User Guide
Motor / Generator
EM-PMI540-T2000
www.danfoss.com
User Guide
EM-PMI540-T2000
Revision history Table of revisions
Date Changed Rev
July 2021 Updated user guide 0202
2 | © Danfoss | July 2021 BC265857530809en-000202
User Guide
EM-PMI540-T2000
Contents
General information
Safety information
Product overview
Design principles
Transportation and storage
Installation
Operation
Intended use of the user guide................................................................................................................................................... 5
Product naming convention ....................................................................................................................................................... 5
Conformity according to standards...........................................................................................................................................6
Warranty.............................................................................................................................................................................................. 7
Terms and abbreviations...............................................................................................................................................................7
Responsibility of the manufacturer........................................................................................................................................... 8
General safety statement...............................................................................................................................................................9
Safety message signal words....................................................................................................................................................... 9
Safety symbols...................................................................................................................................................................................9
Personal protective equipment................................................................................................................................................10
Security features.............................................................................................................................................................................10
Electromagnetic compatibility (EMC).....................................................................................................................................11
Intended use of the electric machine.....................................................................................................................................13
Used technology............................................................................................................................................................................ 14
System introduction..................................................................................................................................................................... 15
Connections and interfaces........................................................................................................................................................16
Rating plate......................................................................................................................................................................................18
Tightening torques........................................................................................................................................................................19
System design.................................................................................................................................................................................20
Cooling and temperature measurement ........................................................................................................................20
Insulation lifetime.....................................................................................................................................................................20
Inverter......................................................................................................................................................................................... 21
Mounting structure....................................................................................................................................................................... 22
Supporting structure requirements...................................................................................................................................22
Shaft alignment and load...................................................................................................................................................... 23
Transportation................................................................................................................................................................................ 26
Receiving and unpacking............................................................................................................................................................26
Lifting................................................................................................................................................................................................. 26
Storage...............................................................................................................................................................................................28
Extended storage......................................................................................................................................................................29
Required tools.................................................................................................................................................................................31
Insulation resistance test.............................................................................................................................................................31
Mechanical installation................................................................................................................................................................31
Allowed mounting positions................................................................................................................................................31
Mounting the electric machine........................................................................................................................................... 33
Cooling connections............................................................................................................................................................... 35
Electrical installation.....................................................................................................................................................................36
Power connections.................................................................................................................................................................. 36
High voltage connection..................................................................................................................................................36
Connection diagram.......................................................................................................................................................... 38
Cable gland assembly and power line connection.................................................................................................39
Low voltage connections.......................................................................................................................................................44
Grounding connections......................................................................................................................................................... 48
Anti-condensation heater connections............................................................................................................................51
Operation conditions....................................................................................................................................................................54
Condition monitoring during operation...............................................................................................................................54
Recommended lubricants...........................................................................................................................................................54
Recommended coolants............................................................................................................................................................. 55
Emergency operation...................................................................................................................................................................55
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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
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User Guide
EM-PMI540-T2000
General information
Intended use of the user guide
Product naming convention
This user guide is the installation, operation and maintenance user guide for the EM-PMI540-T2000
electric machine.
This user guide contains instructions necessary to safely and properly handle, install, operate and
maintain the electric machine. They should be brought to the attention of anyone who installs, operates
or maintains the machine or associated equipment.
All of the safety warnings and instructions in this user guide must be followed to prevent injury to
personnel or damage to property. Only qualified and authorized personnel, familiar with health and
safety requirements and national legislation, shall be permitted to handle, install, operate and maintain
the device.
This user guide must be kept for future reference during installation, operation and maintenance.
This user guide uses illustrations as examples only. Illustrations in this user guide may not necessarily
reflect all system features.
In this user guide, EM-PMI family permanent magnet motors and generators are referred to as the electric
machine.
Frame model indicates dimensions and electrical characteristics of the electric machine. The following
naming convention is used to refer to the electric machine frame model:
EM-PMI540-T2000-XXXX+XX
•
The naming codes of the electric machine
Part of the name Meaning
EM Electric Machine
PMIXXX or PMEXXX Permanent Magnet Internal and a number relative to
the diameter of the electric machine, or Permanent
Magnet External and a number relative to diameter of the
electric machine
TXXXX Average continuous torque of the motor range, relative
to the lenght of the machine
XXXX Rated rotation speed
+XX Options, see option table below. Standard options are
indicated by a star (*).
The power input of the machine may require one or several three phase power systems. This is indicated
by a power connection option marking, for example: DUAL or QUAD in the machine model code. One
three phases power system can include one or three connection boxes in the machine. The most usual
case is when an electric machine has a single connection box, but this is not shown in the machine
model code.
Example: EM-PMI540-T2000-1300-DUAL
•
The electric machine can include some of the options available. The options of the electric machine are
shown also in the rating plate, following the frame model code. Note! Only options that differ from the
standard delivery are indicated. Following options are used, see Table below. For detailed information of
the models, options and characteristics, see product data sheets.
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User Guide
EM-PMI540-T2000
General information
EM-PMI540-T2000 options
Variant Code Description Additional information
High voltage connections -DUAL Two galvanically isolated 3
phase systems
Low voltage connections
Connection extension * None Two connection boxes each containing
N-end attachment * None
Bearing insulation * Non-insulated bearings Non-insulated bearings
Shaft grounding * None
Rotation sensor (resolver) * None No resolver
Winding temperature
sensor
Bearing temperature sensor * None
Anti-condensation heaters * None None
Marine classification * No marine classification
*
+LVB1 Low voltage connections
+CE1 Double phase connections Extended connection boxes with two M32
+NE4 Male shaft, no flange DIN5480 W55x2x26x8a
+BIN Insulated bearing in N-end Insulated bearing in N-end
+BIA Insulated bearing in both
+SG1 D-end shaft grounding In-built grounding ring
+RES1 Resolver In-built non contacting resolver, 8-pole
* Temperature surveillance 3 x PT100 (two wire) in windings
+TEMP4 Redundant temperature
+TEMP5 Redundant temperature
+BTMP1 PT100 in bearings Plug-in connector
+HEAT1 One anti-condensation
+CL1 ABS American Bureau of Shipping
+CL2 BV Bureau Veritas
+CL3 DNV
+CL4 LR Lloyd’s Register
+CL5 RINA
Low voltage connections
done with connector
done with connection box
and terminal strip
ends
surveillance
surveillance
heater
Two connection boxes each containing
one 3 phase system with one M32 cable
gland per phase
DEUTSCH HD34-24-47PE connector for LV
connections
Connection box with 2x M25 cable glands
(reserve 2x plugged M16 threads
available) and terminal block for LV
connections
one 3 phase system with one M32 cable
gland per phase
cable glands per phase
Insulated bearing in both ends
pair
6 x PT100 (two wire) in windings
12 x PT100 (two wire) in windings
230VAC/130W
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:
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EM-PMI540-T2000
General information
Applicable Directives and standards
Standard Explanation
Low Voltage Directive
2006/95/EC (until 19.4.2016)
and Low Voltage Directive
2014/35/EU (from 20.4.2016
onwards)
IEC 60034-1:2010 Rotating electrical machines - Part 1: Rating and performance
IEC 60034-5:2001/A1:2007 Rotating electrical machines - Part 5: Degrees of protection provided by the
IEC 60034-6:1991 Rotating electrical machines - Part 6: Methods of cooling
IEC 60034-7:1992/A1:2001 Rotating electrical machines - Part 7: Classification of types of construction,
IEC 60034-8:2007/A1:2014 Rotating electrical machines - Part 8: Terminal markings and direction of rotation
IEC 60034-14:2004/A1:2008 Amendment 1 - Rotating electrical machines - Part 14: Mechanical vibration of
Electrical equipment means any equipment designed for use with a voltage
rating of between 50 and 1000 V for alternating current. This electric
machine is subject to the Low Voltage Directive 2006/95/EC or 2014/35/EC.
integral design of rotating electrical machines (IP code) - Classification
mounting arrangements and connection box position (IM Code)
certain machines with shaft heights 56 mm and higher - Measurement, evaluation
and limits of vibration severity.
Warranty
Terms and abbreviations
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.
Defects arising from the improper or negligent use, operation, and/or installation of the equipment, nonexecution of regular preventive maintenance, as well as defects resulting from external factors or
equipment and components not supplied/recommended by Danfoss, will not be covered by the
warranty.
The warranty will not apply if the customer at its own discretion makes repairs and/or modifications to
the equipment without prior written consent from Danfoss.
The symbols, terms and abbreviations in the Tables below are possibly used in this manual.
