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Danfoss EM-PMI540-T2000 User Manual Download Page 34

Mechanical mounting connections of the electric machine (horizontal mounting)

1 Shaft of the electric machine; spline structure of the shaft (DIN5480 W55x2x30x26x8a).

2 D-end flange (SAE1/2) and bolt bores for mounting the electric machine (12 pieces).

3 Bores for the lifting eyes.

4 Mounting foot rails (see 

Main dimension drawing

).

5 Mounting bolts (12 pcs of DIN912 M12 socket head). Not included in the delivery.

Vertical assembly

In vertical assembly, follow the Steps given in the previous Section 

Horizontal assembly

.

User Guide

EM-PMI540-T2000

Installation

 

34 | 

©

 Danfoss | July 2021

BC265857530809en-000202

Summary of Contents for EM-PMI540-T2000

Page 1: ...User Guide Motor Generator EM PMI540 T2000 www danfoss com...

Page 2: ...Revision history Table of revisions Date Changed Rev July 2021 Updated user guide 0202 User Guide EM PMI540 T2000 2 Danfoss July 2021 BC265857530809en 000202...

Page 3: ...r 21 Mounting structure 22 Supporting structure requirements 22 Shaft alignment and load 23 Transportation and storage Transportation 26 Receiving and unpacking 26 Lifting 26 Storage 28 Extended stora...

Page 4: ...d lubrication 59 Cooling system maintenance 61 Dismounting Troubleshooting Aftersales Service policy 65 Service parts 65 Disposal Storage installation and maintenance checklists User Guide EM PMI540 T...

Page 5: ...electric machine frame model EM PMI540 T2000 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 relat...

Page 6: ...ed 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...

Page 7: ...efects 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 warra...

Page 8: ...y 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 responsib...

Page 9: ...ous 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 a...

Page 10: ...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...

Page 11: ...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 pe...

Page 12: ...cal 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 str...

Page 13: ...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 abo...

Page 14: ...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 ele...

Page 15: ...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 mac...

Page 16: ...onnections bores Grease escape fill connections depending on option BHS maintenance use only Air ventilation plug Vibration sensor connection points Electrical interfaces Power connections through the...

Page 17: ...able gland six glands with DUAL option 11 Connection boxes two boxes with DUAL option 12 Bearing temperature measurement connector N end BTMP1 option Connected through the connection box Type 4 pin M1...

Page 18: ...ted 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...

Page 19: ...n the details of the delivery the rating plate might not have CE marking Tightening torques Tightening torque tolerance is 5 of the specified tightening torque Use threadlocking adhesive for RST bolts...

Page 20: ...t 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 c...

Page 21: ...ne 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 electr...

Page 22: ...iciently 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 mu...

Page 23: ...and shaft failures Flexible coupling does not compensate for excessive misalignment The type of the electric machine shaft is cylindrical shaft with diameter of 70 mm h7 and contact length of 130 mm...

Page 24: ...03 0 07 3000 4000 0 02 0 05 4000 6000 0 02 0 03 Angular alignment of the shaft and mating structure Maximum angular misalignment values Non flexible coupling Flexible coupling rpm mm 100 mm mm 100 mm...

Page 25: ...DOC 000454 Calculate the relevant values with the help of the document Contact Danfoss service at https danfosseditron zendesk com hc en gb or send email to editron service danfoss com to obtain the d...

Page 26: ...n supports of the electric machine Check upon arrival and unpacking The electric machine and the package must be inspected immediately upon arrival Make sure that the rating plate data in the cover le...

Page 27: ...fting See the electric machine rating plate for weight information Lift the electric machine using the correct lifting lugs eyes only Do not go under a lifted load Lifting slings cannot touch the elec...

Page 28: ...e lifting eyes should be mounted with their full threaded length Vertical lifting Install 4 pieces of lifting eyes to the lifting bores in the N end bearing shield non shaft end Lifting eye should be...

Page 29: ...tric machine Rotate the shaft of the electric machine by hand monthly at least ten revolutions to prevent grease migration If necessary use a tool for example a spanner Do not damage the shaft in any...

Page 30: ...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 pe...

