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Danfoss EM-PMI540-1500 User manual

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User Guide
Motor / Generator
EM-PMI540-1500
danfoss.com
4
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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. 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 ...........................................................................................................................................................
6.4.1.1. High voltage connection ........................................................................................................................................
EM-PMI540-T1500
Table of Contents
| BC265856800806en-000106
©
Danfoss | Produced By: Danfoss Power Solutions | January 2019 | 1
34
35
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57
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6.4.1.2. Connection diagram ................................................................................................................................................
6.4.1.3. Cable gland assembly and power line connection .......................................................................................
6.4.2. Low voltage

connections ................................................................................................................................................
6.4.3. Grounding connections ..................................................................................................................................................
6.4.4. Anti-condensation heater 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
EM-PMI540-T1500
Table of Contents
2 |
©
Danfoss | Produced By: Danfoss Power Solutions | January 2019 | BC265856800806en-000106
Revision Information
6
EM-PMI540-T1500
| BC265856800806en-000106
©
Danfoss | Produced By: Danfoss Power Solutions | January 2019 | 3
This manual is the installation, operation and maintenance manual for the EM-PMI540-
T1500

electric machine.
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
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-T1500-XXXX+XX
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.
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-T1500-1200-DUAL
EM-PMI540-T1500
1. General information
4 |
©
Danfoss | Produced By: Danfoss Power Solutions | January 2019 | BC265856800806en-000106
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.
Table 2. EM-PMI540-T1500 options
Feature Option Standard
option Explanation
High voltage
connections -DUAL 2 connection boxes each containing one 3 phase system with
one M32 cable gland per phase
Connection
extension
* x None
+CE1 2 connection boxes each containing one 3 phase system with
two M32 cable glands per phase
N-end attachment * x None
+NE4 Male shaft, no ange. DIN5480 W55x2x30x26x8a
Bearing insulation
* x Bearing types according to BHS
+BIN SKF 6214 insulated bearing in N-end
+BIA SKF 6214 insulated bearing in both ends
Shaft grounding * x No shaft grounding
+SG1 In-built grounding ring
Rotation sensor
(resolver)
* x No rotation sensor
+RES1 In-built non contacting 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 in connector
Anti-condensation
heaters
* x None
+HEAT1 230VAC/50W
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/EC (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.
Machinery Directive 2006/42/EC This electric machine is partly subject to the Machinery Directive
2006/42/EC and it is considered as partly completed machinery, as a
part of the nal machinery.
IEC 60034-1:2010 Rotating electrical machines - Part 1: Rating and performance
EM-PMI540-T1500
1. General information
| BC265856800806en-000106
©
Danfoss | Produced By: Danfoss Power Solutions | January 2019 | 5
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 60034-6:1993 Rotating electrical machines - Part 6: Methods of cooling
IEC 60034-7:1993 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/A1:2007 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.
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
c Rated coolant liquid ow l/min
EM-PMI540-T1500
1. General information
6 |
©
Danfoss | Produced By: Danfoss Power Solutions | January 2019 | BC265856800806en-000106
T
c Rated 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.
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.
EM-PMI540-T1500
1. General information
| BC265856800806en-000106
©
Danfoss | Produced By: Danfoss Power Solutions | January 2019 | 7
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 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.
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.
EM-PMI540-T1500
2. Safety information
8 |
©
Danfoss | Produced By: Danfoss Power Solutions | January 2019 | BC265856800806en-000106
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.
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.
EM-PMI540-T1500
2. Safety information
| BC265856800806en-000106
©
Danfoss | Produced By: Danfoss Power Solutions | January 2019 | 9