Symbols
Symbol Variable Unit
U Rated voltage (phase-to-phase AC) V
I Rated current (AC) A
P Rated Power (S1) kW
T Rated torque (S1) at rated speed Nm
T
max
n Rated speed rpm
Max n Maximum speed rpm
f Rated supply frequency at nominal speed Hz
PF Power factor (cosφ)
Q
c
Maximum torque Nm
Rated coolant liquid flow l/min
rms
rms
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General information
Symbols (continued)
Symbol Variable Unit
T
c
T
amb
RES_COS Cosine signal received from the resolver deg
RES_SIN Sinusoidal signal received from the machine resolver deg
GND Ground in electrical connections
Ω (Ohm) Resistance Ω
Rated coolant liquid input temperature °C
Rated ambient temperature °C
Term / abbreviation
Term/ Abbreviation Explanation
Resolver Rotation meter in electric machines, used for measuring degrees of rotation
AC Alternating current
DC Direct current
PMSM Permanent Magnet Synchronous Machine
SRPM Syncronous Reluctance assisted Permanent Magnet
S1 Duty type according to the IEC60034; Continuous running duty
S9 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.
•
The installation of the system complies with the requirements of the appropriate regulations.
•
The electric machine is used in accordance with the instructions in this user guide.
•
The electric machine is installed, maintained and serviced in accordance with the instructions in this
user guide.
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Safety information
General safety statement
Safety message signal words
•
The electric machine is intended for use as a component for industrial and commercial installations.
The end product containing the electric machine must conform with all related regulations.
•
The use of the electric machine is prohibited in hazardous areas unless it is expressly designed for
such use.
•
The electric machine is intended for installation, use and maintenance by qualified personnel, familiar
with health and safety requirements and national legislation. Ignoring these instructions may
invalidate all applicable warranties.
•
These instructions must be followed to make sure of safe and correct installation, operation and
maintenance of the electric machine. They should be brought to the attention of anyone who installs,
operates or maintains the electric machine or associated equipment.
•
High voltage and rotating parts can cause serious or fatal injuries. For electric machine covered by
this user guide, it is important to observe safety precautions to protect personnel from possible
injury.
Safety message signal words indicate the severity of a potential hazard.
DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. CAUTION may also alert against unsafe practices.
NOTICE Indicates a potentially hazardous situation which, if not avoided, could result in property
damage.
Safety symbols
The following safety and information related symbols appear in this user guide and on the electric
machine.
Danger
This symbol is identified by a yellow background, red octagonal band and a black STOP text.
It indicates a hazardous situation that causes severe injury or death. Action indicated by this
symbol may not be executed.
General warning
This symbol is identified by a yellow background, black triangular band, and a black
exclamation point symbol. It indicates a general potentially hazardous situation.
Electric shock warning
The symbol is identified by a yellow background, black triangular band, and a black
arrowhead symbol. It indicates dangerous electrical voltage that could cause an electric shock
to a person.
Burn warning
The symbol is identified by a yellow background, black triangular band, and a black wavy
lines symbol. 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.
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EM-PMI540-T2000
Safety information
Magnet warning
The symbol is identified by a yellow background, black triangular band, and a black magnet
symbol. It indicates strong magnetic field that could cause harm to a person or property.
Rotating shaft warning
The symbol is identified by a yellow background, black triangular band, and a black rotating
shaft symbol. It indicates strong rotating shaft that could cause harm to a person or property.
General Information.
Read the instructions in the user guide.
Personal protective equipment
Personal protective equipment shall be used when necessary during handling, installation and
maintenance of the electric machine to avoid injury.
Use eye protective equipment like safety goggles or mask when you work with the electric
machine. Permanent damage to the eye could be caused if bearing grease, melted nitrile
rubber (radial lip seal), glycol or other fluids splash.
Use hearing protective equipment when you work on the electric machine. Hearing injuries
can be caused by too loud noise (noise in excess of 85 dBA).
Use head protective equipment like helmet when you lift the electric machine! Head injuries
can be caused by object impact.
Use cut resistant gloves when you handle and maintain the electric machine. There is a risk of
cut injuries.
Use protective footwear when you lift or move the electric machine! Foot injuries could be
caused if lifting system or lifting brackets fail.
Security features
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
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Safety information
connector of the electric machine. You can connect the temperature signal to the temperature
surveillance pin in the inverter (EC-C) and make sure that the inverter has the machine temperature
protection feature activated.
The electric machine can be ordered with bearing temperature measurement. This option includes one
PT100 temperature sensor at both D-end and N-end bearings. The signal can be read out using a
separate connector at both ends.
The electric machine has leakage sensors (2pcs) at the lower part of the electric machine. This feature is
useful in moist conditions to detect possible excessive water in contact with the electric machine.
Separate connectors for both leakage signals exist.
Electromagnetic compatibility (EMC)
When interfacing other equipment, connect only equipment that are specified as part of the
system and that are compatible.
Magnetic and electromagnetic fields generated near the current-carrying conductors and
permanent magnets in electric machines represent a health danger to persons with heart
pacemakers, metal implants and hearing aids. Persons with a heart pacemaker, metal
implants or hearing aids must consult a doctor before they enter the following areas:
•
Areas in which electric equipment and parts are operated
•
Areas in which electric equipment with permanent magnets are stored, mounted,
operated or repaired
If necessary, perform a special electromagnetic compatibility (EMC) test on the installation.
EMC stands for Electromagnetic compatibility. It is the ability of electric equipment to operate without
problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere
with any other product or system within its locality. This is a legal requirement for all equipment taken
into service within the European Economic Area (EEA).
Our products are designed with high standards of EMC in mind. Connect the power lines and groundings
along the instructions in this user guide to achieve the required level of EMI protection.
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.
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EM-PMI540-T2000
Product overview
For harsh conditions, like salty air in marine applications, it is recommended to check the
surface treatment possibilities with the factory.
The electric machines have been developed especially for heavy duty, marine and transportation
applications. They are more reliable, smaller, lighter and more efficient than conventional products on
the market.
Typical applications of the electric machines are:
Motor (electric propulsion) and generator for hybrid marine vessels or mobile work machine and bus
•
parallel hybrid applications.
Traction motor and generator for electrical or hybrid electrical mobile work machines or buses.
•
The electric machines feature Synchronous Reluctance assisted Permanent Magnet (SRPM) motor
technology, having several advanced features:
Extremely compact and robust structure.
•
High efficiency throughout the operation range.
•
Liquid cooling with water/glycol mixture.
•
Low coolant flow required.
•
High allowed coolant temperature.
•
IP65 enclosure class to maximize reliability.
•
Multiple mounting possibilities.
•
Extended speed and torque capabilities compared to standard PM machines.
•
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.
•
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Product overview
The electric machine
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.
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:
Power train of a marine vessel, transportation vehicle or a heavy duty work machine.
•
Power generation equipment.
•
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.
In a power generation equipment the electric machines are intended to be powered by a prime mover,
for example, an internal combustion engine and controlled by the above mentioned electric power
inverter.
The electric machine is solely intended for professional use, and may be operated only by trained
professionals. The maintenance of the electric machine may be done only by trained professionals.
Forbidden use of the electric machine
It is forbidden to use, handle and maintain the machine in following ways (including but not limited to):
•
Using the electric machine for other purposes than defined in this user guide.
•
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.
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Product overview
•
Exceeding the designed limits during the electric machine operation.
•
Using non-original service parts of wrong material causing corrosion problems and mechanical
failures in time.
•
Operating and performing maintenance for the electric machine without appropriate personal
protective equipment.
•
Using electric machine parts like frame, shaft end or terminal box for climbing or for support for other
structures.
•
Causing any kind of impact forces to the electric machine (for example hitting or hammering or
dropping objects).
•
Operating the electric machine with electric connections other than defined in the user guide and/or
other documents.
•
Operating the electric machine with insufficiently tightened connections or cable glands.
•
Operating the electric machine with power cables routed against the instructions.
•
Operating the electric machine without properly dimensioned and operating cooling system.
•
Operating the electric machine without following the bearing lubrication instructions.
•
Touching the connection terminal of the electric machine or doing maintenance or adjustment
operations on the electric machine with the electricity connected.
•
Accessing the connection box(es) if the shaft can be turned by an external prime mover.
•
Lifting the electric machine from wrong lifting points and without correct lifting equipment.
•
Lifting additional load with the machine.
•
Storing the electric machine outdoors in wet or dusty conditions.
•
Storing the electric machine without correct support to prevent rolling or falling of the machines.
•
Using the electric machine in potentially explosive environment.
