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Danfoss EM-PMI540-T3000, User Manual

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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-T3000

Table of Contents

2 | 

©

Danfoss | Produced By: Danfoss Power Solutions | November 2018

| BC265857716810en-000103

Summary of Contents for EM-PMI540-T3000

Page 1: ...User Guide Motor Generator EM PMI540 T3000 danfoss com...

Page 2: ...nology 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...

Page 3: ...monitoring during operation 7 3 Recommended lubricants 7 4 Recommended coolants 7 5 Emergency operation 8 Maintenance 8 1 Regular maintenance 8 2 Cleaning 8 3 Bearings and lubrication 8 4 Cooling syst...

Page 4: ...Revision Information 3 EM PMI540 T3000 BC265857716810en 000103 Danfoss Produced By Danfoss Power Solutions November 2018 3...

Page 5: ...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 referre...

Page 6: ...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...

Page 7: ...llation 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 n...

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

Page 9: ...result in death or serious injury CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION may also alert against unsafe practices NOTICE...

Page 10: ...as 12x PT100 temperature sensors in the windings The temperature signals can be read out from the measurement connector of the machine You can connect any of the temperature signals to the temperature...

Page 11: ...ed 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 insta...

Page 12: ...e assisted Permanent Magnet SRPM motor technology having several advanced features Extremely compact and robust structure High e ciency throughout the operation range Liquid cooling with water glycol...

Page 13: ...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...

Page 14: ...quipment 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...

Page 15: ...e electric machines are liquid cooled with water glycol mixture For more information see chapter Cooling A low voltage measurement signal connector is attached to the electric machines Di erent temper...

Page 16: ...Figure 4 Overview of electric machine system EM PMI540 T3000 3 Product overview BC265857716810en 000103 Danfoss Produced By Danfoss Power Solutions November 2018 15...

Page 17: ...ted mechanically and electrically as a part of a machinery or as a part of a power generation equipment Figure 5 Connections and interfaces EM PMI540 T3000 3 Product overview 16 Danfoss Produced By Da...

Page 18: ...r connection box 12 Low voltage connector measurement connector low voltage grounding through the connector metal body 13 Lifting points Rating plate Each electric machine has a rating plate which can...

Page 19: ...f the electric machine kg 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 me...

Page 20: ...ts for foot mounting 200 Nm Connection box mounting screws 7 Nm Connection box cover plate screws 4 Nm Cable gland tighten from the cap of the gland 15 Nm Cable lug 15 Nm EM PMI540 T3000 3 Product ove...

Page 21: ...u 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 a...

Page 22: ...e temperature protection feature activated Mounting structure Supporting structure requirements Do not install the electric machine near or in direct contact with easily ammable materials The surface...

Page 23: ...der For all dimensions of the electric machine see the product drawings Shaft alignment and load Improper alignment misalignment may result in bearing overloads premature bearing failures vibrations a...

Page 24: ...and mating structure The maximum external force directed to the shaft axially and radially may not exceed machine speci c values Calculate these values with the document DOC 000454 EM PMI540 T3000 4...

Page 25: ...Figure 12 External shaft forces of the machine EM PMI540 T3000 4 Design principles 24 Danfoss Produced By Danfoss Power Solutions November 2018 BC265857716810en 000103...

Page 26: ...st be inspected immediately upon arrival Make sure that the rating plate data in the cover letter complies with the purchase order Any external damage in shaft ends anges electrical interfaces and pai...

Page 27: ...eyes only Do not go under a lifted load Figure 13 Lifting lugs eyes for lifting slings and lifting position of the machine Horizontal lifting For lifting use the inbuilt lifting eyes in the machine fr...

Page 28: ...ect to any external vibrations during storage to avoid damage to the bearings It is recommended to use anti condensation heaters if tted or direct winding heating to avoid water condensing in the mach...

Page 29: ...electric machine Use isolated electric tools Only trained and quali ed personnel familiar with the relevant safety requirements can work with the electric machine Use correct personal protective equip...

Page 30: ...ard horizontal mounting option MDH is the only possible mounting option When mounting the machine can be turned around its axis shaft for maximum of 45 both directions from its default installation di...

Page 31: ...oduct data sheet Rated values can be found in the machine rating plate It is recommended to use coolant connector equipped with o ring seal or to use sealing washer for example Usit or Bonded seals in...

Page 32: ...gasket 5 Connection box cover plate 6 Insulation sheet mounting bolts 4 pcs 7 Mounting bolts 4 pcs for connection box 8 Mounting bolts 12 pcs for coverplate The connection box es of the electric machi...

Page 33: ...ith connection option other than SINGLE the electrical connection principles from the inverters are shown in the Figure below See also Wiring Diagram The amount of inverters depends upon the motor and...

Page 34: ...le diameter Cable gland 35 mm2 50 mm2 70 mm2 P itcsh blueglobe mstri225 x x P itcsh blueglobe mstri232 x x 1 Remove the small hexagonal piece from the BlueGlobe sealing insert as shown in Figure BlueG...

Page 35: ...eath of the cable as shown in Figure Cable to the gland assembly Figure 20 Cable to the gland assembly 4 After the cable gland is in place remove the length A piece of the sheath and cut the braid scr...

Page 36: ...nside the cable lug body and crimp the cable lug twice in di erent places See Figure Connecting cable lug Figure 23 Connecting cable lug 7 Cut piece of shrink tube and shrink it over the cable lug and...

Page 37: ...s shown in Figure Cable lug connection to connection the box Do not tighten the connection at this point to ensure tting of the cable gland Make sure that there is at least 10 mm air gap between the c...

