Danfoss EM-PMI540B-T4000 Electric Machine, Permanent Magnet Internal

FEATURES

GENERATOR SPECIFIC FEATURES

MOTOR SPECIFIC FEATURES

GENERAL

The machine is developed especially for demanding applications. The design of these machines makes them smaller, lighter and more efficient than conventional products on the market.

TYPICAL APPLICATIONS

SPECIFICATIONS

General electrical properties

Nominal voltage (line-to-line)500 VAC
Voltage stressIEC 60034-25:2009, Curve A: Without filters for motors up to 500 VAC
Nominal efficiency96%
Pole pair number8
Power supplyInverter fed
Nominal inverter switching frequency8 kHz
Minimal inverter switching frequency4 kHz (with 10% derated performance)
Maximum phase-to-phase peak-to-peak voltage without du/dt1.5 kV
Maximum voltage rise time without du/dt8 kV/μs

Basic information

Machine typeSynchronous reluctance assisted permanent magnet
Frame materialFrame including coolant circuit: Aluminum 6063; Endshields: AlSi7Mg
Mounting directionOnly horizontal assembly (see user guide for details)
Mounting (IEC 60034-7)See Table 7
Standard flange D-end (SAE J617)SAE 1½ mating transmission housing
D-end shaftMale cylindrical shaft, diameter 70 mm h7
Bearing typeStandard: 6216/C3 (with LGHP2 grease); +BIN option: D-end: 6216/C3 (with LGHP2 grease), N-end: 6216/C3VL0241 (with LGHP2 grease); +BIA option: 6216/C3VL0241 (with LGHP2 grease)
Standard rotation directionClockwise (both directions possible)
Protection classIP67
Duty type (IEC 60034-1)S1/S9
Machine coatingCoating is optional
Nominal altitude (IEC 60034-1)Up to 4000 m (see Picture 1 for details)

Mechanical

Total weight987.9 kg (+/- 2%, no options)
Moment of inertia10.9 kgm²
Torsional stiffness of shaft drive end18*10^5 Nm/rad (130 mm from the end of D-end shaft)
Rotating mass451 kg
Maximum static torque range on the shaft, max. 25000 cycles, R=0 (*)7500 Nm
Maximum dynamic torque range on the shaft, max. 1e6 cycles, R=0 (*)6000 Nm
Maximum allowed vibratory torque range, 1e9...1e10 cycles (*)0.3 x nominal torque of machine
Maximum deceleration (fault stop)1000 rad/s²

(*) The values are based on structural analysis, and they are not applicable to any marine class rules or requirements.

Dimensions

Length (frame)1014 mm
Diameter (frame)600 mm

Cooling

Cooling liquidPlain water with appropriate corrosive inhibitor (max. 50% corrosive inhibitor)
Cooling liquid corrosive inhibitor typeEthylene glycol (Glysantin G48 recommended)
Cooling method (IEC 60034-6)IC 71 W
Minimum cooling liquid flow40 l/min
Coolant circuit capacity5.41
Maximum operating pressure2 bar
Pressure loss0.5 bar with 40 l/min (+25°C coolant) (see Picture 2 for details)
Nominal cooling liquid temperature+65°C (derating required if exceeded)
Minimum cooling liquid temperature-20°C
Maximum cooling liquid temperature+70°C

Temperature rating

Insulation class (IEC 60034-1)H (+180°C)
Temperature rise (IEC 60034-1)+85°C
Maximum winding temperature+150°C
Nominal ambient temperature+65°C
Min. ambient temperature-40°C

Vibration & Shock tolerance

Mechanical vibration3.19 GRMS (ISO 16750-3:2023, Test XVI - Hybrid-electric/fully electric commercial vehicle, sprung mass (vehicle body), large and heavy DUT)
Mechanical shock50 G (ISO 16750-3:2023, 4.2.2 Test for devices on rigid points on the body and on the frame)

