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Installation, Operation and Maintenance Manual for PAHT

1. 63 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Parts list PAHT and PAHT G pumps 18 Spare parts list for PAHT 50 90 180B4195 Cylinder barrel set PAHT 50 90 180B4192 Valve plate set PAHT 50 70 180B4193 Valve plate set PAHT 80 90 180B4252 Swash plate set PAHT 50 180B4255 Swash plate set PAHT 63 180B4258 Swash plate set PAHT 70 180B4253 Swash plate set PAHT 80 180B4256 Swash plate set PAHT 90 o sE c e U Vi U 1 Oy St ea e co 18084194 Piston set 50 90 un Designation p A PP IS IS O T E po meer 1 TT TI O O IS T s pes pem x A spe memes ass x sp eme CE DREES SE RR mp meme Fas 1 b b bb ep mee CEI RR RR e po reng eem fx A mp omm l O E epo ns pem IE 5 r eege pem III fe gt s menm 1177 e p pes x TT mpm m E RR RR TT E E E RI RI mop mme enee mp meas enee ffx o mp meme pem l k LE E EL mp s m o lI p eme n k EE mue pem T
2. R A 11 35 71 Direction ofrotation 13 46 48 Disassembling o 15 E EC Declaration of Conformity 5 Electrical failure 16 Electrical hazard 6 7 16 Electric motor 6 7 8 9 10 11 12 15 16 S EE 21 32 48 50 51 71 72 73 A 74 75 76 83 84 Electrics a0 e 2e X 3992322539593 12 F FOIS ee hee ona 9 16 52 81 ST EE e 13 Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Filtration 9 12 14 16 32 34 40 45 49 71 73 78 Fish bonechart 71 Flow 7 9 13 14 20 22 23 24 25 26 o SR 27 28 29 30 31 33 34 43 48 49 Po D 50 52 71 72 73 74 75 76 77 78 Flowcurves 26 27 28 29 30 31 Fluid 11 12 15 16 32 48 71 73 75 Fl sli A s s a E 8 11 48 49 82 G General information 7 50 Guideline 40 43 44 50 69 72 H a e le PPS 7 9 Initial startup 8 48 75 Inspection 9 14 40 50 Installation 6 7 8 11 12 14 16 21 01777 32 52 53 71 72 76 81 82 INSTRUCCION uos be ea nesat e e ei aia 41 nstrumentation 6 12 Introduction 23g e e we 54 xu SE 6 20 M Maintenance 6 7 13 14 21 32 225717 40 49 52 53 Mechanical failure 16 MOUNTING 8 12 13 15 16 32 22v1777 7 45 47 52 72 76 Motor requirement
3. Data sheet PAHT 2 308 and PAHT G 2 308 pumps Below sectional drawing is an example of a PAHT pump Shaft sealing Mounting flange Retainer ring SE Vii 2 Piston shoe i AA DA NAIL Valve plate SY RY x Swash plate n T Cylinder barrel N t Eu ien E HT gt TSS ES gt 7 d v SS 1 SS s p bi Y E n iH d Pe NI Spring J ISS 19 2 Connecting flange N 2 Housing with bearing Z 2 Benefits Zero risk of lubricant contamination Pump can be installed horizontally or Oil lubricants are replaced with the vertically pumped medium water so there is no No pulsation dampeners necessary due contamination risk from the pump to extremely low pressure pulsation Low maintenance costs Powered by electric motors or combus Efficient design and all stainless steel tion engines 15 57 A long Suitable 17 7 de ife When Danfoss specifications are pressure and water supply from a tank met service intervals of up to 8 000 Noneed for cooling circuits due to very hours can be expected Service is easy high mechanical efficiency and can be carried out on site due to Certified quality the simple design and few parts Fulfills the stringent hygiene require Low energy costs ments VDI 6022 HACCP The highly efficient axial piston design Certificates provides the lowest electricity con ISO 9006 ISO 14001 sumption of any comparable pump on ATEX available on
4. 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Small air bubbles will accumulate and create large bubbles causing internal cavitation and thus making the pump very noisy WARNING The pump can only run few minutes with air in the fluid without being damaged The pump and the inlet line must be com pletely bled before start up otherwise the pump will cavitate and make high noise WARNING The pump can only run few minutes with air in the fluid without being damaged Too high inlet pressure causes too high pressure inside the pump damaging the pistons and eventually the pump Inlet pressure below min limit causes cavitation and insufficient internal lubrication resulting in wear on internal pump parts Mount