Danfoss EM-PMI240 User manual

User Guide
Motor / Generator
EM-PMI240
danfoss.com

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1. General information
1.1. Copyright .........................................................................................................................................................................................
1.2. Intended use of the manual .....................................................................................................................................................
1.3. Product naming convention ....................................................................................................................................................
1.4. Conformity according to standards .......................................................................................................................................
1.5. Warranty ..........................................................................................................................................................................................
1.6. Terms and abbreviations ...........................................................................................................................................................
1.7. Trademarks .....................................................................................................................................................................................
1.8. Responsibility of the manufacturer .......................................................................................................................................
2. Safety information
2.1. General safety statement ..........................................................................................................................................................
2.2. Safety message signal words ...................................................................................................................................................
2.3. Safety symbols ..............................................................................................................................................................................
2.4. Personal protective equipment ..............................................................................................................................................
2.5. Security features ...........................................................................................................................................................................
2.6. Electromagnetic compatibility (EMC) .................................................................................................................................
3. Product overview
3.1. Intended use of the electric machine .................................................................................................................................
3.2. Used 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. Insulation lifetime ..............................................................................................................................................................
4.1.3. Inverter ..................................................................................................................................................................................
4.2. Mounting structure ...................................................................................................................................................................
4.2.1. Supporting structure requirements ............................................................................................................................
4.2.2. Shaft alignment and load ...............................................................................................................................................
5. Transportation and storage
5.1. Transportation ............................................................................................................................................................................
5.2. Receiving and unpacking .......................................................................................................................................................
5.3. Lifting .............................................................................................................................................................................................
5.4. Storage ...........................................................................................................................................................................................
5.4.1. Extended storage ..............................................................................................................................................................
6. Installation
6.1. Required tools .............................................................................................................................................................................
6.2. Insulation resistance test .........................................................................................................................................................
6.3. Mechanical installation ............................................................................................................................................................
6.3.1. Allowed mounting positions .........................................................................................................................................
6.3.2. Mounting the electric machine ....................................................................................................................................
6.3.3. Cooling connections ........................................................................................................................................................
6.4. Electrical installation .................................................................................................................................................................
6.4.1. Power connections ...........................................................................................................................................................
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6.4.1.1. High voltage connection ........................................................................................................................................
6.4.1.2. Connection diagram ................................................................................................................................................
6.4.2. Low voltage  connections ................................................................................................................................................
6.4.3. Grounding connections ..................................................................................................................................................
7. Operation
7.1. Operation conditions ...............................................................................................................................................................
7.2. Condition 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 system maintenance ................................................................................................................................................
9. Dismounting
10. Troubleshooting
11. Aftersales
11.1. Service policy ............................................................................................................................................................................
11.2. Service parts ..............................................................................................................................................................................
12. Disposal
13. Storage, installation and maintenance checklists
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Table of Contents
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Revision Information
1 First revision
2 Bearing type added
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Copyright
Danfoss Oy. All rights reserved. 
No parts of this manual may be reproduced or transmitted in any form or by any means, electrical
or mechanical including photocopying, recording or by an information storage or retrieval system,
without permission in writing from the publisher.
All specications and contents of this manual are subject to change without notice.
Intended use of the manual 
This manual 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 book must be followed to prevent injury to
personnel or damage to property . Only qualied and authorized personnel, familiar with health
and safety requirements and national legislation, shall be permitted to handle, install, operate and
maintain the device.
This manual must be kept for future reference during installation, operation and maintenance. 
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 electrical characteristics of the electric machine. The
following naming convention is used to refer to the electric machine frame model: 
EM-PMI240-T180
Table 1. 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 (*).
Table 2. EM-PMI240-T180  options
Variant Code Description Additional information
Drive-end shaft 
* Male shaft  DIN5480 W40x2x18x8f
+S2 Female spline  ANSI B92.1B 14T 12/24
D-end attachment
* Standard ange  SAE 6, transmission housing
+DE1 Flange interface for hydraulic
pump Four bolt, SAE C ange
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Protection class 
