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Summary of Contents for Danfoss EM-PMI240-T180
- Page 1 User Guide Motor / Generator EM-PMI240-T180 www.danfoss.com...
- Page 2 User Guide EM-PMI240-T180 Revision history Table of revisions Date Changed May 2024 Sections updated: Product naming convention, Shaft alignment and load, Storage, Condition 0202 monitoring during operation July 2021 Updated user guide 0201 © Danfoss | May 2024 BC355256345493en-000202...
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Page 3: Table Of Contents
Electrical installation..................................33 Power connections.................................. 33 High voltage connection..............................33 Connection diagram................................35 Low voltage connections...............................36 Grounding connections................................. 38 Operation Operation conditions..................................40 Condition monitoring during operation..........................41 Recommended lubricants................................41 Recommended coolants................................42 Emergency operation...................................42 Maintenance © Danfoss | May 2024 BC355256345493en-000202 | 3... - Page 4 User Guide EM-PMI240-T180 Contents Regular maintenance................................... 44 Cleaning......................................45 Bearings and lubrication................................46 Cooling system maintenance..............................48 Dismounting Troubleshooting Aftersales Service policy....................................52 Disposal Storage, installation and maintenance checklists © Danfoss | May 2024 BC355256345493en-000202...
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Page 5: General Information
For detailed information on the models, options and characteristics, see product-specific data sheet. EM-PMI240-T180 options Variant Code Description Additional information Drive-end shaft Male shaft DIN 5480 W40x2x18x8f Female shaft, spline 14 tooth spline 12/24 pitch (ANSI B92.1B 1996 - Class 6e) © Danfoss | May 2024 BC355256345493en-000202 | 5... -
Page 6: Conformity According To Standards
User Guide EM-PMI240-T180 General information EM-PMI240-T180 options (continued) Variant Code Description Additional information D-end attachment Standard flange SAE 6, transmission housing +DE1 Flange interface for SAE C, 4 bolt mating transmission housing hydraulic pump Mounting direction Only horizontal assembly With standard bearing option... -
Page 7: Warranty
EM-PMI240-T180 General information 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. In order for the warranty to be valid, the customer must follow the requirements of this and all related documents, especially those set out in the product installation and maintenance, as well as the applicable standards and regulations in force in each country. -
Page 8: Responsibility Of The Manufacturer
User Guide EM-PMI240-T180 General information 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. • The installation of the system complies with the requirements of the appropriate regulations. -
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 | May 2024 BC355256345493en-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 | May 2024 BC355256345493en-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 | May 2024 BC355256345493en-000202 | 11... -
Page 12: Product Overview
The electric machine Intended use of the electric machine This electric machine is intended to be used as a motor or generator and as a part of a machinery, for example in: © 12 | Danfoss | May 2024 BC355256345493en-000202... -
Page 13: Used Technology
(IM) technology. The SRPM technology combines the benefits of PM and Synchronous Reluctance technology, having increased torque capability over wide speed range and ability to produce torque to higher speeds. The electric machine efficiency at lower speeds is also good. © Danfoss | May 2024 BC355256345493en-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
Grease escape/fill connections; depending on model and option (+BHS): maintenance use only. • Air ventilation plug. Electrical interfaces: • Power connections. • Measurement connections. • Low voltage (measurement signal) grounding connection. • Power grounding connection. © Danfoss | May 2024 BC355256345493en-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 | May 2024 BC355256345493en-000202... - Page 17 Maximum rotation speed Insul. class Temperature rating (class) of insulation of the electric machine according to IEC60034-1 Temp. class Temperature rating (class) of individual insulation materials of the insulation according to IEC60034-1 © Danfoss | May 2024 BC355256345493en-000202 | 17...
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Page 18: Tightening Torques
Use threadlocking adhesive for RST, that is, stainless steel bolts to avoid breakage. Do not install dry screws or other fastening equipment. Add suitable lubrication, for example Wuerth HSP 1400, to prevent excess friction. Tightening torques to use unless otherwise noted 10.9 12.9 Thread © 18 | Danfoss | May 2024 BC355256345493en-000202... -
Page 19: Design Principles
The insulation of the electric machine has the following lifetime expectancy. Insulation class Lifetime expectancy F (150°C) 20 000 h H (175°C) 20 000 h 100 000 h if driven with maximum winding temperature of 150°C © Danfoss | May 2024 BC355256345493en-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. Parallel alignment of the shaft and mating structure © 22 | Danfoss | May 2024 BC355256345493en-000202... - Page 23 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. © Danfoss | May 2024 BC355256345493en-000202 | 23...
- Page 24 User Guide EM-PMI240-T180 Design principles External shaft forces of the electric machine © 24 | Danfoss | May 2024 BC355256345493en-000202...
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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 Do not go under a lifted load. Lifting slings cannot touch the electric machine during the lifting. Lifting lugs/eyes/points for lifting slings and lifting position of the electric machine Lifting eye type: RS M8 0,20t (2 pcs) © 26 | Danfoss | May 2024 BC355256345493en-000202...
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Page 27: Storage
The storage should be dry, dust free and vibration free. • Treat the unprotected electric machine surfaces such as the shaft-end and flanges against corrosion. Seal the cable exit holes and cooling bores for storage. © Danfoss | May 2024 BC355256345493en-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 | May 2024 BC355256345493en-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 | May 2024 BC355256345493en-000202 | 29... -
Page 30: Required Tools
Reference value of 150 MΩ has to be exceeded at reference ambient temperature 25°C (measured with 500 V / 1 min insulation resistance test). Contact Danfoss Editron service if the reference value is not exceeded. Mechanical installation Allowed mounting positions If the application is a moving work machine or similar, it is allowed to deviate from the allowed mounting position for the duration of 30% of the work cycle. -
Page 31: Mounting The Electric Machine
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. © Danfoss | May 2024... - Page 32 5. Attach the mounting bolts. For steel housing the minimum length of the bolt is 40 mm and for aluminum housing 45 mm. Refer to Chapter on page 18 for the correct tightening Tightening torques torques. Mechanical mounting connections of the electric machine (horizontal mounting) © 32 | Danfoss | May 2024 BC355256345493en-000202...