a low pressure switch in front of the pump and check its set point function The low pressure switch will ensure that the pump does not start until the minimum inlet pressure has been reached If pump rotates in wrong direction it will take in water from the high pressure outlet line Pressure will be built up inside the pump and it will eventually be damaged Higher rpm than specified in the pump data sheet results in wear of the pistons i e pistons may be damaged High rpm will also increase pressure pulsations from the pump and the noise level will increase If rpm is changed noise frequency will also change At too low outlet pressure the pump will create higher pressure pulsations and th
5. al lee las f rpeemem mem TT xor mem las T T al as n fx ll m ES TT el nem qam l 1 el mae men sl rn O IS rd Le las 3 E nl rm rene e 1 pee ETE p ai lem EIC 1 T neg es 1 1 1 Cm sens me p E omes wee O l o a eme ear el om m E Ew v emsees m el EIC 21 Ew rem en 1 01707 p x T e eemen mes 3 1 al ees las 1 1 7 secan 66 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 PAHT and PAHT G pumps Parts list Exploded view for PAHT G 50 90 21 UNE UNOE WNE WNOE 67 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Parts list PAHT and PAHT G pumps 26 Tool sets 18020237 Shaft seal tool set 18020236 Shaft seal tool set PAHT 50 90 PAHT 20 32 180B4259 Tool set 180Z0235 Tool set PAHT PAHT G 2 12 5 PAHT 256 308 180Z0235 Tool set PAHT PAHT G 2 6 3 Designation mew TT EE x ox po po EES A 2 1 pes i 2271 me E ns Lo Sam
6. 16 33 34 48 49 75 82 Storage 9 10 15 48 49 Ss A 52 System 6 7 8 9 11 12 13 14 15 277 21 32 33 34 43 44 46 48 49 53 74 75 76 79 80 81 82 83 84 T Table of Contents 2 3 18 20 42 58 70 Technical data 8 22 Temperature 7 11 12 13 14 16 22 23 24 25 33 34 40 45 47 177777 48 49 52 53 71 73 82 83 84 Transportation 6 9 Trouble shooting 69 79 V Valve 7 11 12 13 16 33 34 43 0037577777 46 48 49 72 74 75 80 82 W Warning s uu en ommo as 6 9 13 72 75 Warranty DORI RER Rege eed 6 9 15 32 Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed 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 86 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013
7. Provided that the pump is installed and operated according to Danfoss specifications Danfoss PAHT pumps typically run 8 000 hours between service routines However the service schedule for your Danfoss PAHT pump may vary according to the application and other factors The life of a pump may be greatly shortened if Danfoss recommendations concerning system design and operation are not followed In our experience poor filtration is the number one cause of pump damage Danfoss Other factors that affect pump performance and lifetime include running the pump at speeds outside specifications supplying the pump with water at temper atures higher than recommended running the pump at inlet pressures outside specifications running the pump at outlet pressures outside the specifications We recommend that you inspect your pump after 8 000 hours of operation even if it is running without any noticeable problems Replace any worn parts as necessary including pistons and shaft seals to keep your pump running efficiently and to prevent breakdown If worn parts are not replaced then our guidelines recommend more frequent inspection Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential change
8. T EL Dm eme Im x om sis m x s nsan Fas x A fas ges pem _ fas eem L0 e emeng LE E Das ees asses A o RR O TT I 64 180R9288 IOM PAHT PAHT 20 90 pumps v01 05 2013 PAHT and PAHT G pumps Parts list Exploded view for PAHT 50 90 19 UNE UNOE WNE WNOE 65 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Parts list PAHT and PAHT G pumps 20 Spare parts list for PAHT G 50 90 180B4330 Swash plate set 180B4328 Swash plate set PAHT G 90 PAHT G 70 180B4329 Swash plate set 180B4326 Swash plate set PAHT G 80 PAHT G 50 180B4327 Swash plate set 180B4339 Cylinder barrel set PAHT G 63 PAHT G 50 90 180B4344 Valve plate set 180B4340 Valve plate set PAHT G 80 90 PAHT G 50 70 180B4343 Piston set PAHT G 50 90 U N T o Nn o O N car on Pes um pemon m II IN frown assi 1777177777 IER INCA peen las x 117 1 soe enses a 7 9 we x E m ew CEI 8177
