Danfoss EM-PMI540-T4000 User manual

User Guide
Motor / Generator
EM-PMI540-T4000
www.danfoss.com

Revision history Table of revisions
Date Changed Rev
April 2023 Minor modifications and improvements 0202
User Guide
EM-PMI540-T4000
2 | ©Danfoss | April 2023 BC265857716810en-000202

General information 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
Safety information General safety statement...............................................................................................................................................................9
Safety message signal words....................................................................................................................................................... 9
Safety symbols...................................................................................................................................................................................9
Personal protective equipment................................................................................................................................................10
Security features.............................................................................................................................................................................10
Electromagnetic compatibility (EMC).....................................................................................................................................11
Product overview Intended use of the electric machine.....................................................................................................................................13
Used technology............................................................................................................................................................................13
System introduction..................................................................................................................................................................... 14
Connections and interfaces........................................................................................................................................................15
Rating plate......................................................................................................................................................................................16
Tightening torques........................................................................................................................................................................18
Design principles System design.................................................................................................................................................................................19
Cooling and temperature measurement ........................................................................................................................19
Insulation lifetime.....................................................................................................................................................................19
Inverter......................................................................................................................................................................................... 20
Mounting structure.......................................................................................................................................................................21
Supporting structure requirements...................................................................................................................................21
Shaft alignment and load...................................................................................................................................................... 22
Transportation and storage Transportation................................................................................................................................................................................ 25
Receiving and unpacking............................................................................................................................................................25
Lifting................................................................................................................................................................................................. 25
Storage...............................................................................................................................................................................................27
Extended storage......................................................................................................................................................................28
Installation Required tools.................................................................................................................................................................................30
Insulation resistance test.............................................................................................................................................................30
Mechanical installation................................................................................................................................................................30
Allowed mounting positions................................................................................................................................................30
Mounting the electric machine...........................................................................................................................................32
Cooling connections............................................................................................................................................................... 33
Electrical installation.....................................................................................................................................................................34
Power connections.................................................................................................................................................................. 34
High voltage connection..................................................................................................................................................34
Connection diagram.......................................................................................................................................................... 35
Cable gland assembly and power line connection.................................................................................................36
Low voltage connections.......................................................................................................................................................41
Grounding connections......................................................................................................................................................... 44
Anti-condensation heater connections............................................................................................................................47
Operation Operation conditions....................................................................................................................................................................51
Condition monitoring during operation...............................................................................................................................51
Recommended lubricants...........................................................................................................................................................51
Recommended coolants............................................................................................................................................................. 52
Emergency operation...................................................................................................................................................................52
User Guide
EM-PMI540-T4000
Contents
©Danfoss | April 2023 BC265857716810en-000202 | 3

Maintenance Regular maintenance................................................................................................................................................................... 54
Cleaning............................................................................................................................................................................................ 55
Bearings and lubrication............................................................................................................................................................. 56
Cooling system maintenance....................................................................................................................................................58
Dismounting
Troubleshooting
Aftersales Service policy...................................................................................................................................................................................62
Service parts.....................................................................................................................................................................................62
Disposal
Storage, installation and maintenance checklists
User Guide
EM-PMI540-T4000
Contents
4 | ©Danfoss | April 2023 BC265857716810en-000202

This user guide is the installation, operation and maintenance user guide for the EM-PMI540-T4000
electric machine.
Intended use of the user guide
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.
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-PMI540-T4000-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. 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-T4000-1600-QUAD
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. For detailed information of the models, options and characteristics, see
product data sheets.
User Guide
EM-PMI540-T4000
General information
©Danfoss | April 2023 BC265857716810en-000202 | 5

EM-PMI540-T4000 options
Variant Code Description Additional information
High voltage connections -DUAL Two galvanically isolated 3
phase systems
Two connection boxes each containing
one 3 phase system with one M32 cable
gland per phase
-QUAD Four galvanically isolated 3
phase systems
Four connection boxes each containing
one 3 phase system with one M32 cable
gland per phase
Bearing insulation * Non-insulated bearings Non-insulated bearings
+BIN Insulated bearing in N-end Insulated bearing in N-end
+BIA Insulated bearing in both
ends
Insulated bearing in both ends
Shaft grounding * None
+SG1 D-end shaft grounding In-built grounding ring
Rotation sensor (resolver) * None No resolver
+RES1 Resolver In-built non contacting resolver, 8-pole
pair
Winding temperature
sensor
* Temperature surveillance 6 x PT100 in the windings
+TEMP4 Redundant temperature
surveillance
12 x PT100 in the windings
Bearing temperature sensor * None
+BTMP1 PT100 in bearings Plug-in connector
Anti-condensation heaters * None
+HEAT2 Two anti-condensation
heaters
2 x 230VAC/130W
Marine classification * No marine classification
+CL1 ABS American Bureau of Shipping
+CL2 BV Bureau Veritas
+CL3 DNV
+CL4 LR Lloyd’s Register
+CL5 RINA
+CL6 CCS China Classification Society
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:
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) - Classification
IEC 60034-6:1991 Rotating electrical machines - Part 6: Methods of cooling
User Guide
EM-PMI540-T4000
General information
6 | ©Danfoss | April 2023 BC265857716810en-000202

