Danfoss EM-PMI240, User Manual

Page 1: ...User Guide Motor Generator EM PMI240 danfoss com...

Page 2: ...d technology 3 3 System introduction 3 4 Connections and interfaces 3 5 Rating plate 3 6 Tightening torques 4 Design principles 4 1 System design 4 1 1 Cooling and temperature measurement 4 1 2 Insula...

Page 3: ...Recommended lubricants 7 4 Recommended coolants 7 5 Emergency operation 8 Maintenance 8 1 Regular maintenance 8 2 Cleaning 8 3 Bearings and lubrication 8 4 Cooling system maintenance 9 Dismounting 10...

Page 4: ...Revision Information 1 First revision 2 Bearing type added EM PMI240 BC355256345493en 000103 Danfoss Produced By Danfoss Power Solutions September 2020 3...

Page 5: ...intenance This manual uses illustrations as examples only Illustrations in this manual may not necessarily re ect all system features Product naming convention Frame model indicates dimensions and ele...

Page 6: ...001 Rotating electrical machines Part 7 Classi cation of types of construction mounting arrangements and connection box position IM Code IEC 60034 8 2007 A1 2014 Rotating electrical machines Part 8 Te...

Page 7: ...d from the machine resolver deg GND Ground in electrical connections Ohm Resistance Table 5 Term abbreviation Term Abbreviation Explanation Resolver Rotation meter in electric machines used for measur...

Page 8: ...thorized 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 manual The elec...

Page 9: ...on 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 a...

Page 10: ...e 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...

Page 11: ...r 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...

Page 12: ...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 machi...

Page 13: ...syncronous permanent magnet machine the rotation of the rotor shaft is syncronized with the frequency of the power supply current The reluctance technology maximizes the pull out torque of the machin...

Page 14: ...machine type and the option chosen The heater is used to prevent any water condensing inside the machine enclosure Connections and interfaces The electric machines are connected mechanically and elec...

Page 15: ...used for grounding 4 Cooling liquid bores G 3 4 5 Low voltage connector DEUTSCH HD34 24 47PE 6 Phase connections AMPHENOL HVBI005R10AMHARD 7 Connector locking plate mechanical safety feature 8 Bearin...

Page 16: ...ording 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 Qc Rated coolant liquid ow l min Pole pairs Number of magneti...

Page 17: ...ndividual insulation materials of the insulation according to IEC60034 1 Bear D end Bearing type in the D end of the machine Bear N end Bearing type in the N end of the machine Max pressure Cooling li...

Page 18: ...achine 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 m...

Page 19: ...n Danfoss Editron the electric machine performance may di er from rated values The optimum performance of the electric machine is obtained with Danfoss Editron inverters These inverters are Compact an...

Page 20: ...angement of the electric machine must be secure and su ciently rigid to prevent vibrations and mechanical failures Necessary actions should be taken to avoid corrosion on the mating housing arrangemen...

Page 21: ...ection counterpart is of type SAE 6 Mating transmission housing ange Alignment between the shaft and mating structure must be accurate The misalignment can be parallel or angular misalignment or combi...

Page 22: ...m angular misalignment values Non exible 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 The maximum...

Page 23: ...Figure 10 External shaft forces of the electric machine EM PMI240 4 Design principles 22 Danfoss Produced By Danfoss Power Solutions September 2020 BC355256345493en 000103...

Page 24: ...e rotated 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 pu...

Page 25: ...machine Lifting eye type RS M8 0 20t 2 pcs Horizontal lifting Install 2 pieces of lifting eyes to the lifting bores of the electric machine frame Mount the lifting eyes with their full threaded lengt...

Page 26: ...eal 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...

Page 27: ...s 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...

Page 28: ...tact Danfoss representative if the reference value is not exceeded Mechanical installation Allowed mounting positions If the application is a moving work machine or similar it is allowed to deviate fr...

Page 29: ...Figure 13 Nominal allowed horizontal mounting position of the electric machine EM PMI240 6 Installation 28 Danfoss Produced By Danfoss Power Solutions September 2020 BC355256345493en 000103...

Page 30: ...ceed the maximum axial and radial forces calculated for the shaft with the document DOC 000454 Refer to chapter Allowed mounting positions for the correct mounting positions of the electric machine Mo...

Page 31: ...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 lubri...