•
Allowing dirt or liquid to enter into the electric machine or connection box.
•
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
traditional induction machine (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.
The supply current to the machine stator windings create rotating magnetic field, which in turn rotates
the rotor containing permanent magnets. In the synchronous permanent magnet machine, the rotation
of the rotor (shaft) is synchronized with the frequency of the power supply current. The reluctance
technology maximizes the pull-out torque of the machine.
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
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.
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Product overview
Machine topology
1 Electric machine stator and stator windings
2 Electric machine rotor
3 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.
Overview of the Danfoss drive train system
The electric machines are liquid cooled with water/glycol mixture. For more information, see
Chapter Cooling connections.
A low voltage measurement signal connector is attached to the electric machines. Different temperature
and resolver signals can be read, depending on the machine options chosen. For more information about
the connection, see Chapter Low voltage connections.
The electric machines (some models) can be equipped with one or two anti-condensations heater(s),
depending on the machine type and the option chosen. The heater is used to prevent any water
condensing inside the machine enclosure.
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Product overview
Overview of electric machine system
Connections and interfaces
The electric machines are connected mechanically and electrically as a part of a machinery or as a part of
a power generation equipment.
Mechanical interfaces:
Lifting points.
•
Flange mounting (D-end).
•
Mounting foot rails.
•
Shaft connection.
•
Cooling system connections (bores).
•
Grease escape/fill connections; depending on option (+BHS); maintenance use only.
•
Air ventilation plug.
•
Vibration sensor connection points.
•
Electrical 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.
•
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Product overview
Connections and interfaces
1 Grease fill connection (nipple); D-end (+BHS option)
2 Bearing temperature measurement connector, D-end (+BTMP1 option). Type: 4-pin M12 A coded male.
3 Vibration sensor connection points.
Both in the D- and N- end, one on the top and two on the sides.
4 Lifting points.
The two outmost needed for normal lifting.
5 Inner lifting points.
Can be used for additional lifting lug/eye connections and as machine enclosure (power) grounding connection
point when mounted.
6 Grease fill connection (nipple); N-end (+BHS option).
7 Cooling system connections (bores).
8 Mounting foot rails.
Four rails in 90º circular pattern around the frame.
9 Air ventilation plug.
10 Power connection; cable gland (six glands with -DUAL option).
11 Connection boxes (two boxes with -DUAL option).
12 Bearing temperature measurement connector, N-end (+BTMP1 option).
Connected through the connection box. Type: 4-pin M12 A coded male.
13 Cable gland for the anti-condensation heater connection.
Anti-condensation heater connector inside the connection box.
14 Low voltage connector (measurement connector), low voltage grounding through the connector metal body.
15 Grease escape connections, N-end (+BHS option dependent).
One axial and one radial plug (downwards) in the N-end.
16 Leakage connectors.
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.
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Product overview
Rating plate
Each electric machine has a rating plate which can be found on the machine frame. The rating plate
contains machine rating and identification. 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.
Rating plate
Rating plate fields
Field Explanation Unit
1 Electric machine product family: EM-PMI or EM-PME
2 Electric machine type code and options
Serial No. Serial number
U Rated voltage V
I Rated current (AC) I
P Rated power (S9) according to IEC60034-1 kW
n Rated speed rpm
T Rated torque (S9) at rated speed Nm
PF Power factor
f Rated supply frequency at nominal speed Hz
Q
c
Pole pairs Number of magnetic pole pairs of the machine
T
c
Mounting Allowed mounting position according to IEC60034-7
Mass Mass of the electric machine kg
Duty Defined rotating electric machine duty cycles by IEC60034-1 standard
T
amb
IP rating Enclosure class according to IEC60034-5
Rated coolant liquid flow l/min
Rated coolant liquid input temperature °C
Rated ambient temperature °C
rms
rms
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Product overview
Tightening torques
Rating plate fields (continued)
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 rpm
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
Bear. / D-end Bearing type (types) in the D-end of the electric machine
Bear. / N-end Bearing type in the N-end of the electric machine
Max. pressure Cooling liquid max pressure
CE Depending on the details of the delivery, the rating plate might not have CE-marking
Tightening torque tolerance is +/- 5% of the specified tightening torque.
Use threadlocking adhesive for RST bolts.
Do not install dry screws or other fastening equipment.
Add suitable lubrication, for example Wuerth HSP 1400, to prevent excess friction.
Connection Torque
Mounting bolts for D-end attachment 80 Nm
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
8.8 10.9 12.9
Thread Nm Nm Nm
M5 7 10 11
M6 11 17 19
M8 27 40 47
M10 54 79 93
M12 93 137 160
M14 148 218 255
M16 230 338 395
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Design principles
System design
This Chapter describes design principles that must be taken into account when designing the system
using the electric machine.
Cooling and temperature measurement
Do not operate the electric machine without correctly dimensioned and operating cooling
system.
Mount the electric machine in correct position, see Chapter Allowed mounting position.
When you connect the cooling system make sure that the cooling medium flows freely in and
out from the electric machine with the cooling medium flow equal or higher than rated.
The cooling medium temperature at the inlet of the electric machine must be lower or equal
to the rated temperature.
See more detailed information about coolant connection bore specifications, required coolant liquid flow
and other specifications in the product data sheet. Rated values can be found from the electric machine
rating plate.
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
connector of the machine.
You can connect one temperature signal to the temperature surveillance pin in the inverter (EC-C1200)
and make sure that the inverter has the machine temperature protection feature activated.
The maximum allowed winding temperature of the electric machine is shown in the rating plate and in
the data sheet.
The PT100 temperature sensor characteristics are: resistance 100 Ω at 0 ºC temperature, and the
resistance increases 0.385 Ω per each 1 ºC increase of temperature.
Insulation lifetime
Heat cycles, environment, moisture, vibrations and similar variables have an effect on the
lifetime expectancy of the insulation of the electric machine. 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.
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Design principles
Insulation class Lifetime expectancy
F (150°C) 20 000 h
H (175°C) 20 000 h
Inverter
The electric machine is intended to be powered and controlled with an inverter 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.
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. These inverters are:
•
Compact and light.
•
Liquid cooled.
•
Tolerant to high mechanical vibration (10 G) and shock (50 G).
•
Efficient, efficiency > 98 %.
•
Reliable, no moving components.
100 000 h if driven with maximum winding temperature of 150°C
EC-C1200
Do not exceed the maximum rotation speed of the electric machine.
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L1
L2
U
V
W
-
-
L3
DC +
+
+
DC -
AUX DC +
AUX DC -
User Guide
EM-PMI540-T2000
Design principles
Schematic of the inverter powerstage
Mounting structure
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.
Supporting structure requirements
Do not install the electric machine near or in direct contact with easily flammable materials.
The surface of the electric machine can be hot.
The mating housing arrangement of the electric machine must be secure and sufficiently rigid to prevent
vibrations and mechanical failures. Necessary actions should be taken to avoid corrosion on the mating
housing arrangement.
The supporting structure for the electric machine must be such that the electric machine can be
mounted using its allowed mounting positions, see Chapter Allowed mounting positions.
The mounting space must be adequate for the electric machine mounting and possible auxiliary
components. See the length and the diameter data of the electric machine from the product drawing.
Main dimensions of the electric machine are shown in the Figure below (the illustration may differ from
the actual electric machine).
The electric machine has a SAE 1/2 D-end flange (IM 3001). A SAE 1/2 flywheel housing is required as
mating flange. The connection boxes are connected to N-end.
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Design principles
Main dimensions of the electric machine
Symbol Explanation
L
F
L
S
D
M
D
S
Length of the electric machine frame (including the connection box(es).
Length of the shaft (from the end of the shaft to the electric machine D-end mounting shoulder).
Diameter of the flange mounting bore circle.
Diameter of the mounting shoulder.
For all dimensions of the electric machine, see the product drawings.
Shaft alignment and load
Improper alignment (misalignment) may result in bearing overloads, premature bearing
failures, vibrations and shaft failures. Flexible coupling does not compensate for excessive
misalignment.
The type of the electric machine shaft is cylindrical shaft with diameter of 70 mm h7 and contact length
of 130 mm. The flange type is SAE 1/2 Transmission housing.
Alignment between the shaft and mating structure must be accurate.
The misalignment can be parallel or angular misalignment, or combination of those. With parallel
misalignment, the center lines of both shafts are parallel but they are offset. With angular misalignment,
the shafts are at an angle to each other. Figures below illustrate the parallel and angular misalignment.