Page 38: ...crews For example Loctite 221 Check the power cable shield grounding see Chapter Grounding connections Low voltage connections Plug the unused socket holes of the low voltage connector with suitable p...

Page 39: ...n TEMP4 14 Temperature 9 Temperature 9 PT100 P windings option TEMP4 40 Temperature 9 PT100 N windings option TEMP4 26 Temperature 10 Temperature 10 PT100 P windings option TEMP4 41 Temperature 10 PT1...

Page 40: ...ortant to ensure proper grounding earthing of the machine and cable shields connected to the machine In the electric machine the foot stand has a connection point for machine enclosure grounding both...

Page 41: ...Figure 28 The machine enclosure grounding point safety grounding EM PMI540 T3000 6 Installation 40 Danfoss Produced By Danfoss Power Solutions November 2018 BC265857716810en 000103...

Page 42: ...Figure 29 Low voltage cable grounding points EM PMI540 T3000 6 Installation BC265857716810en 000103 Danfoss Produced By Danfoss Power Solutions November 2018 41...

Page 43: ...n also use the machine enclosure grounding point for the measurement 3 Measure the resistance between the two cable shields or between the cable shield and the enclosure grounding point 4 Change the m...

Page 44: ...he heater HEAT1 or heaters HEAT2 are factory assembled see Figure Heater connector locations The installed heater may not be used when the machine mains are switched on and the machine is running Afte...

Page 45: ...on Entanglement hazard Do not touch the electric machine during operation Do not run the electric machine when the heater is in use Use su cient personal protective equipment when you are near the ele...

Page 46: ...he deviation and repair the electric machine Refer to Chapter 9 Troubleshooting Maximum temperature of the bearings of the electric machine is 120 C Maximum temperature of the windings of the electric...

Page 47: ...g system maintenance If the cooling of the electric machine fails limited operation is still possible with no coolant ow The operation speed must be limited to half 1 2 of the rated speed and maximum...

Page 48: ...chine Read the instructions in the manual before you start to work with the electric machine To ensure safe and reliable operation of the machine obey the maintenance instructions carefully Regular ma...

Page 49: ...peration Functioning Cooling system functions as speci ed X Tubing and connection tightness No visible leakage If leaking tighten connections appropriately or replace parts X Ventilation plug Cleanlin...

Page 50: ...ng option The expression of L10 in bearing lifetime information is a standard way of expressing the lifetime and means the time period at the end of which 90 of the bearings are still reliably working...

Page 51: ...se For further information contact Danfoss representative The maximum relubrication interval in operation is 6 months The amount of grease per relubrication is 20 g The relubrication interval depends...

Page 52: ...grease escape holes Cooling system maintenance The electric machine cooling system requires certain regular maintenance activities The coolant liquid ow direction must be changed yearly This is done...

Page 53: ...es in the machine frame and the lifting slings to the lifting eyes Support the machine with lifting slings when dismounting Refer to Chapter Lifting 2 Loosen the mounting bolts for more information re...

Page 54: ...Apply bearing lubricant grease See Chapter Bearings and lubrication Too much grease at the bearing housing electric machine with BHS option Open grease escape valve and let the electric machine run fo...

Page 55: ...nsulation fault Measure the insulation resistance refer to the manufacturer limits See Chapter Insulation resistance test Replace the electric machine if necessary Anti condensation heater failure The...

Page 56: ...ore information and purchasing Figure 34 Recommended service parts Part number Item order number Qty Description Type 1 10451 1 Seal O ring 184 5 X 3 NBR70 2 11040 1 Seal Radial lip D end 75 X 100 X 1...

Page 57: ...n N end BIN and BIA options SKF 6216 C3VL0241 INSOCOAT 8 10451 1 Seal O ring 184 5 X 3 NBR70 9 10349 1 Plug for Grease escape hole both in D end and in N end M16 x 1 5 VSTI16X1 5SED71 10 10358 1 Venti...

Page 58: ...lectric machine and any of its parts by appropriate means in accordance with local laws and regulations EM PMI540 T3000 12 Disposal BC265857716810en 000103 Danfoss Produced By Danfoss Power Solutions...

Page 59: ...equired Shaft alignment as speci ed see chapter Shaft alignment and load D end attachment bolt tightening torque 40 Nm N end attachment bolt tightening torque 30 Nm Cooling circuit connected and coola...

Page 60: ...shield grounding resistances measured and valid Do not try to tighten bolts or screws that are not discussed in the product manual and that are notneeded for the normal installation procedures Sealin...

Page 61: ...edure not applicable PASS Procedure passed FAIL Procedure failed Table 14 Electric Machine Weekly Maintenance Checklist N A PASS FAIL General construction Noise or vibration during operation in genera...

Page 62: ...c Machine Monthly Maintenance Checklist N A PASS FAIL General construction Noise or vibration during operation in general Cleanliness of the enclosure and connected parts Electrical system Weariness o...

Page 63: ...able gland tightening torque to the box 15 Nm Cable lug tightening torque to the busbar 13 Nm Connection box cover bolts tightening torque 4 Nm Cooling system Coolant ow direction changed and connecti...

Page 64: ...leaning instructions refer to chapter Cleaning Notes EM PMI540 T3000 13 Storage installation and maintenance checklists BC265857716810en 000103 Danfoss Produced By Danfoss Power Solutions November 201...

Page 65: ...description Part type Quantity Item order number _ _ _ _ _ Notes Signature Date EM PMI540 T3000 13 Storage installation and maintenance checklists 64 Danfoss Produced By Danfoss Power Solutions Novem...

Page 66: ...orage in this User Guide or from the Data Sheet Fill in the date of each inspection to the table below Table 21 Storage checklist Procedure Date Date Date Date Date Storage base as speci ed vibration...

Page 67: ......

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