Page 32: ...nting 1 D end ange SAE 6 with mounting holes 2 Shaft connection DIN5480 Spline W40x2x18x8f 3 Lifting points M8x1 25 15 mm deep Can be also used for support or grounding EM PMI240 6 Installation BC3552...

Page 33: ...r 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 Lo...

Page 34: ...t plug Installing the high voltage cables 1 Remove the connector locking plate See gure below 2 Install the high voltage cables Refer to the instructions of the manufacturer of the mating connectors 3...

Page 35: ...ure 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 informat...

Page 36: ...r 1 Deutsch HD34 24 47PE Low voltage connector details Figure 19 Pin con guration of the Deutsch HD34 24 47PE connector EM PMI240 6 Installation BC355256345493en 000103 Danfoss Produced By Danfoss Pow...

Page 37: ...er 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 b...

Page 38: ...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 Chang...

Page 39: ...e Use su cient personal protective equipment when you are near the electric machine Read the instructions in this user guide before you install the electric machine Operation conditions The electric m...

Page 40: ...for life bearings do not need relubrication during their lifetime Grease relubricable bearings BHS option need regular greasing See Chapter Maintenance Bearings and lubrication for further information...

Page 41: ...See also Chapter Cooling system maintenance If the cooling of the electric machine fails limited operation is still possible with no coolant ow The operation speed must be limited to half 1 2 of the r...

Page 42: ...nstructions in the manual before you start to work with the electric machine To ensure safe and reliable operation of the machine obey the maintenance instructions carefully Regular maintenance Inspec...

Page 43: ...akage If leaking tighten connections appropriately or replace parts X Ventilation plug Cleanliness Clean if necessary See Chapter Cleaning X Coolant ow Coolant ow direction Change direction by changin...

Page 44: ...commended lubricant in Chapter Recommended lubricants Bearing relubrication Beware of rotating parts Do not touch the electric machine during operation The surface of the electric machine can be hot U...

Page 45: ...achine has reached its operating temperature 2 Remove the plugs from the grease escape holes 3 Open the grease nipple plugs 4 Use grease piston to enter speci c amount of grease into the grease nipple...

Page 46: ...ce activities 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 speci ed See Chapter Recommended coolants EM PMI240 9...

Page 47: ...aring damage Inadequate lubrication electric machine with BHS option Apply bearing lubricant grease See Chapter Bearings and lubrication Contact Danfoss for further information Electric machine overhe...

Page 48: ...ings lubrication and conditions Insulation fault Measure the insulation resistance refer to the manufacturer limits See Chapter Insulation resistance test Replace the electric machine if necessary Tem...

Page 49: ...hc en gb or send email to editron service danfoss com Service parts The recommended service parts are listed in this Section Quantity describes the number of components in a single electric machine Ma...

Page 50: ...electric machine and any of its parts by appropriate means in accordance with local laws and regulations EM PMI240 12 Disposal BC355256345493en 000103 Danfoss Produced By Danfoss Power Solutions Sept...

Page 51: ...allation Supporting structure as required Shaft alignment as speci ed see chapter Shaft alignment and load Cooling circuit connected and coolant owing Used coolant Power connections Cable gland assemb...

Page 52: ...iscussed in the product manual and that are not needed for the normal installation procedures Sealing of the screws may break EM PMI240 13 Storage installation and maintenance checklists BC35525634549...

Page 53: ...stalled N A Procedure not applicable PASS Procedure passed FAIL Procedure failed Table 16 Electric machine weekly maintenance checklist N A PASS FAIL General construction Noise or vibration during ope...

Page 54: ...Table 18 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 sy...

Page 55: ...Cleanliness of the enclosure and connected parts Electrical system Weariness of the cables Electrical connections in general Cooling system Coolant ow direction changed and connection checked Coolant...

Page 56: ...d that are not needed for the normal installation procedures Sealing of the screws may break For cleaning instructions refer to Chapter Cleaning EM PMI240 13 Storage installation and maintenance check...

Page 57: ...rt description Part type Quantity Item order number _ _ _ _ _ Notes Date Signature EM PMI240 13 Storage installation and maintenance checklists 56 Danfoss Produced By Danfoss Power Solutions September...

Page 58: ...for storage in this User Guide or from the Data Sheet Fill in the date of each inspection to the Table below Table 23 Storage checklist Procedure Date Date Date Date Date Storage base as speci ed vib...

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