* Standard protection class  IP65 protection class
+IP67 IP67 protection class  IP67  protection class
Rotation sensor
(resolver)
* None No resolver
+RES1 Resolver In-built non contacting resolver, 4-pole
pair
Winding temperature
sensors
* Temperature surveillance 3 x PT100 (two wire) in windings
+TEMP4 Redundant temperature
surveillance 6 x PT100 (two wire) in windings (requires +LVB1)
Conformity according to standards
The electric machine  has been  designed to be in conformity with the  following directives and to
meet the requirements specied in the following standards:
Table 3. 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)
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.
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 integral design of rotating electrical machines (IP code) -
Classication
IEC 60034-6:1991 Rotating electrical machines - Part 6: Methods of cooling
IEC 60034-7:1992/A1:2001 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: Terminal markings and direction
of rotation
IEC 60034-14:2004/A1:2008 Amendment 1 - Rotating electrical machines - Part 14: Mechanical vibration of certain machines with shaft heights 56 mm and higher -
Measurement, evaluation and limits of vibration severity.
Warranty
Danfoss offers warranty against defects in workmanship and materials for its products for a period
of twelve (12) months from commissioning or eighteen months (18) from delivery (Incoterms-
EXW), whichever occurs rst.
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, non-execution 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
modications to the equipment without prior written consent from Danfoss.
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Terms and abbreviations
The  symbols, terms and abbreviations in the Tables below are possibly used in this manual.
Table 4. Symbols
Symbol Variable Unit
U Rated voltage (phase-to-phase AC) Vrms
I Rated current (AC) Arms
P Rated Power (S9) kW
T Rated torque (S9) at rated speed Nm
T
max Maximum torque Nm
n Rated speed rpm
Max n Maximum speed rpm
f Rated supply frequency at nominal speed Hz
PF Power factor (cos φ )
Q
cRated coolant liquid ow l/min
T
cRated coolant liquid input temperature °C
T
amb Rated ambient temperature °C
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
Table 5. 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
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.
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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 qualied 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 manual.
The electric machine  is installed, maintained and serviced in accordance with the instructions
in this manual.
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General safety statement
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 qualied 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 manual, it is important to observe safety precautions to protect personnel from
possible injury.
Safety message signal words
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 manual and on the electric
machine.
Danger
This symbol  is identied 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 identied 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 identied 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 identied 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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Magnet warning
The symbol is identied by a yellow background, black triangular band, and a black magnet symbol. It indicates strong magnetic
eld that could cause harm to a person or property.
Rotating shaft warning
The symbol is identied 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 manual.
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 device.  Permanent damage to the eye
could be caused if bearing grease, melted nitrile rubber (radial lip seal), glycol or other uids 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 connector of the 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.
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Electromagnetic compatibility (EMC)
When interfacing other equipment, connect only equipment that are specied as part of the system and that
are  compatible.
Magnetic and electromagnetic elds 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 manual to achieve the required level of EMI  protection.
It is the responsibility of the installer to ensure 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 2004/108/EC.
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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.
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 dened in this  manual.
Disregarding the obligation to comply with the manual, safety signs and rating plate of the
electric machine.
Using the electric machine, making adjustments 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 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 dened in the manual
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.
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Used technology
The electric machine  is a  Syncronous Reluctance assisted Permanent Magnet (SRPM) machine. This
technology has several benets compared to standard permanent magnet (PM) technology and
traditional induction machine (IM) technology. The SRPM technology combines the benets of PM
and Syncronous 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 eld, which in turn
rotates the rotor containing permanent magnets. In the 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 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.
Figure 1. Machine  topology
1 Electric machine stator and stator windings
2 Electric machine rotor
3 Permanent magnets in the rotor
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System introduction
Figure 2. 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-
condensation  heater(s), depending on the 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 electrically as a part of a machinery or as a
part of a power generation equipment.
Mechanical interfaces:
Lifting points.
Flange mounting (D-end).
Shaft connection(s).
Cooling system connections (bores).
Grease escape/ll connections; depending on model and option (BHS): maintenance use only.
Air ventilation plug.
Electrical interfaces:
Power connections
Measurement connections
Low voltage (measurement signal) grounding connection
Power grounding connection
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Figure 3. Connections and interfaces
1 D-end mounting holes, 8 pcs ( ⌀ 11 - THRU)
2 Shaft connection DIN5480 Spline W40x2x18x8f
3 Lifting holes, 2 pcs. M8x1.25 (15 mm deep). They can be 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 Bearing grease nipple - option dependent  (both bearings have one)
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Rating plate
Figure 4. Rating plate
Table 6. Rating plate elds
Field Explanation Unit
1 Electric machine product family: EM-PMI or EM-PME
2 Electric machine type code and options
Serial No. Serial number
URated voltage
(phase-to-phase AC) Vrms
I Rated current (AC) Irms
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
QcRated coolant liquid ow l/min
Pole pairs Number of magnetic pole pairs of the machine
TcRated coolant liquid input temperature °C
Mounting Allowed mounting position according to IEC60034-7
Mass Mass of the electric machine kg
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Duty Dened rotating electric machine duty cycles by IEC60034-1 standard
Tamb Rated ambient temperature °C
IP rating Enclosure class according to IEC60034-5
Cooling Cooling method according to IEC60034-6
Rotation Direction of rotor  rotation with default phase order. Observed facing the D-end.
Max n Maximum rotation speed rpm
Insul. class 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-
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 liquid max pressure
Tightening torques
Tightening torque tolerances are: -10%...0% of the specied tightening torque. Exceeding the specied tightening
torque is not allowed.
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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This chapter describes design principles that must be taken into account when designing the
system using the  electric machine.
System design
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  ows  freely in and out from the electric
machine with the cooling medium ow 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 specications, required coolant
liquid ow and other specications 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.
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.
Insulation class Lifetime expectancy
F (150°C) 20 000 h
H (175°C) 20 000 h
100  000 h if driven with maximum winding temperature of 150°C
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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 machine is driven with a inverter from  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.
Do not exceed the maximum rotation speed of the machine.
Figure 5. EC-C1200
EM-PMI240
4. Design principles
18 | © Danfoss | Produced By: Danfoss Power Solutions | September 2020 | BC355256345493en-000103

Figure 6. Schematic of the inverter powerstage
The main machine power driving parameters are shown in the machine rating plate. For
more  information, please 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.
Mounting structure
Supporting structure requirements
Do not install the electric machine near or in direct contact with easily ammable 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).
EM-PMI240
4. Design principles
| BC355256345493en-000103
© Danfoss | Produced By: Danfoss Power Solutions | September 2020 | 19