Connections

Coolant connection2 x G3/4 bore (see dimension drawing for details)
Cable directionCable direction fixed upwards
HV cables2 x 3 x 95 mm² max.; 4 x 3 x 95 mm² max.
HV cable glandsPflitsch blueglobe TRI bg 232ms tri
HV cable recommended typeHUBER+SUHNER Radox Elastomer S, screened, single core, automotive cable (FHLR4GC13X) (www.hubersuhner.com)
HV cable lug size70-8, 95-8
Recommended cable lug70 mm²: Druseidt with narrow flange 03906; 95 mm²: Druseidt with narrow flange 03910 (www.druseidt.de)
HV connection boxes2 x 3 phase box; 4 x 3 phase box

LV connector

LV connector type47 pin DEUTSCH HD34-24-47PE for resolver and temperature measurement (https://www.te.com)
LV connector pin typeDEUTSCH HD34-24-47PE
LV mating connector typeGold plated
LV mating connector pin typeDEUTSCH HD36-24-47SE or DEUTSCH HD36-24-47SE-059
LV connector pin configurationDEUTSCH 0462-201-1631, DEUTSCH 0462-005-2031; Plug: DEUTSCH 0413-204-2005 (size 20), Plug: DEUTSCH 0413-003-1605 (size 16); See Table 1 and Table 2

Angle/Speed sensor

TypeExternally excited SIN/COS resolver
Pole pair number8
Input7 V
Frequency10 kHz
Output2 V +/- 0.2 V
Input impedance80 +/- 16 Ohm
Output impedance380 +/- 76 Ohm

Anti-condensation heater (+HEAT2 option)

2 x 130 W 230 VAC Single-phase heater resistors

Heater connector (+HEAT2 option)

Hummel art no. 7651 0 5101 D (combination of housing 7651 0 00 00 0, insert 7084 951101/7084 9 51 12 1, crimp pins 7010 9 42 01 1) (https://www.hummel.com)

Heater mating connector

Hummel art no. 7550 6 51 02 D (combination of housing 7550 6 00 00 0, insert 7084 9 5110 2 / 70849 51 12 2, crimp socket 7010 9 42 00 2)

Heater connector pin type

Hummel art. no. 7010 9 42 01 1

Heater connector pin configuration

See Table 5

Bearing temp. measurement connector type

D-end: 4-pin M12 A coded male
N-end: DEUTSCH HD34-24-47PE

Bearing temp. measurement mating type

D-end: 4-pin M12 A coded female
N-end: DEUTSCH HD36-24-47SE or DEUTSCH HD36-24-47SE-059

Bearing temp. measurement connector pin configuration

See Table 1, Table 2 and Table 6

Pin Configuration Tables

Table 1 Pin configuration of LV-connector (+DUAL)