9. The high pressure pump must stop if low level switch is activated Adjust pressure relief valve to working pressure Check the temperature switch controls The high pressure pump must stop if temperature is above specified set point 9 Check the filter pressure svvitch controls A vvarning must be given if pressure is above specifted set point If the system is running vvithin the system design limits the system is released for operation A 5 17 Check the filter condition Evaluate contamination found in filter replace filter elements if necessary A 5 18 Instruct operator and maintenance personnel Before using the pump pump unit the personnel must be instructed in using the pump pump unit its function components documentation and safety Danfoss offers commissioning and service at system manufacturer s location Rate quotes are offered upon request 13 User manual 6 7 Operation of motor pump unit Maintenance and service of the pump unit pu Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps A 6 1 General safety information Before inspecting the pump unit read the Safety chapter 2 in this user manual 6 2 What to listen and look for If one or more of the following examples are observed please act as indicated A Loose bolts check all bolts and if necessary contact the maintenance department in order to have all bolts tightened to the spe
10. is as follows PAHT 2 3 2 4 6 3 PAHT 10 12 5 20 25 32 50 63 70 80 90 256 308 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 31 Data sheet 7 32 PAHT 2 308 and PAHT G 2 308 pumps See the figure below for instructions on how to mount the pump and connect it to an electric motor or combustion engine Pump Bell housing Coupling Motor If alternative mounting is required please contact your Danfoss sales representative for further information Note Do not add any axial or radial loads to the pump shaft 7 1 Filtration Proper filtration is crucial for the performance maintenance and warranty of your pump Protect your pump and the application in which it is installed by always ensuring that all filtration specifications are met and by always changing filter cartridges according to schedule Since water has very low viscosity Danfoss PAHT pumps have been designed with very narrow clearances in order to control internal leakage rates and improve component performance To minimize wear on the pump it is therefore essential to filter inlet water properly The main filter must have a filtration efficiency of 99 9896 at 10 um We strongly recommend that you always use precision depth filter cartridges rated 10 um abs 5000 Please note that we do not recommend bag filters or string wound filter cartridges which typically have onl
11. 32 122 32 122 32 122 32325 32 125 Sound dB A 81 pressure level 20000 s weight 34 34 za 34 Measurements according to EN ISO 3744 2010 dB A LA Measured at max pressure and rpm for a motor pump unit values are calculated 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Data sheet PAHT 2 308 and PAHT G 2 308 pumps 4 4 PAHT 256 308 PAHT 256 180B1001 180B6090 AISI 316 or higher PAHT 308 180B1002 180B6091 AISI 316 or higher Code number PAHT Code number PAHT G Housing material Geometric cm rpm 256 308 displacement 156 18 8 in rpm UJ O UJ O Min outlet barg pressure A UJ A UJ UN psig Max outlet barg pressure si continuous ES N N Inlet pressure barg continuous ps g Max inlet barg pressure peak T O O KN O O bz 00 psig Speed Min speed continuous rpm Max speed 1250 continuous rpm A UN O A UN O Typical flow Flow curves available in item 5 450 rpm at l min max pressure 282 1250 rpm at l min max pressure EM o 450 rpm at gpm max pressure 1250 rpm at gpm max pressure Typical motor size 1000 rpm at kW max pressure Un 1200 rpm at 100 125 max pressure o o o o T mil 3 N N z 549 6 405 6 2 50 37 122 0 50 32 122 661 3 448 0 2 50 37 122 0 50 32 122 Torque at max outlet pressure Medi