Page 31: ...stance test Measure the insulation resistance of the electric machine before and after the installation of the electric machine Because of the structure of the electric machine it is possible that the...

Page 32: ...e allowed installation angles in each case Nominal allowed horizontal mounting position of the electric machine Allowed deviations from the horizontal mounting limitations Line type Meaning Allowed de...

Page 33: ...t rails on the side of the electric machine 4 pieces For these mounting rails use bolts of minimum strength M10 8 8 and minimum 20mm thread engagement See Chapter Tightening torques for details 3 Alig...

Page 34: ...es for mounting the electric machine 12 pieces 3 Bores for the lifting eyes 4 Mounting foot rails see Main dimension drawing 5 Mounting bolts 12 pcs of DIN912 M12 socket head Not included in the deliv...

Page 35: ...machine To prevent damage to the cooling connectors refer to the documentation of the manufacturer for the correct tightening torque of the cooling liquid nipples When selecting cooling liquid nipple...

Page 36: ...easurement connector of the machine You can connect the temperature signal to the temperature monitoring pin in the inverter EC C and make sure that the inverter has the electric machine temperature p...

Page 37: ...page 44 and Anti condensation heater connections on page 51 10 Connection box gasket The Figure below illustrates the connection box from the inside The power connections are located in the upper part...

Page 38: ...ric machines are intended to be powered and controlled by three phase alternating current supplied by an inverter or inverters The electric machine is not suitable for direct online use The amount of...

Page 39: ...able below Cable gland assembly instruction can also be found from PFLITSCH gland catalog available from http www pflitsch de Use correct type of gland for different cable diameters These are shown in...

Page 40: ...the Figure The distance A depends of the length of the cable lug used Measure with the cable lug that is used and cut to suitable length Install two layers of copper tape on the cable so that the dis...

Page 41: ...he sheath and cut the braid screen cover from 10 mm distance C from the gland bottom as shown in Figure below Make sure that the cable gland spring is against the cable sheath that is protected with c...

Page 42: ...See Figure below Connecting cable lug 7 Cut piece of shrink tube and shrink it over the cable lug and braid screen as shown in Figure below This is done to keep the braid screen in place and for extra...

Page 43: ...d of the cable If the air gap is smaller use extra insulation shrink tube to cover the lug Cable lug connection to the connection box example only the connection box may look different 9 Screw the cab...

Page 44: ...plugs DEUTSCH 0413 003 1605 size 16 DEUTSCH 0413 204 2005 size 20 See more information and instructions about DEUTSCH connectors at https www deutschconnector com The electric machine has a connector...

Page 45: ...windings 33 Temperature 2 PT100 N windings 32 Temperature 3 Temperature 3 PT100 P windings 45 Temperature 3 PT100 N windings 31 Temperature 4 Temperature 4 PT100 P windings option TEMP4 TEMP5 30 Tempe...

Page 46: ...S_N Resolver RES_COS_N in built non contacting 35 Resolver COS_P Resolver RES_COS_P in built non contacting 20 Resolver SIN_N Resolver RES_SIN_N in built non contacting 36 Resolver SIN_P Resolver RES_...

Page 47: ...ral Heater ground protective earth M5 screw inside connection box 3 Reserve 4 Reserve 5 Temperature 1 PT100 P windings 6 Temperature 1 PT100 N windings 7 Temperature 2 PT100 P windings 8 Temperature 2...

Page 48: ...1 PT100 N windings TEMP5 option 27 Temperature 12 PT100 P windings TEMP5 option 28 Temperature 12 PT100 N windings TEMP5 option 29 Resolver RES_COS_N in built non contacting RES1 option 30 Resolver RE...

Page 49: ...ing the electric machine to make sure the electric machine is correctly grounded The grounding points on the frame of the electric machine are for safety grounding and signal cables and power cable sh...

Page 50: ...age cable grounding points Power cable grounding through the cable gland Testing the power cable shield grounding earthing User Guide EM PMI540 T2000 Installation 50 Danfoss July 2021 BC265857530809en...

Page 51: ...connection is valid 1 Connect one terminal of the measurement device to the low voltage cable shield in the non machine end of the cable 2 Connect the other terminal of the measurement device to the...

