☐ ☐ ☐ (to the bus bar) Connection box cover bolts 4 Nm ☐ ☐ ☐ tightening torque Cooling system 66 | © Danfoss | April 2023 BC265858156812en-000202...
  • Page 67 Sealing of the screws may break. For cleaning instructions, refer to Chapter Cleaning on page 52. Used service parts Part description Part type Quantity Item (order) number © Danfoss | April 2023 BC265858156812en-000202 | 67...
  • Page 68 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) 68 | © Danfoss | April 2023 BC265858156812en-000202...
  • Page 69 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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