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Design principles
Parallel alignment of the shaft and mating structure
Maximum parallel misalignment values
Non flexible coupling Flexible coupling
rpm mm mm
0-1000 0,07 0,13
1000-2000 0,05 0,10
2000-3000 0,03 0,07
3000-4000 0,02 0,05
4000-6000 < 0,02 0,03
Angular alignment of the shaft and mating structure
Maximum angular misalignment values
Non flexible coupling Flexible coupling
rpm 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
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Design principles
The maximum external force directed to the shaft axially and radially may not exceed
machine specific values. 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
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EM-PMI540-T2000
Transportation and storage
Transportation
Receiving and unpacking
Heavy equipment. Handle with care during transportation.
Electric machine is shipped in first class condition. It has been inspected and packed correctly to prevent
damage from ordinary handling during shipment. During transportation, shocks, fails and humidity
should be avoided. Protect the cooling holes for transportation.
The weight of the electric machine can be found on the machine rating plate, and in the product data
sheet.
Do not touch the electric machine during the insulation resistance check. Discharge the
electric machine afterwards.
Lifting
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.
Check upon arrival and unpacking
•
The electric machine and the package must be inspected immediately upon arrival. Make sure that
the rating plate data in the cover letter complies with the purchase order. Any external damage (in
shaft-ends, flanges, electrical interfaces and paint) must be photographed and reported immediately.
•
It is recommended to measure the insulation resistance of the electric machine upon arrival, or before
installing the electric machine. Reference value of 150 MΩ shall be exceeded in room temperature,
otherwise contact Danfoss representative. Refer to Chapter Insulation resistance test on page 31.
•
Remove any shaft locks and rotate the shaft. It is normal for the rotation of the shaft to be difficult.
Use correct, adequately dimensioned lifting devices and inspect them before lifting.
Do not lift from the shaft of the electric machine!
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Transportation and storage
Do not apply any excess weight on the electric machine when lifting.
Use correct lifting slings. Use correct position and angle of lifting.
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.
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EM-PMI540-T2000
Transportation and storage
Lifting lugs/eyes/points for lifting slings and lifting position of the electric machine
Storage
1 Lifting eye type of ANSI B18.15.1M M12x19 is recommended in M12 bores for horizontal and vertical lifting. Not
included in the delivery. Use the outmost lifting positions in horizontal lifting.
Horizontal lifting
Install 2 pieces of lifting eyes to the lifting bores in the electric machine frame. The lifting eyes should be
mounted with their full threaded length.
Vertical lifting
Install 4 pieces of lifting eyes to the lifting bores in the N-end bearing shield (non-shaft end). Lifting eye
should be mounted with its full threaded length.
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.
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Transportation and storage
Store the electric machine always indoors with the storage temperature above -20 ºC and the relative
•
humidity less than 60 %.
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.
The electric machine must not be subject to any external vibrations during storage to avoid damage
•
to the bearings.
Use anti-condensation heaters, if fitted, or direct winding heating to avoid water condensing in the
•
electric machine.
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.
Extended storage
Electric machines equipped with relubricable bearings: apply grease before and after long term storage.
It is recommended to inspect the electric machine in storage at periodic intervals. Use attached storage
checklist.
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.
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Installation
The following safety and information related symbols appear in this user guide and on the electric
machine.
Risk of electric shock when the connection box is open. When you work with power
connections make sure that electricity is disconnected and rotor rotation is prevented.
Magnetic and electromagnetic fields generated near the current-carrying conductors and
permanent magnets in electric machines represent a health danger to persons with heart
pacemakers, metal implants and hearing aids. Persons with a heart pacemaker, metal
implants or hearing aids must consult a doctor before they enter the following areas:
•
Areas in which electric equipment and parts are operated.
•
Areas in which electric equipment with permanent magnets are stored, mounted, operated
or repaired.
Risk of electric shock when working with the electric machine. Use isolated electric tools.
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.
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Installation
Required tools
Insulation resistance test
Following tools are required to install the electric machine:
•
Grease pump.
•
Ratchet torque wrench.
•
Hex head wrench kit with different metric sizes.
•
Socket wrench kit with different metric sizes.
•
Cable gland tightening tool. Size according to cable glands.
•
Cable skinning knife.
•
Crimping tool for cable lugs. Consult cable lug manufacturer for correct size.
•
Lifting slings with sufficient rated capacity.
•
Lifting eyes. Size according to machine type. See Chapter Lifting on page 26.
Do not touch the electric machine during the insulation resistance check. Discharge the
electric machine afterwards.
Mechanical installation
Measure the insulation resistance of the electric machine before and after the installation of
the electric machine.
Use a voltage of 500 V in the insulation resistance test.
Measure the insulation resistance of the electric machine before and after the installation of the electric
machine. Because of the structure of the electric machine, it is possible that the stator is damaged during
the installation.
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 VDC / 1 min Megger).
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. This applies to electric
machines with grease lubricated bearings.
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Installation
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.
Nominal allowed horizontal mounting position of the electric machine
Allowed deviations from the horizontal mounting limitations
Line type Meaning
Allowed deviations from the horizontal mounting limitations, continuous operation. (Depicted from
the shaft end.)
Allowed deviations from the horizontal mounting limitations, for the maximum duration of 30% of
the work cycle. (Depicted from the shaft end.)
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Installation
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.
Use the mounting foot rails only for additional support if needed.
Refer to Chapter Allowed mounting positions for the correct mounting positions of the electric
machine.
Mount the electric machine on a correct supporting structure as discussed in Chapter Supporting structure
requirements.
Horizontal assembly
1. Lift the electric machine to the correct mounting position. See Chapter Lifting for details.
2. The electric machine is mounted from its D-end flange (SAE1/2 transmission housing flange). SAE1/2
flywheel housing is required as a mating flange. If additional support is needed, use the mounting foot
rails on the side of the electric machine (4 pieces). For these mounting rails, use bolts of minimum
strength M10 8.8. and minimum 20mm thread engagement. See Chapter Tightening torques for details.
3. Align the electric machine with the mating housing alignment. See Chapter Shaft alignment and load.
4. Connect the shaft of the electric machine, make sure to use full spline engagement. Lubricate the
spline.
A recommended spline lubricant is a 50/50 compound of a high temperature grease and a
molybdenum disulphide powder. When applied initially and re-applied at proper intervals, it
will help prevent fretting corrosion and premature wear. This lubricant is not soluble in oil
and should be used accordingly. Further products which may be recommended are Molycote,
Metaflux, Never Seeze, Optimol and similar.
5. Attach the mounting bolts. For steel housing the minimum length of the bolt is 40 mm and for
aluminum housing 45 mm.
Use tightening torque of 69 Nm for D-end bolts. The N-end of the electric machine is not
intended to be used for mounting.
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Installation
Mechanical mounting connections of the electric machine (horizontal mounting)
1 Shaft of the electric machine; spline structure of the shaft (DIN5480 W55x2x30x26x8a).
2 D-end flange (SAE1/2) and bolt bores for mounting the electric machine (12 pieces).
3 Bores for the lifting eyes.
4 Mounting foot rails (see Main dimension drawing).
5 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.
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Installation
Mechanical mounting connections of the electric machine (vertical mounting)
1 Mounting foot rails (4 rails in 90º circular pattern around the frame).
2 Bores for the lifting eyes, N-end.
3 D-end flange (SAE1/2) and bolt bores for mounting the machine (12 pieces).
4 Shaft of the electric machine; spline structure of the shaft (DIN5480 W55x2x30x26x8a).
5 Mounting bolts (12 pcs of DIN912 M12 socket head). Not included in the delivery.
Cooling connections
Make sure that cooling liquid runs freely into and out from the electric machine.
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.
Connect the electric machine properly to the cooling circuit. Make sure that the coolant flow is equal or
higher than rated and the coolant temperature at the inlet of the machine cooling is lower or equal to the
rated temperature. For more information, see Chapter Recommended coolants and product data sheet.
Rated values can be found in the electric machine rating plate.
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Installation
Electrical installation
Aluminum frame water-cooled construction is only to be used with a closed fresh water circulation with
corrosive inhibitor described in the data sheet. The water cooling circuit connection is described in the
data sheet. Use only suitable and high-class connection parts and seals to connect the electric machine to
the water circuit. Check for possible leaks after the piping and joints have been connected.
Use only suitable and high-class connection parts and seals to connect the electric machine to the water
circuit. Check for possible leaks after the piping and joints have been connected.
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
(Loctite 577 or similar) at the coolant connections to prevent loosening. Loosening can be caused by
vibration or temperature variations.