DescriptionPINOption
phase U1, main sensor, PT100 (P)47
phase U1, main sensor, PT100 (N)46
phase V1, main sensor, PT100 (P)33
phase V1, main sensor, PT100 (N)32
phase W1, main sensor, PT100 (P)45
phase W1, main sensor, PT100 (N)31
phase U2, main sensor, PT100 (P)30
phase U2, main sensor, PT100 (N)29
phase V2, main sensor, PT100 (P)44
phase V2, main sensor, PT100 (N)43
phase W2, main sensor, PT100 (P)28
phase W2, main sensor, PT100 (N)16
phase U1, spare sensor, PT100 (P)42+TEMP5
phase U1, spare sensor, PT100 (N)27+TEMP5
phase V1, spare sensor, PT100 (P)15+TEMP5
phase V1, spare sensor, PT100 (N)14+TEMP5
phase W1, spare sensor, PT100 (P)40+TEMP5
phase W1, spare sensor, PT100 (N)26+TEMP5
phase U2, spare sensor, PT100 (P)41+TEMP5
phase U2, spare sensor, PT100 (N)13+TEMP5
phase V2, spare sensor, PT100 (P)39+TEMP5
phase V2, spare sensor, PT100 (N)38+TEMP5
phase W2, spare sensor, PT100 (P)25+TEMP5
phase W2, spare sensor, PT100 (N)12+TEMP5
Resolver COSResolver, RES_COS_N, Inbuilt non-contacting35
Resolver COSResolver, RES_COS_P, Inbuilt non-contacting20
Resolver SINResolver, RES_SIN_N, Inbuilt non-contacting36
Resolver SINResolver, RES_SIN_P, Inbuilt non-contacting21
Resolver EXCNResolver, EXCN, Inbuilt non-contacting22
Resolver EXCPResolver, EXCP, Inbuilt non-contacting10
Resolver shieldResolver, SHIELD/GROUND, Inbuilt non-contacting34
Resolver2 COSResolver 2, RES_COS_N, Inbuilt non-contacting37+RES2
Resolver2 COSResolver 2, RES_COS_P, Inbuilt non-contacting24+RES2
Resolver2 SINResolver 2, RES_SIN_N, Inbuilt non-contacting23+RES2
Resolver2 SINResolver 2, RES_SIN_P, Inbuilt non-contacting11+RES2
Resolver2 EXCNResolver 2, EXCN, Inbuilt non-contacting9+RES2
Resolver2 EXCPResolver 2, EXCP, Inbuilt non-contacting8+RES2
Resolver2 shieldResolver 2, SHIELD/GROUND, Inbuilt non-contacting4+RES2
Bearing temperature, sensor 1PT1002
Bearing temperature, sensor 1PT100_GND18
Bearing temperature, sensor 2PT1003
Bearing temperature, sensor 2PT100_GND19

Table 2 Pin configuration of LV-connectors (+QUAD)

DescriptionPINOption
phase W1, spare sensor, PT100 (P)45+TEMP5
phase W1, spare sensor, PT100 (N)31+TEMP5
phase U2, spare sensor, PT100 (P)30+TEMP5
phase U2, spare sensor, PT100 (N)29+TEMP5
phase V2, spare sensor, PT100 (P)44+TEMP5
phase V2, spare sensor, PT100 (N)43+TEMP5
phase W2, spare sensor, PT100 (P)28+TEMP5
phase W2, spare sensor, PT100 (N)16+TEMP5
phase U3, spare sensor, PT100 (P)42+TEMP5
phase U3, spare sensor, PT100 (N)27+TEMP5
phase V3, spare sensor, PT100 (P)15+TEMP5
phase V3, spare sensor, PT100 (N)14+TEMP5
phase W3, spare sensor, PT100 (P)40+TEMP5
phase W3, spare sensor, PT100 (N)26+TEMP5
phase U4, spare sensor, PT100 (P)41+TEMP5
phase U4, spare sensor, PT100 (N)13+TEMP5
phase V4, spare sensor, PT100 (P)39+TEMP5
phase V4, spare sensor, PT100 (N)38+TEMP5
phase W4, spare sensor, PT100 (P)25+TEMP5
phase W4, spare sensor, PT100 (N)12+TEMP5
HEATHeater, ground / protective earth1+HEAT
HEATHeater, neutral2+HEAT
HEATHeater, phase, 230 VAC3+HEAT
Resolver shieldResolver, SHIELD/GROUND, Inbuilt non-contacting4+RES1
Resolver COSResolver, RES_COS_N, Inbuilt non-contacting5+RES1
Resolver COSResolver, RES_COS_P, Inbuilt non-contacting6+RES1
Resolver SINResolver, RES_SIN_N, Inbuilt non-contacting7+RES1
Resolver SINResolver, RES_SIN_P, Inbuilt non-contacting8+RES1
Resolver EXCNResolver, EXCN, Inbuilt non-contacting9+RES1
Resolver EXCPResolver, EXCP, Inbuilt non-contacting10+RES1
Temperature 1phase U1, main sensor, PT100 (P)11
Temperature 1phase U1, main sensor, PT100 (N)12
Temperature 2phase V1, main sensor, PT100 (P)13
Temperature 2phase V1, main sensor, PT100 (N)14
Temperature 3phase W1, main sensor, PT100 (P)15
Temperature 3phase W1, main sensor, PT100 (N)16
Temperature 4phase U2, main sensor, PT100 (P)17
Temperature 4phase U2, main sensor, PT100 (N)18
Temperature 5phase V2, main sensor, PT100 (P)19
Temperature 5phase V2, main sensor, PT100 (N)20
Temperature 6phase W2, main sensor, PT100 (P)21
Temperature 6phase W2, main sensor, PT100 (N)22
Temperature 7phase U3, spare sensor, PT100 (P)23+TEMP5
Temperature 7phase U3, spare sensor, PT100 (N)24+TEMP5
Temperature 8phase V3, spare sensor, PT100 (P)25+TEMP5
Temperature 8phase V3, spare sensor, PT100 (N)26+TEMP5

