Danfoss EM-PMI540-1500, User Manual

Page 1: ...User Guide Motor Generator EM PMI540 1500 danfoss com...

Page 2: ...hnology 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 Inverter 4...

Page 3: ...monitoring during operation 7 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 sys...

Page 4: ...Revision Information 6 EM PMI540 T1500 BC265856800806en 000106 Danfoss Produced By Danfoss Power Solutions January 2019 3...

Page 5: ...ations in this manual may not necessarily re ect all system features Product naming convention In this user guide EM PMI family permanent magnet motors and generators are referred to as the electric m...

Page 6: ...ing resolver 8 pole pair Winding temperature sensor x 3 x PT100 in the windings TEMP4 6 x PT100 in the windings Bearing temperature sensor x No temperature sensors BTMP1 PT 100 in bearings with plug i...

Page 7: ...ments 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 arisin...

Page 8: ...eriodic load and speed variations Trademarks All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved...

Page 9: ...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 NOTIC...

Page 10: ...chine 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...

Page 11: ...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 ot...

Page 12: ...throughout the operation range Liquid cooling with water glycol mixture Low coolant ow required High allowed coolant temperature IP65 enclosure class to maximize reliability Multiple mounting possibi...

Page 13: ...tments and maintenance without rst reading this manual Exceeding the designed limits during the electric machine operation Using non original service parts of wrong material causing corrosion problems...

Page 14: ...speeds The electric machine e ciency at lower speeds is also good The supply current to the machine stator windings create rotating magnetic eld which in turn rotates the rotor containing permanent ma...

Page 15: ...see chapter Cooling connections A low voltage measurement signal connector is attached to the electric machines Di erent temperature and resolver signals can be read depending on the machine options...

Page 16: ...nding on option BHS maintenance use only Air ventilation plug Vibration sensor connection points Electrical interfaces Power connections through the connection box Measurement connector connection thr...

Page 17: ...h 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 g...

Page 18: ...Electric machine product family EM PMI or EM PME Electric machine type code 2 Electric machine type code and options Serial No Serial number U Rated voltage phase to phase AC Vrms I Rated current AC I...

Page 19: ...Temperature rating class of insulation of the machine according to IEC60034 1 Temp class Temperature rating class of individual insulation materials of the insulation according to IEC60034 1 Bear D en...

Page 20: ...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 activate...

Page 21: ...e temperature protection feature activated Mounting structure Supporting structure requirements Do not install the electric machine near or in direct contact with easily ammable materials The surface...

Page 22: ...g shoulder DM Diameter of the ange mounting bore circle DS Diameter of the mounting shoulder For all dimensions of the electric machine see the product drawings Shaft alignment and load Improper align...

Page 23: ...t and mating structure The maximum external force directed to the shaft axially and radially may not exceed machine speci c values Calculate these values with the document DOC 000454 EM PMI540 T1500 4...

Page 24: ...Figure 12 External shaft forces of the machine EM PMI540 T1500 4 Design principles BC265856800806en 000106 Danfoss Produced By Danfoss Power Solutions January 2019 23...

Page 25: ...e 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 anges electrical interfaces and paint m...

Page 26: ...ing 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 lift...

Page 27: ...subject to any external vibrations during storage to avoid damage to the bearings It is recommended to use anti condensation heaters if tted or direct winding heating to avoid water condensing in the...

Page 28: ...electric machine Use isolated electric tools Only trained and quali ed personnel familiar with the relevant safety requirements can work with the electric machine Use correct personal protective equip...

Page 29: ...nfoss representative if the reference value is not exceeded Mechanical installation Allowed mounting positions The electric machine with standard horizontal mounting option must be installed horizonta...

Page 30: ...nsmission housing ange SAE1 2 ywheel housing is required as a mating ange The mounting foot rails in the side of the electric machine 4 pieces can also be used for mounting 3 Align the electric machin...

Page 31: ...tightening torque of 69 Nm for D end bolts The N end of the electric machine is not intended to be be used for mounting Figure 16 Mechanical mounting connections of the electric machine horizontal mo...

Page 32: ...in the previous chapter Horizontal assembly Figure 17 Mechanical mounting connections of the electric machine vertical mounting 1 Mounting foot rails 4 rails in 90 circular pattern around the frame 2...

Page 33: ...T100 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 t...

Page 34: ...rame 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 vol...

Page 35: ...over plate open for further electrical assembly instructed in Chapter Cable gland assembly and power line connection Connection diagram The electric machines are intended to be powered and controlled...

Page 36: ...ITSCH gland catalogue available from http www p itsch de Use correct type of gland for di erent cable diameters These are shown in Table below Table 7 Cable gland alternatives Cable diameter Cable gla...

Page 37: ...t is used and cut to suitable lenght Do not remove the cable sheath completely at this point and do not cut the braid screen of the cable Figure 22 Cut lenght of the cable sheath 3 Insert the cable to...

Page 38: ...igure below Make sure that the cable gland spring is against the cable sheath before cutting the braid screen Figure 24 Cut the braid screen 5 Cut a piece of length D of the inner sheath shown in Figu...