The electric machines are equipped with at least three PT100 temperature sensors in the windings. The
amount of the sensors depend on the options chosen. The temperature signal(s) can be read out from
the measurement connector of the machine.
You can connect the temperature signal to the temperature monitoring pin in the inverter (EC-C) and
make sure that the inverter has the electric machine temperature protection feature activated.
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.
When installing the connection box lid, make sure there are no foreign particles between the
connection box lid and the insulation and that all connection box fasteners are in place.
Missing or loose screws can compromise the insulation.
Make sure the power cables exit straight from the terminals and do not rub against the sharp
cable through-holes or other sharp edges which could wear out the cable insulation over
time.
Do not place any excess weight on the connection box lid(s).
The high voltage cables of the electric machine are connected to the connection box(es) of the electric
machine. The Figure below shows the components of the high voltage connection box assembly.
Remove the cover of the terminal box.
1.
Install the power cables.
2.
Install the cover of the terminal box back.
3.
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Installation
High voltage connection assembly structure
1 Mounting bolts (7 pcs) for coverplate
2 Connection box cover plate
3 Connection box cover plate gasket
4 Mounting bolts (4 pcs) for connection box
5 Connection box frame
6 Cable glands (3 pcs / connection box)
7 Insulation sheet
8 Phase connection points (L1, L2, L3) for one phase
9 Low voltage (measurement) and anti-condensation heater connection part (see Chapters Low
voltage connections on page 44 and Anti-condensation heater connections on page 51)
10 Connection box gasket
The Figure below illustrates the connection box from the inside. The power connections are located in
the upper part of the connection box. The lower part incorporates the low voltage signal cablings
(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 on
page 44 and Anti-condensation heater connections on page 51.
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Installation
Inside view of the machine connection box
The connection box(es) of the electric machine are in fixed position and cannot be rotated or changed
with each other.
Leave the connection box cover plate open for further electrical assembly as instructed in Chapter Cable
gland assembly and power line connection on page 39.
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.
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.
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Installation
Connection diagram for DUAL option
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.
This Chapter describes how to assemble screened power cables to the electric machine. See the cable
glands recommendations from the 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.
Cable gland alternatives
Cable diameter
Cable gland 35 mm
Pflitcsh blueglobe mstri225 x x
Pflitcsh blueglobe mstri232 x x
2
50 mm
2
70 mm
x
2
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
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Installation
Blueglobe cable gland tightening torques (continued)
Metric thread Nominal torque
M63x1,5 35,0 Nm
M75x1,5 80,0 Nm
M85x2,0 100,0 Nm
Remove the small hexagonal piece from the BlueGlobe-sealing insert as shown in Figure below.
1.
BlueGlobe-sealing
Cut the cable sheath at the distance A from the end of the cable, see Figure below. Pull the cut part of
2.
the sheath partly (length B is from 10 to 15 mm) off the cable as shown in the Figure. The distance A
depends of the length of the cable lug used. 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.
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.
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
™
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Installation
Insert the cable to the cable gland with slight turning motion. This helps the cable to go through the
3.
spring inside the cable gland. Push the cable gland against the sheath of the cable as shown in Figure
below.
Cable to the gland assembly
After the cable gland is in place remove the length A piece of the sheath and cut the braid screen
4.
(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.
Cut the braid screen
Cut a piece of length D of the inner sheath shown below in the Figure Cutting the inner sheath. The
5.
length D must equal to the length of the cable lug body.
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Installation
Cutting the inner sheath
Make sure that the conducting strands of the cable are completely free of silicone and other
6.
impurities. Put the cable inside the cable lug body, and crimp the cable lug twice in different places.
See Figure below.
Connecting cable lug
Cut piece of shrink tube and shrink it over the cable lug and braid screen as shown in Figure below.
7.
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.
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Installation
Shrink tube
Insert the cable through the corresponding hole in the connection box and connect the cable lug to
8.
the connection point. Use spring washer between the cable lug and the connection screw or nut.
Example of the connection is shown in Figure below. Do not tighten the connection at this point to
ensure fitting of the cable gland.
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.
Cable lug connection to the connection box (example only, the connection box may look different)
Screw the cable gland to the connection box as shown in the Figure above. Tighten the cable gland
9.
from the body of the gland. See Chapter Tightening torques.
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.
Tighten the cable lug. Use tightening torque of 15 Nm.
10.
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Installation
Repeat the procedure to the other cables and connection box (if the machine includes DUAL or TRI
11.
option).
Check that the phase connections order in the connection box is correct, that is, the corresponding
12.
phases between the inverter and the machine are connected (U, V, W correspond to the L1, L2, L3
phases).
Close the connection box. Tighten the connection box cover screws. See Chapter Tightening
13.
torques. Use thread locking compound that makes it possible to remove the screws. (For example
Loctite 221).
If you must connect the anti-condensation heater, you can leave the connection box open. See Chapter
Anti-condensation heater connections on page 51.
Check the power cable shield grounding, see Chapter Grounding connections.
Low voltage connections
Plug the unused socket holes of the low voltage connector with suitable plugs:
•
DEUTSCH 0413-003-1605 (size 16)
•
DEUTSCH 0413-204-2005 (size 20)
See more information and instructions about DEUTSCH connectors at https://
www.deutschconnector.com/.
The electric machine has a connector or a connection box which is used to read out in-built temperature
and rotation sensor (resolver) data from the electric machine. The temperature data comes from PT100
sensors in the stator windings and in some cases in the bearings. The rating plate has the information
about the options of the electric machine: different options add sensors, and some electric machines do
not have all the sensors. 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)
Location of the low voltage connectors in the connection box (N-end)
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Installation
1 Low voltage (measurement signal) connector including winding temperature sensors (PT100) and resolver
connections
2 Bearing temperature measurement sensor (PT100) connector in the N-end of the electric machine
3 Inlet (cable gland) for anti-condensation heater cable (see Chapter Anti-condensation heater connections on page
51)
Low voltage connector details
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 Deutch HD34-24-47PE connector
Measurement Description PIN
Temperature 1 Temperature 1, PT100 (P), windings 47
Temperature 1, PT100 (N), windings 46
Temperature 2 Temperature 2, PT100 (P), windings 33
Temperature 2, PT100 (N), windings 32
Temperature 3 Temperature 3, PT100 (P), windings 45
Temperature 3, PT100 (N), windings 31
Temperature 4 Temperature 4, PT100 (P), windings, option TEMP4 + TEMP5 30
Temperature 4, PT100 (N), windings, option TEMP4 + TEMP5 29
Temperature 5 Temperature 5, PT100 (P), windings, option TEMP4 + TEMP5 44
Temperature 5, PT100 (N), windings, option TEMP4 + TEMP5 43
Temperature 6 Temperature 6, PT100 (P), windings, option TEMP4 + TEMP5 28
Temperature 6, PT100 (N), windings, option TEMP4 + TEMP5 16
Temperature 7 Temperature 7, PT100 (P), windings, option TEMP5 42
Temperature 7, PT100 (N), windings, option TEMP5 27
Temperature 8 Temperature 8, PT100 (P), windings, option TEMP5 15
Temperature 8, PT100 (N), windings, option TEMP5 14
Temperature 9 Temperature 9, PT100 (P), windings, option TEMP5 40
Temperature 9, PT100 (N), windings, option TEMP5 26
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Installation
Pin configuration of the Deutch HD34-24-47PE connector (continued)
Measurement Description PIN
Temperature 10 Temperature 10, PT100 (P), windings, option TEMP5 41
Temperature 10, PT100 (N), windings, option TEMP5 13
Temperature 11 Temperature 11, PT100 (P), windings, option TEMP5 39
Temperature 11, PT100 (N), windings, option TEMP5 38
Temperature 12 Temperature 12, PT100 (P), windings, option TEMP5 25
Temperature 12, PT100 (N), windings, option TEMP5 12
Resolver COS_N Resolver, RES_COS_N, in-built non contacting 35
Resolver COS_P Resolver, RES_COS_P, in-built non contacting 20
Resolver SIN_N Resolver, RES_SIN_N , in-built non contacting 36
Resolver SIN_P Resolver, RES_SIN_P , in-built non contacting 21
Resolver EXCN Resolver, EXCN, in-built non contacting 22
Resolver EXCP Resolver, EXCP, in-built non contacting 10
Resolver shield Resolver, SHIELD/GROUND, in-built non contacting 34
Bearing temperature measurement connector (optional), both ends of electric machine
1 PT100 pin
2 PT100 pin
3 PT100 ground pin
4 PT100 ground pin
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Installation
Low voltage connection box details
Pin configuration of LV connections (+LVB1 option)
PIN Description
1
2
3
4
5
6
7
8
9
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Heater, phase, 230 V
Heater, neutral
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
AC
User Guide
EM-PMI540-T2000
Installation
Pin configuration of LV connections (+LVB1 option) (continued)
PIN Description
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35 Resolver, SHIELD/GROUND, in-built non-contacting (+RES1 option)
36
37
38 Reserve
39 Reserve
NA D-end bearing temperature sensor with separate connector (+BTMP1 option)
Temperature 3, PT100 (N), windings
Temperature 4, PT100 (P), windings (+TEMP4 option)
Temperature 4, PT100 (N), windings (+TEMP4 option)
Temperature 5, PT100 (P), windings (+TEMP4 option)
Temperature 5, PT100 (N), windings (+TEMP4 option)
Temperature 6, PT100 (P), windings (+TEMP4 option)
Temperature 6, PT100 (N), windings (+TEMP4 option)
Temperature 7, PT100 (P), windings (+TEMP5 option)
Temperature 7, PT100 (N), windings (+TEMP5 option)
Temperature 8, PT100 (P), windings (+TEMP5 option)
Temperature 8, PT100 (N), windings (+TEMP5 option)
Temperature 9, PT100 (P), windings (+TEMP5 option)
Temperature 9, PT100 (N), windings (+TEMP5 option)
Temperature 10, PT100 (P), windings (+TEMP5 option)
Temperature 10, PT100 (N), windings (+TEMP5 option)
Temperature 11, PT100 (P), windings (+TEMP5 option)
Temperature 11, PT100 (N), windings (+TEMP5 option)
Temperature 12, PT100 (P), windings (+TEMP5 option)
Temperature 12, PT100 (N), windings (+TEMP5 option)
Resolver, RES_COS_N, in-built non-contacting (+RES1 option)
Resolver, RES_COS_P, in-built non-contacting (+RES1 option)
Resolver, RES_SIN_N, in-built non-contacting (+RES1 option)
Resolver, RES_SIN_P, in-built non-contacting (+RES1 option)
Resolver, EXCN, in-built non-contacting (+RES1 option)
Resolver, EXCP, in-built non-contacting (+RES1 option)
Temperature, PT100 (P), bearings N-end (+BTMP1 option)
Temperature, PT100 (N), bearings N-end (+BTMP1 option)
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.