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Page 33: Cooling Connections
Electrical installation Power connections High voltage connection Risk of electric shock. When you work with power connections make sure that electricity is disconnected and that the rotation of the rotor is prevented. © Danfoss | May 2024 BC355256345493en-000202 | 33... - Page 34 1. Remove the connector locking plate. See the Figure below. 2. Install the high voltage cables. Refer to the instructions of the manufacturer of the mating connectors. 3. Install the connector locking plate back. © 34 | Danfoss | May 2024 BC355256345493en-000202...
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Page 35: Connection Diagram
The amount of inverters depends on the electric machine and converter current ratings. See also the relevant wiring diagrams. For an electric machine with option SINGLE (one connection box containing one three-phase system), the electrical connection principle from the inverter is shown in the Figure below. © Danfoss | May 2024 BC355256345493en-000202 | 35... -
Page 36: Low Voltage Connections
See more information and instructions about DEUTSCH connectors at https:// www.deutschconnector.com/. Recommended cable types for low voltage connections Application Cable type Resolver cabling Shielded cable (twisted pair) Temperature measurement (PT100) Shielded cable (twisted pair) © 36 | Danfoss | May 2024 BC355256345493en-000202... - Page 37 Deutsch HD34-24-47PE connector has two kinds of mating pins: 1 mm and 1.5 mm in diameter. Pin configuration of the Deutsch HD34-24-47PE connector Pin configuration of the Deutsch HD34-24-47PE connector Measurement Description Temperature 1 Temperature 1, PT100 (P), windings Temperature 1, PT100 (N), windings © Danfoss | May 2024 BC355256345493en-000202 | 37...
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Page 38: 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. © 38 | Danfoss | May 2024 BC355256345493en-000202... - Page 39 2. Connect the other terminal of the measurement device to the machine enclosure grounding point. 3. Measure the resistance between the cable shield and the enclosure grounding point. © Danfoss | May 2024 BC355256345493en-000202 | 39...
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Page 40: Operation
Read the instructions in this user guide before you install the electric machine. Operation conditions The electric machine should be used for its intended purpose only and within limits specified by the manufacturer, concerning: © 40 | Danfoss | May 2024 BC355256345493en-000202... -
Page 41: Condition Monitoring During Operation
For the maximum coolant liquid temperature at the inlet of the coolant circuit, see the product data sheet. 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 42: 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 43 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 44: 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. © 44 | Danfoss | May 2024 BC355256345493en-000202... -
Page 45: 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... -
Page 46: Bearings And Lubrication
The bearing type for electric machine is 6009/C3. See the recommended lubricant in Chapter Recommended lubricants on page 41. © 46 | Danfoss | May 2024 BC355256345493en-000202... - Page 47 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 48: 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. © 48 | Danfoss | May 2024 BC355256345493en-000202... -
Page 49: 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 | May 2024 BC355256345493en-000202 | 49... -
Page 50: 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 51 Demagnetization of magnets due to Check that the back-EMF of the motor is within specifications. Contact local overheating. Danfoss representative. Replace the electric machine if necessary. Bearing fault. Check the bearing temperature, lubrication and conditions. Contact local Danfoss representative for further information.
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Page 52: Aftersales
Maintenance and service of the electric machine is limited to the procedures described in this user guide. If the electric machine has service parts available, you can find them in Chapter Service parts. For further information, go to https://danfosseditron.zendesk.com/hc/en-gb or send email to editron.service@danfoss.com. © 52 | Danfoss | May 2024 BC355256345493en-000202... -
Page 53: Disposal
User Guide EM-PMI240-T180 Disposal Dispose of the electric machine and any of its parts by appropriate means in accordance with local laws and regulations. © Danfoss | May 2024 BC355256345493en-000202 | 53... -
Page 54: 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 © 54 | Danfoss | May 2024 BC355256345493en-000202... - Page 55 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 | May 2024 BC355256345493en-000202 | 55...
- Page 56 Continuous insulation monitoring. (It is recommended to use continuous insulation monitoring for the whole system where electric machine is used.) Cooling system ☐ ☐ ☐ Functioning of the cooling system in general ☐ ☐ ☐ Tightness of the ventilation plug © 56 | Danfoss | May 2024 BC355256345493en-000202...
- Page 57 ☐ Tightness of the tubing and connections (no leakages) ☐ ☐ ☐ Cleanliness of the ventilation plug Grounding ☐ ☐ ☐ Power cable shield connection resistances to ground (electric machine enclosure) checked © Danfoss | May 2024 BC355256345493en-000202 | 57...
- Page 58 • • Date: Signature: Electric machine storage checklist Date: Electric machine and customer information Customer: Electric machine type (from the rating plate): Customer reference: Electric machine serial number: Service reference: Date installed: © 58 | Danfoss | May 2024 BC355256345493en-000202...
- Page 59 Electric machine type and serial number is correct Electric machine supported correctly Insulation resistance (test insulation resistance every three months in storage) Shaft rotated as specified (10 rotations monthly) © Danfoss | May 2024 BC355256345493en-000202 | 59...
- Page 60 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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