12. 50 37 122 0 50 32 122 Torque at max outlet pressure 15 5 2 50 37 122 Ambient 0 50 temperature 32 122 temperature N MAN N N SS N Measurements according to EN ISO 3744 2010 dB A L values are calculated Measured at max pressure and rpm for a motor pump unit 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Data sheet 24 PAHT 2 308 and PAHT G 2 308 pumps 4 3 PAHT 50 90 PAHT 50 PAHT 63 PAHT 70 PAHT 80 PAHT 90 Code number PAHT 180B0085 180B0086 180B0087 180B0088 180B0089 Code number PAHT G 180B1012 180B1013 180B1014 180B1015 180B1016 Housing material AISI 316 or higher Geometric displacement Min outlet pressure Max outlet pressure continuous Inlet pressure continuous Max inlet pressure peak Min speed rpm 700 700 700 700 700 continuous Max speed rom 1800 1800 1800 1800 1800 continuous Typical flow Flow curves available in item 5 1000 rpm at l min 43 7 51 6 57 2 69 2 79 3 max pressure 1500 rpm at l min 68 7 83 1 92 2 109 2 124 3 max pressure 1200 rpm at gpm 14 2 17 0 18 8 22 5 25 7 max pressure 1800 rpm at gpm 22 1 27 0 30 7 35 2 40 0 max pressure Typical motor size 1500 rpm at kW 11 30 30 37 45 max pressure 1800 rpm at hp 20 50 50 75 max pressure Torque at max 172 6 191 8 219 8 246 6 GUDER pass jur 127 4 141 5 1622 182 0 temperature 37192 37 122 37 122 32329 37 122 temperature
13. 50 90 PAHT G 50 90 o PAHT 256 308 PAHT G 256 308 as well as exploded views of the pumps Not included 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 59 Parts list PAHT and PAHT G pumps 14 Spare parts list for PAHT 20 32 AN xx ov au M OR ORE len pm x pe OT s p ewe pe 7 T ss esi ass 0 ap fmm pe 5 pr mess E E E fa p owes wem IS LLL mp pem 1 ep ewe ie T b po pese p 0 T REES T ron mam 1 T e i anon x LL poemas mme E EI m pee pem RES RR RR E EI 919 sawm pe o RR EI ewe pe PR ERE E E o ewee ps IS IS O ESL fomos pe LLL ras i osmeesse pu E EL fi i waves mew x E EE Bs meme ls Ill fas i mese pam o E LL eme pam Jill pum TO p popeweewae T T 180B4254 Svvash plate set PAHT 25 180B4257 Svvash plate set 180B4251 Svvash plate set PAHT 32 180B4054 Cylinder barrel set PAHT 20 PAHT 20 32 180B4052 Valve plate set PAHT 20 32 180B4053 Piston set PAHT 20 32 U v U YN M del R e q E ca ILI oc oo 60 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 PAHT and PAHT G pumps Parts list Exploded view f
14. E E T ZI rece II enger O 0 sssi eee 1 Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products vvithout notice This also applies to products already on order provided that such alterations can be made vvithout subsequential changes being necessary in specifications already agreed 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 68 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 MAKING MODERN LIVING POSSIBLE Guideline Trouble shooting guide for PAH PAHT PAHT G PAHT 674 and PAH F pumps danfoss high pressurepumps com Guideline Table of Contents Trouble shooting guide for PAH PAHT PAHT G and PAH F pumps 70 Danfoss Trouble shooting guide for PAH PAHT PAHT G PAHT 674 and PAH F pumps Trouble shooting fish bone chart 1 2 180R9288 IOM PAHT PAHT 20 90 pumps v01 05 2013 No flow no pressure Reduced flow reduced pressure High torque on electric motor Noise from pump Noise from installation Typical signs of wear Valve plate Port plate Swash plate Trouble shooting guide for PAH PAHT PAHT G PAHT 674 and PAH F pumps
15. PAHT G the market API available on request Easy installation The lightest and most compact design available 3 Application examples High pressure cleaning with ultra pure Humidification in office buildings elec water as used in the manufacturing of flat panel displays and other electronic products High pressure cleaning with ultra pure water as used in the manufacturing of parts for the automobile industry Adiabatic cooling systems to replace or supplement standard A C systems in server rooms and factories 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 tronic component manufacturing dairies greenhouses etc Dust suppression and odor control systems