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Installation
Ground the cable shields of the low voltage 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.
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
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Installation
Low voltage cable grounding points
Power cable grounding through the cable gland
Testing the power cable shield grounding (earthing)
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Installation
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.
1.
Connect one terminal of the measurement device to the cable shield of one power cable (in the
inverter end of the cable)
2.
Connect the other terminal of the measurement device to the cable shield of an other power cable.
You can also use the machine enclosure grounding point for the measurement.
3.
Measure the resistance between the two cable shields or between the cable shield and the enclosure
grounding point.
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)
The low voltage (measurement signal) cable shield connects to the ground through the connector
grounding/earthing pins. After cable installation, and any time when needed, make sure that the
grounding (earthing) connection is valid.
1.
Connect one terminal of the measurement device to the low voltage cable shield (in the nonmachine end of the cable).
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.
Anti-condensation heater connections
Do not run the electric machine when an anti-condensation heater is in use.
Water condensing inside the electric machine enclosure can result in failure or corrosion of the electric
machine. This often happens in cooler temperatures or higher humidity areas typically in marine
environment, when the machine is not running.
The electric machine can be equipped with anti-condensation heater to avoid condensation issues. The
anti-condensation heater (+HEAT1) or heaters (+HEAT2) are factory assembled. The installed heater may
not be used when the electric machine mains are switched on or when the electric machine is running.
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.
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Installation
Anti-condensation heater connector
1 Anti-condensation heater connector (inside the connection box)
2 Inlet and cable gland for the anti-condensation heater cable
After the installation of the electric machine, and any time when needed, the resistance of the warming
element can be measured. 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.
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Operation
Only trained and qualified personnel familiar with the relevant safety requirements are
allowed to operate the electric machine.
Do not use the electric machine without properly dimensioned and operating cooling system.
Maximum operation temperature, current and rotational speed of the electric machine must
not be exceeded to avoid permanent damage.
The surface of the electric machine might be hot. Do not touch the electric machine during
operation.
Entanglement hazard! Do not touch the electric machine during operation.
Use the anti-condensation heater, if fitted, when the electric machine is not in use. This
prevents condensation and possible damage to the electric machine.
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.
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Operation
Operation conditions
The electric machine should be used for its intended purpose only and within limits specified by the
manufacturer, concerning:
•
Loading.
•
Cooling.
•
Speed range.
•
Service interval.
•
Ambient condition such as temperature and moisture.
The electric machine is designed for the following conditions:
•
Ambient temperature limits: -40°C ...+65 °C.
•
Maximum altitude 1000 m above sea level.
•
Maximum coolant liquid temperature at the inlet of the coolant circuit, see product data sheet.
•
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
Recommended lubricants
Supervise the electric machine during operation to make sure that the electric machine
operates correctly and has a designed lifetime.
If you notice any deviations from the normal operation, for example elevated temperatures,
noise or vibration, stop the electric machine. Find the reason for the deviation and repair the
electric machine. Refer to Chapter Troubleshooting on page 63.
Maximum temperature of the bearings of the electric machine is:
120°C.
The maximum allowed winding temperature of the electric machine is shown on the rating
plate and in the data sheet.
Do not mix different types of greases!
Greased for life bearings do not need relubrication during their lifetime. Grease relubricable bearings
(BHS option) need regular greasing. For further information, see Chapter Bearings and lubrication on page
59.
The recommended grease type for the machine bearings is SKF LGHP-2 or equivalent. LGHP-2 is high
performance, high temperature bearing grease. For further information, see http://www.skf.com/.
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Operation
Recommended coolants
Ethylene glycol is a toxic compound. Avoid exposure to the coolant.
Copper ions concentration of more than approx. 0.06 ppm causes copper induced pitting
corrosion. Do not use copper components in the cooling system.
Hard piping made of metal is recommended for the coolant instead of soft piping as rubber
hoses.
Use correct personal protective equipment when you handle the coolant.
Emergency operation
The electric machines are designed to work properly with water based coolant. Plain water with
appropriate corrosive inhibitor is acceptable, for example 50 % water- 50 % glycol coolant.
Glycol coolant options:
Ethylene glycol based Glysantin® G48® (includes also corrosion inhibitors).
•
Propylene glycol based coolants, like Splash® RV&Marine antifreeze.
•
The electric machine should be operated within the operation limits and in the conditions specified by
the manufacturer. However, it can be used with some limitations in the following fault/emergency
situations.
Cooling of the electric machine fails
The cooling system failure can be caused by dregs (sediment) accumulating to the cooling system tubes.
Try opening the possible blockage by changing the coolant flow direction. See also Chapter Cooling
system maintenance.
If the cooling of the electric machine fails, limited operation is still possible with no coolant flow. The
operation speed must be limited to half (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. The temperature signals can be read out from the measurement connector of
the electric machine, and connect to the temperature surveillance pin in the inverter for example. In case
of a temperature measurement sensor failure in the electric machine, an additional PT100 sensor can be
mounted close to the end of the windings at the low voltage (measurement signal) cable opening inside
the connection box.
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Operation
1. Remove the connection box cover.
2. Mount (glue) an additional PT100 temperature sensor close to the end of the windings at the opening
where the signal cables are routed inside the electric machine enclosure (inside the connection box
lower part). Use resin/glue specified for correct temperatures (Temp.class in the rating plate, class F /
155ºC).
3. Connect the PT100 sensor to the low voltage connector (replace the failed sensor connection by the
new connection).
4. Remount the connector box cover.
When reading the temperature (resistance) values from the additional sensor, add +15ºC to the
measured value. 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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Maintenance
This Chapter contains necessary information for the qualified and trained personnel to carry out regular
maintenance work.
Do not disassemble the electric machine. Only procedures described in this user guide may be
done.
Only trained and qualified personnel familiar with the relevant safety requirements are
allowed to do maintenance to the electric machine.
Risk of electric shock when the connection box is open.
Voltage may be connected to the anti-condensation heater.
Use correct personal protective equipment when you are near the electric machine.
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. Use the Storage, installation and maintenance
checklists on page 68.
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Maintenance
Do not attempt to tighten bolts or screws that are not discussed in this user guide and that are
not needed for normal installation and maintenance procedures. The sealing of the bolts and
screws can break.