Page 52: ...the resistance of the warming element can be measured Connect the measurement device between the heater terminals The resistance should be around 1 k Measuring no value or zero value indicates a poss...

Page 53: ...of the electric machine might be hot Do not touch the electric machine during operation Entanglement hazard Do not touch the electric machine during operation Use the anti condensation heater if fitte...

Page 54: ...es correctly and has a designed lifetime If you notice any deviations from the normal operation for example elevated temperatures noise or vibration stop the electric machine Find the reason for the d...

Page 55: ...caused by dregs sediment accumulating to the cooling system tubes Try opening the possible blockage by changing the coolant flow direction See also Chapter Cooling system maintenance If the cooling o...

Page 56: ...new connection 4 Remount the connector box cover When reading the temperature resistance values from the additional sensor add 15 C to the measured value This gives more correct estimation of the inn...

Page 57: ...he connection box is open Voltage may be connected to the anti condensation heater Use correct personal protective equipment when you are near the electric machine Read the instructions in the user gu...

Page 58: ...f necessary X Anti condensation heater Check anti condensation heater connections and resistance if the option is installed If needed contact Danfoss x Cooling system Operation Functioning Cooling sys...

Page 59: ...nd instructions described in this Chapter Grease can cause skin irritation and eye inflammation Follow all safety precautions specified by the manufacturer of the grease Make sure that the automatic g...

Page 60: ...grease lifetime are estimations only to provide a magnitude of them The bearing lifetime and bearing grease lifetime in customer application may vary Danfoss is not responsible for the actual bearing...

Page 61: ...ple 5 If possible let the electric machine run approximately one hour to let the old grease exit 6 Install the plugs on the grease nipples and on the grease escape holes Cooling system maintenance The...

Page 62: ...page 26 Support the electric machine with lifting slings when dismounting 2 Loosen the mounting bolts For more information refer to Chapter Mounting the electric machine on page 33 3 If force is requi...

Page 63: ...grease See Chapter Bearings and lubrication Too much grease at the bearing housing electric machine with BHS option Open grease escape valve and let the electric machine run for 10 min Clean the grea...

Page 64: ...insulation resistance refer to the manufacturer limits See Chapter Insulation resistance test Replace the electric machine if necessary Anti condensation heater failure The heater element is faulty M...

Page 65: ...ectric machine Maintenance procedures not described in this user guide require special tools and instructions Contact Danfoss for more information and purchasing Recommended service parts Part number...

Page 66: ...earing with BIN and BIA options N end insulated deep groove ball bearing 6214 C3 HC5 hybrid bearing 8 10451 1 Seal O ring 184 5 X 3 NBR70 9 10242 1 Seal O ring 124 5 X 3 NBR70 10 10349 7 Plug for Grea...

Page 67: ...Dispose of the electric machine and any of its parts by appropriate means in accordance with local laws and regulations User Guide EM PMI540 T2000 Disposal Danfoss July 2021 BC265857530809en 000202 67...

Page 68: ...ditions as specified see data sheet Mechanical installation Supporting structure as required Shaft alignment as specified see chapter Shaft alignment and load Cooling circuit connected and coolant flo...

Page 69: ...y maintenance checklist Date Electric machine and customer information Customer Electric machine type from the rating plate Customer reference Electric machine serial number Service reference Date ins...

Page 70: ...AIL Procedure failed Electric machine monthly maintenance checklist N A PASS FAIL General construction Noise or vibration during operation in general Cleanliness of the enclosure and connected parts E...

Page 71: ...eptance N A PASS FAIL General construction Noise or vibration during operation in general Mounting bolt tightness Cleanliness of the enclosure and connected parts Electrical system Weariness of the ca...

Page 72: ...ighten bolts or screws that are not discussed in the product manual and that are not needed for the normal installation procedures Sealing of the screws may break For cleaning instructions refer to Ch...

Page 73: ...torage in this User Guide or in the Data Sheet Fill in the date of each inspection to the Table below Storage checklist Procedure Date Date Date Date Date Storage base as specified vibration free Stor...

Page 74: ...anfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 Danfoss Power Solutions Trading Shanghai Co Ltd Building 22 No 1000 Jin Hai Rd Jin Qiao Pudong New Distri...

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