for example in paper textile and wood production Reduction of NOx emissions in diesel engines 21 Data sheet 4 22 Technical data PAHT 2 308 and PAHT G 2 308 pumps 4 1 PAHT 2 12 5 pumpsice Pata panta mes mem mee Speed Min speed rpm 1000 1000 1000 1000 1000 1000 continuous Max speed rpm 3000 3000 3000 3000 2400 2400 continuous Typical flow Flow curves available in item 5 1000 rpm at l min 2 3 3 1 55 10 5 max pressure 1500 rpm at l min 1 9 3 8 5 1 12 8 16 5 max pressure 1200 rpm at gpm 0 3 1 0 1 8 2 6 3 4 max pressure 1800 rpm at gpm 0 7 1 3 1 7 2 8 4 1 5 3 max pressure Typical motor size 1500 rpm at kW 0 75 1 1 1 5 2 2 4 0 5 5 max pressure 1800 rpm at hp 1 0 1 5 2 0 3 0 7 9 7 5 max
16. at max pressure 5 2 PAHT 10 12 5 flow curves at max pressure 5 3 PAHT 20 32 flow curves at max pressure 5 4 PAHT 50 90 flow curves at max pressure 5 5 PAHT 256 308 flow curves at max pressure 6 Motor requirements 7 Installation 7 1 Filtration 7 2 Noise 7 3 Open system design 7 4 Closed system design 8 Dimensions and connections 8 1 PAHT 2 6 3 8 2 PAHT 10 12 5 8 3 PAHT 20 32 8 4 PAHT 50 90 8 5 PAHT 256 308 9 Service The Danfoss range of PAHT and PAHT G high The range of PAHT G pumps is based on the pressure pumps is specifically designed for use standard PAHT pump series The PAHT G pumps with technical water such as are made with some extra coatings that reduce the wear of the pump This coating is particularly o Ultra pure water that has undergone important for pumps used in gas turbine multiple reverse osmosis processes applications or other similar applications where De ionized water the wear of the pumps is high due to the ultra o Demineralized water pure water quality Danfoss PAHT pumps are positive displacement The next pages will cover both PAHT and PAHT G pumps with axial pistons that move a fixed pumps with the name PAHT pumps amount of water in each cycle Flow is propor tional to the number of input shaft revolutions rom Unlike centrifugal pumps they produce the same flow at a given speed no matter what the discharge pressure 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013
17. com svendhoyer com MAKING MODERN LIVING POSSIBLE Parts list PAHT 2 308 pumps PAHT G 2 308 pumps danfoss high pressurepumps com Parts list Table of Contents Parts list for PAHT and PAHT G pumps 52181237 58 PAHT and PAHT G pumps 1 General 2 Spare parts list for PAHT 2 Bi Exploded view for PAHT 2 4 Spare parts list for PAHT G 2 5 Exploded view for PAHT G 2 6 Spare parts list for PAHT 3 2 6 3 7 Exploded view for PAHT 3 2 6 3 8 Spare parts list for PAHT G 3 2 6 3 9 Exploded view for PAHT G 3 2 6 3 10 Spare parts list for PAHT 10 12 5 11 Exploded view for PAHT 10 12 5 12 Spare parts list for PAHT G 10 12 5 ES Exploded view for PAHT G 10 12 5 14 Spare parts list for PAHT 20 32 15 Exploded view for PAHT 20 32 16 Spare parts list for PAHT G 20 32 17 Exploded view for PAHT G 20 32 18 Spare parts list for PAHT 50 90 19 Exploded view for PAHT 50 90 20 Spare parts list for PAHT G 50 90 21 Exploded view for PAHT G 50 90 22 Spare parts list for PAHT 256 308 23 Exploded view for PAHT 256 308 24 Spare parts list for PAHT G 256 308 25 Exploded view for PAHT G 256 308 26 Tool sets Not included 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Parts list 1 General PAHT and PAHT G pumps This parts list provides an overview of the content of the various service sets for the PAHT 2 6 3 PAHT G 2 6 3 PAHT 10 12 5 PAHT G 10 12 5 PAHT 20 32 PAHT G 20 32 PAHT
18. instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 Systems can be either Water hydraulic systems in which the water is recirculated back to tank e Open ended systems with water supply from a tank Open ended systems with direct water supply boosted pressure The design of the system must ensure that selfemptying of the pump during standstill is avoided The minimum boost pressure is 2 barg 29 psig and the maximum peak pressure is 20 barg 290 psig The recommended normal boost pressure is 2 6 barg 29 87 psig 3 7 barg 43 5 101 5 psig abs If itis unknown what the peak inlet pressure can be then there should be a 15 barg 218 psig safety relief valve on the inlet side of the pump Note All mentioned pressures refer to measures in the respective pump gauge ports The inlet pressure of the pump must never exceed the outlet pressure This may typically occur in boosted or open ended systems with supply direct from the tap and where a bypass valve is activated 2 1 Closed water hydraulic systems water recirculated The numbers 1 3 refer to the drawing below In order to eliminate the risk of cavitation always ensure a minimum inlet pressure of 0 barg 0 psig 1 barg 14 5 psig abs by observing the following guidelines 1 Place the tank above pump and pump inlet 2 Place the main filter in the return line and not in the suction line 3 Dimension the inlet line with a mini
19. listed in section 1 3 Manufacturer and customer service address 3 2 Application range See appendix 1 Data sheet 3 3 Electric motor data See recommended motor in appendix 1 Data sheet or appendix 3 IOM for motors The motors mentioned are the most common used motors by Danfoss High Pressure Pumps 3 4 Noise and vibration Noise level for a pump unit with a standard motor measured according to EN ISO 3744 2010 see appendix 1 Data sheet Possibilities to reduce noise and vibration are described in the same Data sheet 3 5 Dimension drawings Dimensions of the different pumps can be found in appendix 1 Data sheet 3 6 Spacerequirement When doing service or replacing the complete pump unit it is recommended to have sufficient space available around the pump in order to ensure easy access Sufficient space means at least 1 meter 40 inches around the pump When working with high pressures it is important to have the right space available around the pump as stated in the safety requirements User manual 4 Arrivalinspection transportation handling lifting and storage A 3 7 Filtration 10um absolute B gt 5000 Requirements are specified in appendix 1 Data sheet and appendix 2 Instruction Danfoss recommends not to build a filter bypass function or use filters with an integrated bypass If the above recommendation is not followed the warranty for the pump will automatically become void It sh
20. no water supply to the pump 1 2 Pump reversing electric motor is running the wrong direction i e counter clockwise 1 3 No rotation of electric motor 1 4 No rotation of pump 1 5 Axial load on pump shaft may cause high internal leakage Only applying to PAH 2 12 5 PAHT 2 308 PAH F 20 40 PAHT G 2 308 1 6 Pump damage the internal parts may be damaged If no water comes out of the pump 1 1 1 Check that inlet valve is open 1 1 2 Check that booster pump is running 1 2 1 Change the phase on the electric motor to make it run clockwise WARNING The pump must not run without water for more than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure in pump housing and will eventually break down 1 3 1 Check that main switch is switched on 1 3 2 Check the electricity at the facility 1 3 3 Ensure that motor relay is switched on 1 3 4 Ensure that fuse is not blown 1 3 5 Ensure that booster pump is started 1 3 6 Check that the monitor switches are working correctly 1 3 7 Disconnect pump from electric motor and check that the motor is capable of running with no load 1 4 1 Ensure that coupling between electric motor and pump is connected 1 4 2 Check if coupling is damaged 1 4 3 Check that electric motor is sized correctly 1 4 4 Check that the electrical installation is correctly sized 1 4 5 Contact Danfoss Sales office for guidelines in how