Page 39: ...ink tube and shrink it over the cable lug and braid screen as shown in Figure below This is done to keep the braid screen in place and for extra insulation The shrink tube must be speci ed for operati...

Page 40: ...here 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 Figure 2...

Page 41: ...nused socket holes of the low voltage connector with suitable plugs DEUTSCH 0413 003 1605 size 16 DEUTSCH 0413 204 2005 size 20 The electric machine has a connector which is used to read out in built...

Page 42: ...ture 5 PT100 P windings option TEMP4 44 Temperature 5 PT100 N windings option TEMP4 43 Temperature 6 Temperature 6 PT100 P windings option TEMP4 28 Temperature 6 PT100 N windings option TEMP4 16 Resol...

Page 43: ...eration it is important to ensure proper grounding earthing of the machine and cable shields connected to the machine In the electric machine the middle lifting bores can be used as a connection point...

Page 44: ...e machine enclosure grounding point safety grounding Figure 33 Low voltage cable grounding points EM PMI540 T1500 6 Installation BC265856800806en 000106 Danfoss Produced By Danfoss Power Solutions Jan...

Page 45: ...the cable shield and the enclosure grounding point 4 Change the measurement device terminal s to the shield of di erent power cable and repeat the measurement until all cables have been measured Testi...

Page 46: ...ith 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 Fig...

Page 47: ...ion Entanglement hazard Do not touch the electric machine during operation Do not run the electric machine when the heater is in use Use su cient personal protective equipment when you are near the el...

Page 48: ...the deviation and repair the electric machine Refer to Chapter 9 Troubleshooting Maximum temperature of the bearings of the electric machine is 120 C Maximum temperature of the windings of the electri...

Page 49: ...e temperature measurement of the electric machine fails The operation temperature of the machine is measured by PT100 temperature sensors in the electric machine windings The temperature signals can b...

Page 50: ...chine Read the instructions 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 ma...

Page 51: ...the connections or ow direction from the pump See Chapter Cooling system maintenance X Coolant quality Coolant as speci ed Proper glycol used and water glycol mixture appropriate Re ll if necessary S...

Page 52: ...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 Da...

Page 53: ...lubrication interval of the machine BHS option compared to rotation speed and bearing temperature EM PMI540 T1500 8 Maintenance 52 Danfoss Produced By Danfoss Power Solutions January 2019 BC2658568008...

Page 54: ...can hold a lot of grease 6 Install the plugs on the grease nipples and on the grease escape holes Cooling system maintenance The electric machine cooling system requires certain regular maintenance a...

Page 55: ...es in the machine frame and the lifting slings to the lifting eyes Support the machine with lifting slings when dismounting Refer to Chapter Lifting 2 Loosen the mounting bolts for more information re...

Page 56: ...on Apply bearing lubricant grease See Chapter Bearings and lubrication Too much grease at the bearing housing electric machine with BHS option Open grease escape valve and let the electric machine run...

Page 57: ...ation and conditions Insulation fault Measure the insulation resistance refer to the manufacturer limits See Chapter Insulation resistance test Replace the electric machine if necessary Anti condensat...

Page 58: ...e parts The recommended service parts are listed in the table below Quantity describes the number of components in a single electric machine Maintenance procedures not decribed in this manual require...

Page 59: ...wer connections DUAL two connection boxes M32 X 1 5 BG PFLITSCH 7 10935 1 Bearing N end Deep groove ball non insulated in N end BI0 and BID options SKF 6214 C3 7 11093 1 Bearing N end Deep groove ball...

Page 60: ...lectric machine and any of its parts by appropriate means in accordance with local laws and regulations EM PMI540 T1500 12 Disposal BC265856800806en 000106 Danfoss Produced By Danfoss Power Solutions...

Page 61: ...equired Shaft alignment as speci ed see chapter Shaft alignment and load D end attachment bolt tightening torque 40 Nm N end attachment bolt tightening torque 30 Nm Cooling circuit connected and coola...

Page 62: ...e shield grounding resistances measured and valid Do not try to tighten bolts or screws that are not discussed in the product manual and that are notneeded for the normal installation procedures Seali...

Page 63: ...edure not applicable PASS Procedure passed FAIL Procedure failed Table 14 Electric Machine Weekly Maintenance Checklist N A PASS FAIL General construction Noise or vibration during operation in genera...

Page 64: ...c 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 o...

Page 65: ...able gland tightening torque to the box 15 Nm Cable lug tightening torque to the busbar 13 Nm Connection box cover bolts tightening torque 4 Nm Cooling system Coolant ow direction changed and connecti...

Page 66: ...cleaning instructions refer to chapter Cleaning Notes EM PMI540 T1500 13 Storage installation and maintenance checklists BC265856800806en 000106 Danfoss Produced By Danfoss Power Solutions January 201...

Page 67: ...description Part type Quantity Item order number _ _ _ _ _ Notes Signature Date EM PMI540 T1500 13 Storage installation and maintenance checklists 66 Danfoss Produced By Danfoss Power Solutions Janua...

Page 68: ...torage in this User Guide or from the Data Sheet Fill in the date of each inspection to the table below Table 21 Storage checklist Procedure Date Date Date Date Date Storage base as speci ed vibration...

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