Correct supervision and maintenance of the electric machine makes sure that the electric machine has
reliable operation and designed lifetime.
Maintenance schedule
Object Check/Task Weekly Monthly Yearly
General construction Operation Noise, vibration. If clearly increased, contact Danfoss. X
Mounting 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. X
Enclosure and
connected parts
Shaft seals Check the wear. Replace if necessary. X
Electrical system Cables Wearing of the cables. Replace if necessary. X
Electrical connections Check connections. Make sure that tightening torque is correct for the
Groundings (earthings) Check groundings (earthings). Make sure that the connection resistance is
Anti-condensation
heater
Cooling system Operation Functioning. Cooling system functions as specified. X
Tubing and connection
tightness
Ventilation plug Cleanliness. Clean if necessary. See Chapter Cleaning. X
Coolant flow Coolant flow direction. It is recommended to change the coolant flow
Coolant quality Coolant as specified. Correct glycol used, and water/glycol mixture
Lubrication Relubrication (+BHS
option)
Check cleanliness. Clean if necessary. See Chapter Cleaning. X
cable glands. See Chapter Tightening torques.
correct. Re-connect if necessary.
Check anti-condensation heater connections and resistance, if the option
is installed. If needed, contact Danfoss.
No visible leakage. If leaking, tighten the connections, or replace parts. X
direction by changing the connections or flow direction from the pump.
See Chapter Cooling system maintenance.
correct. Refill if necessary. See Chapter Cooling system maintenance.
Relubricate depending on the use (see Chapter Bearings and lubrication),
if the option has been installed. Maximum relubrication interval is six
months.
X
X
X
X
x
X
X
Cleaning
Never open or remove the watertight ventilation plugs. Clean them only from the outside.
Risk of electric shock if the electric machine is cleaned against instructions allowing water to
go in to the electric machine.
Keep the electric machine clean. For cleaning, use non-abrasive and non-corrosive cleaning products.
Make sure that the detergent may be used for aluminum.
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Maintenance
When pressure washing the electric machine, make sure that the water spray does not directly hit the
gaskets.
Ventilation plugs
Bearings and lubrication
Grease relubricable bearings
The grease relubricable bearings need regular greasing. Follow the relubrication interval and
instructions described in this Chapter.
Grease can cause skin irritation and eye inflammation. Follow all safety precautions specified
by the manufacturer of the grease.
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.
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Maintenance
It is recommended to have a piping for the grease exiting the electric machine. The grease
exit hole is often in an inconvenient location when the electric machine is installed.
The bearing type for electric machine with option +BHS is 6214/C3 (non-insulated bearings) or 6214/C3
HC5 (insulated bearing). See the recommended lubricant in Chapter Recommended lubricants on page
54.
Bearing relubrication
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.
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.
The maximum relubrication interval in operation is six months. The amount of grease per
relubrication is 20 g.
The relubrication interval depends on the used rotation speed and bearing temperature, and is
presented in the Figure below. The different curves represent different bearing temperatures. The higher
the temperature is and the higher the rotation speed is, the lower the relubrication interval is.
Relubrication interval of the machine (BHS option) compared to rotation speed and bearing temperature
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Maintenance
Relubrication interval of the machine (BHS option) compared to rotation speed and bearing temperature,
vertical installation
Cooling system maintenance
For more information about the location of grease nipples and grease escape holes, see
Chapter Connections and interfaces on page 16.
Bearing relubrication:
It is normal if no grease exits the electric machine. This is because the cavities inside the
electric machine can hold a lot of grease.
Make sure that the electric machine has reached its operating temperature.
1.
Remove the plugs from the grease escape holes.
2.
Open the grease nipple plugs.
3.
Use grease piston to enter specific amount of grease into the grease nipple.
4.
If possible, let the electric machine run approximately one hour to let the old grease exit.
5.
Install the plugs on the grease nipples and on the grease escape holes.
6.
The electric machine cooling system requires certain regular maintenance activities.
It is recommended to change the direction of the coolant liquid flow yearly. This is done by changing the
order of the coolant connections, or changing the coolant pump direction. The reason for changing the
coolant flow direction is to prevent possible dregs (sediment) accumulating to the cooling system.
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.
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Dismounting
Make sure that the mating structure is not damaged. Do not pluck any bores or use at headed
bolts or rods for pushing the electric machine out of the mating structure.
For dismounting the electric machine, follow the Steps below.
1. Prepare the electric machine for lifting, for more information refer to Chapter Lifting on page 26.
Support the electric machine with lifting slings when dismounting.
2. Loosen the mounting bolts. For more information refer to Chapter Mounting the electric machine on
page 33.
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.
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Troubleshooting
Some difficulties may occur while operating the electric machine. Possible causes and actions are given in
the Table below. If the situation occurs, it should be corrected as soon as possible. These instructions do
not cover all details or variations in the equipment nor provide information for every possible condition
to be met in connection with installation, operation or maintenance.
For more information, contact Danfoss service at https://danfosseditron.zendesk.com/hc/en-gb or send
email to editron.service@danfoss.com.
Troubleshooting chart
Symptom Possible cause Action
Excessive vibration, noise Imbalance at the connected electric
machine or the powertrain components.
Misalignment between the electric
machine and the used device.
Attachment bolts are loose. Replace and tighten the bolts.
Clearance at the spline connection. Check the spline connection.
Imbalance at the electric machine. Contact Danfoss.
Particles inside the electric machine.
Bearing damage.
Inadequate lubrication (electric machine
with BHS option).
Bearing temperature rise Inadequate lubrication (electric machine
with BHS option).
Too much grease at the bearing housing
(electric machine with +BHS option).
Incorrect bearing grease. Check that the used grease is of correct type.
Incorrect radial lip seal. Check that the correct type of radial lip seal is used.
Overloaded bearing. Check that the system is not causing excess force or vibration to the
Bearing damage. Contact Danfoss for further information.
Electric machine overheating Overload. Reduce load. Check the electric machine model description and rating
Cooling system failure. Check the cooling system integrity, flow and fluid temperature.
Leakage in the cooling system. Check the cooling system circuit and connections.
Rigid particle inside the machine cooling
channel.
Wrong machine parameters in the
inverter.
Winding short circuit. Replace the electric machine.
Significant lubricant leak Worn radial lip seal. Contact Danfoss.
Block at the grease outlet channel. Clean the grease escape channel from solidified grease using brush if
Check the balance and installation of the actuator and drivetrain
components.
Check the connections and couplings.
Apply bearing lubricant/grease. See Chapter Bearings and lubrication .
Contact Danfoss for further information.
Apply bearing lubricant/grease. See Chapter Bearings and lubrication.
Open grease escape valve and let the electric machine run for 10 min.
Clean the grease escape channel from solidified grease using brush if
necessary.
machine bearings.
plate, check the inverter limits.
Change the cooling flow direction to flush the cooling system from
sediment possibly accumulated. See Chapter Emergency operation.
Try pulsating coolant to open the channels. Contact Danfoss.
Check and correct the machine parameters from the inverter.
necessary.
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Troubleshooting
Troubleshooting chart (continued)
Symptom Possible cause Action
Electric machine does not work
properly or the performance is
poor
Anti-condensation heater failure The heater element is faulty. Measure the resistance of the heater element. See Chapter Anti-
Temperature measurement failure The PT100 sensor is faulty. Measure the resistance of the PT100 sensor, see Chapter Low
Wrong electric machine parameters in
the inverter.
Demagnetization of magnets due to
overheating.
Bearing fault. Check the bearings, lubrication and conditions.
Insulation fault. Measure the insulation resistance, refer to the manufacturer limits. See
Check and correct the electric machine parameters from the inverter.
Measure the winding resistance, refer to manufacturer data. Replace the
electric machine if necessary.
Chapter Insulation resistance test. Replace the electric machine if
necessary.
condensation heater connections on page 51. If the heater is faulty,
contact Danfoss.
voltage connections. If the sensor is faulty, read out the signal from
another sensor. Contact Danfoss. See Chapter Emergency operation.
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Aftersales
Service policy
Service parts
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 on page 65.
For further information, go to https://danfosseditron.zendesk.com/hc/en-gb or send email to
editron.service@danfoss.com.