21. pipes and hoses 4 40 gpm US 150 l min bar psi In 90 bends 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Instruction 3 Building up the pump unit Danfoss Pump instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 2 4 General comments on Filtration A good filtration is vital to ensure a long and trouble free life of the pump When selecting a filter or strainer please note that filter materials should be compatible with water i e should neither corrode or dissolve Also be aware of the electrochemical series of the applied materials o Main filter must have a fineness of 10 um abs 510 gt 5000 o The pressure loss across the filter should be monitored Please contact Danfoss High Pressure Pumps for further filter details Water tank Must be made of corrosion proof material such as stainless steel or plastic and must be sealed to prevent entrance of impurities from the environ ment Automatic pressure equalization between tank and surroundings must be ensured Inlet from the water supply the return line and inlet to the pump should be placed in opposite ends of the tank to calm and deaerate the water and to ensure optimum opportunity for particles to settle 3 1 Mounting If alternative mounting is desired please contact Danfoss High Pressure Pumps Choose proper tolerances to ensure an easy mounting of the elastic coupling with
22. port on the outlet for optional 10x 8 x 45 2 DIN 6885 mounting of i e pressure transducer 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 47 Instruction 4 5 48 Initial start up Operation Danfoss Pump instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 NEN PAHT PAHT G 50 63 70 80 90 Outlet O Inlet I Bleeding C Gauge 1 4 ports Thread ISO 1 BSPP with 1 BSPP with M6 width 1 4 BSPP with 24 mm long thread 24 mm long thread across flat 5mm 15 mm long thread 120 Nm 180 Nm 4 Nm 15 Nm 89 Ib f ft 133 Ib f ft 3 Ib f ft 11 Ib f ft Recommended torque values refer to steel washers containing a rubber sealing element Before start up loosen the top bleeding plug C When water appears from the bleeding plug retighten the plug WARNING Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump 5 1 Water quality Water of drinking water quality confirming to the EEC directive 98 83 EC and without abrasive sediments demineralized water de ionised water softened water and RO water Please contact Danfoss High Pressure Pumps sales organization in case of doubt 5 2 Temperature Fluid temperature Min 3 C 374 F to max 50 C 122 F Ambient temperature Min 0 C 32 F to max 50 C 122 F Storage temperature Min 40 C 40 F to max 70 C 158 F To protect
23. pump Wipe the parts clean and dry with a lint free clothing C Inspectall parts including shaft seal and if necessary replace them see appendix 4 Parts list D Ifthe pump is going to be returned to Danfoss for repair or a warranty claim it is important to contact Danfoss in order to receive a return number and a form to fill out with product information A copy of the form together with contact information and reason for returning should be sent to the email address on the form The same documents should be attached to the shipment 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Productinformation see label on product Only 1 product on each report Code number Serial number Application Inlet pressure Rpm ipump motor only Hours of operation Outlet pressure Number of duty cycles valves only Pumps in parallel yes no Returns without a return number will be rejected 7 5 Assembling the pump unit Assemble the pump according to the Disassem bling and Assembling Instruction available at www danfoss high pressurepumps com 7 6 Procedure for mounting the pump back onto electric motor A Mount the flexible coupling and bell housing according to appendix 2 Instruction 7 7 Getting the pump unit back into operation Find instructions of how to put the pump unit back into operation in chapter 4 Arrival inspec tion transportation handling lifting and storage and Installatio