Table 3 Pin configuration of +LVB connection (+DUAL)

DescriptionPINOption
phase W3, spare sensor, PT100 (P)27+TEMP5
phase W3, spare sensor, PT100 (N)28+TEMP5
phase U4, spare sensor, PT100 (P)29+TEMP5
phase U4, spare sensor, PT100 (N)30+TEMP5
phase V4, spare sensor, PT100 (P)31+TEMP5
phase V4, spare sensor, PT100 (N)32+TEMP5
phase W4, spare sensor, PT100 (P)33+TEMP5
phase W4, spare sensor, PT100 (N)34+TEMP5
phase U1, spare sensor, PT100 (P)35+TEMP5
phase U1, spare sensor, PT100 (N)36+TEMP5
phase V1, spare sensor, PT100 (P)37+TEMP5
phase V1, spare sensor, PT100 (N)38+TEMP5
phase W1, spare sensor, PT100 (P)39+TEMP5
phase W1, spare sensor, PT100 (N)40+TEMP5
phase U2, spare sensor, PT100 (P)41+TEMP5
phase U2, spare sensor, PT100 (N)42+TEMP5
phase V2, spare sensor, PT100 (P)43+TEMP5
phase V2, spare sensor, PT100 (N)44+TEMP5
phase W2, spare sensor, PT100 (P)45+TEMP5
phase W2, spare sensor, PT100 (N)46+TEMP5
phase U3, spare sensor, PT100 (P)47+TEMP5
phase U3, spare sensor, PT100 (N)48+TEMP5
phase V3, spare sensor, PT100 (P)49+TEMP5
phase V3, spare sensor, PT100 (N)50+TEMP5
phase W3, spare sensor, PT100 (P)51+TEMP5
phase W3, spare sensor, PT100 (N)52+TEMP5
phase U4, spare sensor, PT100 (P)53+TEMP5
phase U4, spare sensor, PT100 (N)54+TEMP5
phase V4, spare sensor, PT100 (P)55+TEMP5
phase V4, spare sensor, PT100 (N)56+TEMP5
phase W4, spare sensor, PT100 (P)57+TEMP5
phase W4, spare sensor, PT100 (N)58+TEMP5
Bearing temperature, sensor 1PT10059+BTMP
Bearing temperature, sensor 1PT100_GND60+BTMP
Bearing temperature, sensor 2PT10061+BTMP
Bearing temperature, sensor 2PT100_GND62+BTMP
Reserve63
Reserve64
Reserve65
Reserve66
Resolver2 shieldResolver 2, SHIELD/GROUND, Inbuilt non-contacting67+RES2
Resolver2 COSResolver 2, RES_COS_N, Inbuilt non-contacting68+RES2
Resolver2 COSResolver 2, RES_COS_P, Inbuilt non-contacting69+RES2
Resolver2 SINResolver 2, RES_SIN_N, Inbuilt non-contacting70+RES2
Resolver2 SINResolver 2, RES_SIN_P, Inbuilt non-contacting71+RES2
Resolver2 EXCNResolver 2, EXCN, Inbuilt non-contacting72+RES2
Resolver2 EXCPResolver 2, EXCP, Inbuilt non-contacting73+RES2
D-END 1/2
Bearing temperature, sensor 1PT10074+BTMP
Bearing temperature, sensor 1PT100_GND75+BTMP
Bearing temperature, sensor 2PT10076+BTMP
Bearing temperature, sensor 2PT100_GND77+BTMP
D-END 2/2
HEAT2Heater 2, ground / protective earth78+HEAT2
HEAT2Heater 2, neutral79+HEAT2
HEAT2Heater 2, phase, 230 VAC80+HEAT2