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
Part number Item (order)
1 10945 1 Seal, O-ring 208 X 4 NBR70
2 10974 1 Seal, Radial lip, D-end 65 X 90 X 10 FKM, TRELLEBORG,
3 10935 1 Standard bearing and with +BIN option. D-
3 11093 1 Bearing with +BIA option. D-end, insulated
4 10242 1 Seal, O-ring 124,5 X 3 NBR70
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number
Qty Description Type
TREB00650-VCBVR
6214 C3
end, non-insulated deep groove ball
bearing
6214 C3 HC5 (hybrid bearing)
deep groove ball bearing
User Guide
EM-PMI540-T2000
Aftersales
Part number Item (order)
number
5 10546 2 Grease nipple (both in D-end and N-end) DIN 71412, M10 x 1
6 10473 6 Cable gland (power connections), DUAL
7 10935 1 Standard bearing. N-end, non-insulated
7 11093 1 Bearing with +BIN and +BIA options, N-
8 10451 1 Seal, O-ring 184.5 X 3 NBR70
9 10242 1 Seal, O-ring 124,5 X 3 NBR70
10 10349 7 Plug for Grease escape hole (both in D-end
11 10358 1 Ventilation plug PMF 100444 Metal Vent
Qty Description Type
M32 X 1.5, BG PFLITSCH
(two connection boxes)
6214 C3
deep groove ball bearing.
6214 C3 HC5 (hybrid bearing)
end, insulated deep groove ball bearing.
M16 x 1.5 , VSTI16X1.5SED71
and in N-end) (horizontal and radial holes)
The bearing type depends on the Bearing insulation option selected.
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Disposal
Dispose of the electric machine and any of its parts by appropriate means in accordance with local laws
and regulations.
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Storage, installation and maintenance checklists
Electric machine installation 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:
N.A = Procedure not applicable PASS = Procedure passed FAIL = Procedure failed
Installation checklist
Approval N.A PASS FAIL
General
Electric machine type is correct ☐ ☐ ☐
Electric machine is
undamaged
Insulation resistance check
(Reference value of 150 MΩ
should not be exceeded at
reference ambient
temperature 25°C (measured
with 500 VDC / 1 min
Megger))
Environmental conditions as
specified (see data sheet)
>150MΩ ☐ ☐ ☐
☐ ☐ ☐
☐ ☐ ☐
Mechanical installation
Supporting structure as required ☐ ☐ ☐
Shaft alignment as specified (see chapter Shaft alignment
and load).
Cooling circuit connected
and coolant flowing
Used coolant:
Power connections
Cable gland assembly as specified (cable gland to cables)
with correct cable diameter
Cable lug air cap (to metallic
structures)
Cable lug tightening torque
(to the busbar)
Connection box cover bolts
tightening torque
Grounding
Electric machine enclosure grounding connected ☐ ☐ ☐
Low voltage cable shield grounding connected ☐ ☐ ☐
Power cable shield connection resistances to ground
(electric machine enclosure) measured and valid
≥10 mm ☐ ☐ ☐
13 Nm ☐ ☐ ☐
4 Nm ☐ ☐ ☐
☐ ☐ ☐
☐ ☐ ☐
☐ ☐ ☐
☐ ☐ ☐
68 | © Danfoss | July 2021 BC265857530809en-000202
User Guide
EM-PMI540-T2000
Storage, installation and maintenance checklists
Installation checklist (continued)
Approval N.A PASS FAIL
Low voltage cable shield grounding resistances measured
and valid
Notes:
•
•
•
•
•
•
•
•
•
•
•
•
•
Date:
Signature:
☐ ☐ ☐
Do not try to tighten bolts or screws that are not discussed in the product manual and that are not
needed for the normal installation procedures. Sealing of the screws may break.
Electric machine weekly maintenance 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:
N.A = Procedure not applicable PASS = Procedure passed FAIL = Procedure failed
Electric machine weekly maintenance checklist
N.A PASS FAIL
General construction
Noise or vibration during operation
in general
Cooling system
☐ ☐ ☐
©
Danfoss | July 2021 BC265857530809en-000202 | 69
User Guide
EM-PMI540-T2000
Storage, installation and maintenance checklists
Electric machine weekly maintenance checklist (continued)
N.A PASS FAIL
Functioning of the cooling system in
general
Notes:
☐ ☐ ☐
•
•
•
•
•
•
•
•
•
•
•
•
Electric machine monthly maintenance 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:
N.A = Procedure not applicable PASS = Procedure passed FAIL = Procedure failed
Electric machine monthly maintenance checklist
N.A PASS FAIL
General construction
Noise or vibration during operation
in general
Cleanliness of the enclosure and
connected parts
Electrical system
Weariness of the cables ☐ ☐ ☐
Insulation resistance
(If the electric machine is in
continuous use, it is recommended
to do the insulation resistance test
every three or four months.)
Cooling system
Functioning of the cooling system in
general
Tightness of the ventilation plug ☐ ☐ ☐
☐ ☐ ☐
☐ ☐ ☐
☐ ☐ ☐
☐ ☐ ☐
70 | © Danfoss | July 2021 BC265857530809en-000202
User Guide
EM-PMI540-T2000
Storage, installation and maintenance checklists
Electric machine monthly maintenance checklist (continued)
N.A PASS FAIL
Cleanliness of the ventilation plug ☐ ☐ ☐
Notes:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Electric machine yearly maintenance 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:
N.A = Procedure not applicable PASS = Procedure passed FAIL = Procedure failed
Electric machine yearly maintenance checklist
Acceptance N.A PASS FAIL
General construction
Noise or vibration during operation in general ☐ ☐ ☐
Mounting bolt tightness
Cleanliness of the enclosure and connected parts ☐ ☐ ☐
Electrical system
Weariness of the cables ☐ ☐ ☐
Electrical connections in general ☐ ☐ ☐
Cable lug tightening torque
(to the busbar)
Connection box cover bolts
tightening torque
Cooling system
Coolant flow direction changed and connection checked ☐ ☐ ☐
Coolant quality as specified ☐ ☐ ☐
Used coolant:
Functioning of the cooling system in general ☐ ☐ ☐
Tightness of the tubing and connections (no leakages) ☐ ☐ ☐
13 Nm ☐ ☐ ☐
4 Nm ☐ ☐ ☐
©
Danfoss | July 2021 BC265857530809en-000202 | 71
User Guide
EM-PMI540-T2000
Storage, installation and maintenance checklists
Electric machine yearly maintenance checklist (continued)
Acceptance N.A PASS FAIL
Cleanliness of the ventilation plug ☐ ☐ ☐
Grounding
Power cable shield connection resistances to ground
(electric machine enclosure) checked
Low voltage cable shield grounding resistances checked ☐ ☐ ☐
Notes:
☐ ☐ ☐
•
•
•
•
•
•
•
•
•
•
•
•
•
Do not try to tighten bolts or screws that are not discussed in the product manual and that are not
needed for the normal installation procedures. Sealing of the screws may break.
For cleaning instructions, refer to Chapter Cleaning on page 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
User Guide
EM-PMI540-T2000
Storage, installation and maintenance checklists
Electric machine and customer information
Customer: Electric machine type (from the rating plate):
Customer reference: Electric machine serial number:
Service reference: Date installed:
This storage checklist is used when storing the electric machine. Regular inspection is required. See
specifications for storage in this User Guide or in the Data Sheet.
Fill in the date of each inspection to the Table below.
Storage checklist
Procedure Date Date Date Date 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
Danfoss
Power Solutions GmbH & Co. OHG
Krokamp 35
D-24539 Neumünster, Germany
Phone: +49 4321 871 0
Danfoss
Power Solutions ApS
Nordborgvej 81
DK-6430 Nordborg, Denmark
Phone: +45 7488 2222
Danfoss
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2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515 239 6000
Danfoss
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(Shanghai) Co., Ltd.
Building #22, No. 1000 Jin Hai Rd
Jin Qiao, Pudong New District
Shanghai, China 201206
Phone: +86 21 2080 6201
Products we offer:
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www.hydro-gear.com
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www.daikin-sauer-danfoss.com
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•
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•
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Electric converters
•
Electric machines
•
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•
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•
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•
Hydraulic integrated
•
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•
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Position controls and
•
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Telematics
•
Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and
electric components. We specialize in providing state-of-the-art technology and solutions
that excel in the harsh operating conditions of the mobile off-highway market as well as the
marine sector. Building on our extensive applications expertise, we work closely with you to
ensure exceptional performance for a broad range of applications. We help you and other
customers around the world speed up system development, reduce costs and bring vehicles
and vessels to market faster.
Danfoss Power Solutions – your strongest partner in mobile hydraulics and mobile
electrification.
Go to www.danfoss.com for further product information.
We offer you expert worldwide support for ensuring the best possible solutions for
outstanding performance. And with an extensive network of Global Service Partners, we also
provide you with comprehensive global service for all of our components.
Local address:
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Danfoss | July 2021 BC265857530809en-000202
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