Applicable Directives and standards (continued)
Standard Explanation
IEC 60034-7:1992/A1:2001 Rotating electrical machines - Part 7: Classification 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.
It should be noted, that the commissioning party is responsible for establishing the conformity of the end
product with the Directive 2006/42/EC, when the EM-PMI electric machines are fitted into machinery.
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 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, 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 modifications 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.
Symbols
Symbol Variable Unit
URated voltage (phase-to-phase AC) Vrms
IRated current (AC) Arms
PRated Power (S1) kW
TRated torque (S1) at rated speed Nm
Tmax Maximum torque Nm
nRated speed rpm
Max n Maximum speed rpm
fRated supply frequency at nominal speed Hz
PF Power factor (cosφ)
QcRated coolant liquid flow l/min
TcRated coolant liquid input temperature °C
Tamb Rated ambient temperature °C
RES_COS Cosine signal received from the resolver deg
RES_SIN Sinusoidal signal received from the machine resolver deg
User Guide
EM-PMI540-T4000
General information
©Danfoss | April 2023 BC265857716810en-000202 | 7

Symbols (continued)
Symbol Variable Unit
GND Ground in electrical connections
Ω (Ohm) Resistance Ω
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 Synchronous 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.
User Guide
EM-PMI540-T4000
General information
8 | ©Danfoss | April 2023 BC265857716810en-000202

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 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
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.
User Guide
EM-PMI540-T4000
Safety information
©Danfoss | April 2023 BC265857716810en-000202 | 9

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 12 x PT100 temperature sensors in the windings. The temperature signals can
be read out from the measurement connector of the electric machine. You can connect any of the
User Guide
EM-PMI540-T4000
Safety information
10 | ©Danfoss | April 2023 BC265857716810en-000202

temperature signals 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 (four wire) at both D-end and N-end bearings. The signal can be read out
using a separate connector at both ends.
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.
User Guide
EM-PMI540-T4000
Safety information
©Danfoss | April 2023 BC265857716810en-000202 | 11

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 machines 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.
•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.
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.
User Guide
EM-PMI540-T4000
Product overview
12 | ©Danfoss | April 2023 BC265857716810en-000202

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.
•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
User Guide
EM-PMI540-T4000
Product overview
©Danfoss | April 2023 BC265857716810en-000202 | 13

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.
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 for 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
User Guide
EM-PMI540-T4000
Product overview
14 | ©Danfoss | April 2023 BC265857716810en-000202

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.
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 eyes.
•Foot mounting and additional flange connection (D-end).
•Shaft connection.
•Cooling system connections (bores).
•Grease escape/fill connections; maintenance use only.
•Air ventilation plug.
•Vibration sensor connection points.
Electrical interfaces:
•Power connections through the connection box.
•Measurement signal connectors.
•Anti-condensation heater connections (+HEAT2 option).
•Bearing temperature connectors (+BTMP1 option).
User Guide
EM-PMI540-T4000
Product overview
©Danfoss | April 2023 BC265857716810en-000202 | 15

Connections and interfaces
1 Bearing temperature measurement connector, D-end (+BTMP option).
2 Anti-condensation heater connector , D-end.
3 Vibration sensor connection points.
In the D- end, one on the top and two on the sides.
4 Grease fill connection (nipple); D-end.
5 Lifting eyes.
6 Cooling system connections (bores).
7 Grease fill connection (nipple); N-end.
8 Power connection; cable gland (three glands per connection box).
9 Low voltage connector (measurement connector), low voltage grounding through the connector metal body.
10 Anti-condensation heater connector , N-end.
11 Foot mounting points/bores (total 4 points).
12 Enclosure (power) grounding points (one at each side).
13 Bearing temperature measurement connector, N-end (+BTMP1 option).
14 Air ventilation plug.
15 D-end flange mounting (12 connection bores around the flange).
16 Grease escape connections, D-end.
17 Shaft connection.
Grease escape connection in N-end not visible in the Figure.
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.
User Guide
EM-PMI540-T4000
Product overview
16 | ©Danfoss | April 2023 BC265857716810en-000202

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 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 flow 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
Duty Defined 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 electric machine according to IEC60034-1
User Guide
EM-PMI540-T4000
Product overview
©Danfoss | April 2023 BC265857716810en-000202 | 17

Rating plate fields (continued)
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 CE marking
Tightening torques
Tightening torque tolerance is +/- 5% of the specified tightening torque, unless otherwise
stated.
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 69 Nm
Mounting bolts for foot mounting 200 Nm
Connection box mounting screws 7 Nm
Connection box cover plate screws 4 Nm
Cable lug 15 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
User Guide
EM-PMI540-T4000
Product overview
18 | ©Danfoss | April 2023 BC265857716810en-000202

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 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.
User Guide
EM-PMI540-T4000
Design principles
©Danfoss | April 2023 BC265857716810en-000202 | 19

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
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.
Do not exceed the maximum rotation speed of the electric machine.
EC-C1200
User Guide
EM-PMI540-T4000
Design principles
20 | ©Danfoss | April 2023 BC265857716810en-000202