Table 4 Pin configuration of +LVB connection (+QUAD)

PINDescriptionOption
1Phase, 230 VAC
2Neutral
3Ground/protective earth
4Reserve
5Reserve

Table 5 Pin configuration of heater

PINDescription
1PT100, sensor 1
2PT100_GND, sensor 1
3PT100, sensor 2
4PT100_GND, sensor 2

Table 6 Pin configuration of bearing temperature sensor connector (one two-wire PT100 sensor) in D-end

DescriptionPINOption
phase U1, main sensor, PT100 (P)47
phase U1, main sensor, PT100 (N)46
phase V1, main sensor, PT100 (P)33
phase V1, main sensor, PT100 (N)32
phase W1, main sensor, PT100 (P)45
phase W1, main sensor, PT100 (N)31
phase U2, main sensor, PT100 (P)30
phase U2, main sensor, PT100 (N)29
phase V2, main sensor, PT100 (P)44
phase V2, main sensor, PT100 (N)43
phase W2, main sensor, PT100 (P)28
phase W2, main sensor, PT100 (N)16
phase U3, main sensor, PT100 (P)42+TEMP5
phase U3, main sensor, PT100 (N)27+TEMP5
phase V3, main sensor, PT100 (P)15+TEMP5
phase V3, main sensor, PT100 (N)14+TEMP5
phase W3, main sensor, PT100 (P)40+TEMP5
phase W3, main sensor, PT100 (N)26+TEMP5
phase U4, main sensor, PT100 (P)41+TEMP5
phase U4, main sensor, PT100 (N)13+TEMP5
phase V4, main sensor, PT100 (P)39+TEMP5
phase V4, main sensor, PT100 (N)38+TEMP5
phase W4, main sensor, PT100 (P)25+TEMP5
phase W4, main sensor, PT100 (N)12+TEMP5
Bearing temperature, sensor 1PT10074+BTMP
Bearing temperature, sensor 1PT100_GND75+BTMP
Bearing temperature, sensor 2PT10076+BTMP
Bearing temperature, sensor 2PT100_GND77+BTMP
HEAT2Heater 2, ground / protective earth78+HEAT2
HEAT2Heater 2, neutral79+HEAT2
HEAT2Heater 2, phase, 230 VAC80+HEAT2

Graphs and Tables

Picture 1 Allowed altitudes vs phase cable length

A line graph showing the relationship between altitude and phase cable length. The Y-axis represents Altitude [m] from 0 to 4500, and the X-axis represents Phase cable length [m] from 0 to 17. The line shows a decreasing trend, indicating that allowed altitude decreases as phase cable length increases.

Picture 2 Pressure loss vs coolant flow

A line graph illustrating pressure loss in bar against coolant flow in l/min. The Y-axis ranges from 0 to 1.2, and the X-axis ranges from 35 to 65. The line shows an increasing trend, indicating that pressure loss increases with higher coolant flow rates.

Table 7 Mounting method

A table detailing various mounting methods. It includes columns for Mounting (Foot, Side, Flange, D-end, Dual-end, Spline, Cylindrical), and IEC60034-7 (Code I, Code II). Checkmarks indicate compatibility for different mounting configurations.

Table 8 Product code examples

Product codeDescription
EM-PM1540B-T4000-1600-DUALStandard 1600 rpm unit with standard options
EM-PM1540B-T4000-1600-DUAL+BIA+RES1Standard unit otherwise but with isolated bearings and resolver

Table 9 Option list

VariantCodeDescriptionAdditional information
High voltage connections-DUAL (***Two galvanically isolated three-phase systems1 x M32 cable gland per phase, total of 6 pcs M32 cable glands
-QUADFour galvanically isolated three-phase systems1 x M32 cable gland per phase, total of 12 pcs M32 cable glands
Low voltage connections (signal and auxiliaries)+LVB1Low voltage connections done with connectorSee Connections - section of the data sheet
*Low voltage connections done with connection box and terminal stripD-end: LV connection box with 1 x M16 cable gland + terminal strips; N-end: LV connection box with 1 x M25, 2 x M16 and 1 x M12 cable glands + terminal strips (see user guide for pinout)
D-end shaft*Male shaft, cylindricalCylindrical shaft, diameter 70 mm h7
+S3 (***Male shaft, splineDIN 5480 W70x2x30x34x8f
N-end attachment*NoneMale shaft, no flange
+NE4 (****NoneCylindrical shaft, diameter 70 mm h7 (standard) DIN 5480 W70x2x30x34x8f (+S3)
Foot mounting+FM1FootFoot mounting, shaft height 315 mm
Bearing insulation+BINNon-insulated bearingsNon-insulated bearings
+BIAInsulated bearing in N-endInsulated bearing in N-end
*Insulated bearing in both endsInsulated bearing in both ends
Shaft grounding+SG1D-end shaft groundingInbuilt grounding ring
Rotation sensor*ResolverNo resolver
+RES1ResolverInbuilt non-contacting resolver, 8-pole pair
+RES2Double resolverInbuilt non-contacting resolver, 8-pole pair
Winding temperature sensors*Temperature surveillanceDUAL: 6 x PT100 (two-wire) in windings
+TEMP5Redundant temperature surveillanceQUAD: 12 x PT100 (two-wire) in windings
Bearing temperature sensors*NonePT100 in bearings
+BTMP1*Plugin connector
Anti-condensation heaters*NoneTwo anti-condensation heaters
+HEAT2*2 x 230 VAC/130 W (see user guide for more information)
Machine coating*NoneDark grey RAL7024; Type of coating: Epoxy; Minimum number of coats (MNOC): 2; Minimum nominal dry film thickness: 240 µm

MOTORS

TypeCont. Torque [Nm]Cont. Power [kW]Nom. Current [A]Cont. Torque [Nm]Cont. Power [kW]Nom. Current [A]Peak Torque [Nm]Max. Peak speed [rpm]Nom. speed [rpm]QUADDUAL (a (b
EM-PM1540B-T4000-60045222843875454342463600120059305930
EM-PM1540B-T4000-1200422953171646925907901200240041585930
EM-PM1540B-T4000-16004183701954463977710581600320030625930
EM-PM1540B-T4000-24003565896123240671022142224004000 (c4000

(a Peak torque achieved with two 350A inverters (b Peak torque achieved with four 350A inverters (c Mechanical maximum speed

The maximum allowed peak torque duration at stator winding starting temperature +90°C is 10.5 minutes. The given values indicate typical duration and are not verified. In case more accurate values are required, cyclic dimensions are needed.

GENERATORS

TypeApparent power [kVA]Cont. power [kW]Nom. Current factorApparent power [kVA]Cont. power [kW]Nom. Current factorNom. speed [rpm]Nom. speed [rpm]Volt/ Freq. ratio [VAC/ rpm] (dPower factor
EM-PM1540B-T4000-6003403363880.994083974640.978001070.816
EM-PM1540B-T4000-12006095897050.976746487790.9614001870.416
EM-PM1540B-T4000-16008097599420.9489683110400.9318002400.290
EM-PM1540B-T4000-240098491111850.921074102413080.9525003330.193

(d Back EMF for cold (+20°C) generator

PRODUCT CODE AND OPTIONS

Use product code including all needed options for ordering. Standard options are not given with the code as they are selected by default if a non-standard option is not selected. Standard options are indicated by a star (*).

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