24. the Danfoss specifications requires a written approval from Danfoss High Pressure Pumps e H any changes are made without written approval the warranty will automatically become void It is important that these instructions are always available to the personnel concerned 1 2 Symbols Indicates something to be noted by the reader Indicates a situation which will or could result in damage to the pump and its function A Indicates a situation which will or could result in personal injury and or damage to the pump AN Electrical hazard Indicates a high voltage warning Safety glasses required Safety shoes required 9 Hearing protection required to Safety helmet required 9 Protective garments must be worn Danger HOT AN Do not touch A ener Electrical hazard Protective garments must be worn User manual 2 Safety Danfoss Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps 1 3 Manufacturer and customer service address Danfoss A S High Pressure Pumps Nordborgvej 81 D25 DK 6430 Nordborg Denmark Telephone 45 7488 2222 Fax 45 7445 3831 Email highpressurepumpsadanfoss com Web www danfoss high pressurepumps com A 2 1 General information Dangers that can arise from not following the instructions When the pump or pump system is managed by untrained personnel there is a danger of e Death or fatal injuries e Costly damages and
25. the pump and system are emptied for water User manual Danfoss Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps A F unscrew and remove the bolts and gaskets from the inlet outlet hoses or pipes be careful about jets of water Be aware that the system can be pressurized G Attach the lifting equipment to the pump unit For instructions on lifting the complete pump unit see chapter 4 Arrival inspection transportation handling lifting and storage H Forthe small pumps unscrew the bolts holding the pump to the bell housing and for the bigger pumps unscrew the bolts nuts from the pump and bell housing to the motor and afterwards unscrew the bolts nuts holding the pump and bell housing Carefully pull the pump out of the bell housing by using lifting equipment if necessary J Hold the pump in different positions above a drip tray this should allow most of the water trapped in the pump to drain Clean and dry the pump surface and plug the bleeding and draining plugs K Move the pump to a clean and safe location where the pump can be inspected serviced 7 4 Disassembling and assembling the pump unit A Remove all connections from the pump B Disassemble the pump according to the Disassembling and Assembling Instruction available at www danfoss high pressurepumps com Clean all the parts and surfaces with a fluid compatible with the materials found in the
26. to troubleshoot internal pump parts 1 5 1 Ensure that the air gap between the two coupling parts is min 5 mm It should always be possible to move the plastic part on the coupling at least 3 mm 1 6 1 Contact Danfoss sales office for guidelines in how to troubleshoot internal pump parts 72 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Mount a low pressure switch in front of the pump and check its set point function The low pressure switch ensures that the pump does not start until the inlet pressure has reached minimum inlet pressure see Data sheet Rotation direction for the pump is shown by an arrow on the label on the pump If motor type relay or the electrical fuse is blown check that electric motor is sized correctly To ensure easy mounting of the flexible coupling without using tools the tolerances must be dimensioned accordingly WARNING Any axial and or radial loads on the shaft must be avoided Any axial or radial load will cause breakdown A Bell housing B Flexible coupling C Motor shaft Instructions on internal elements are available on www danfoss high pressurepumps com Guideline 2 Reduced flow reduced pressure pu Trouble shooting guide for PAH PAHT PAHT G PAHT 674 and PAH F pumps 2 1 Wear on pump Large internal leakage due to 2 2 Low inlet pressure 2 3 Rotation speed rpm 2 1 1 Dismantle the pump 2 1 2 Check valve plate Valve plate has marks scrat
27. 0 min and activate all components as often as possible to ensure effective flushing with the cleaning agent 5 Empty the system of the cleaning agent solution Flushing procedure 6 Fill cold water through the return filter and bleed the pump Power Packs PPH 4 6 3 10 and 12 5 are self bleeding 7 Run the system for 30 min and activate all components as often as possible 8 Empty the system of the water 9 Alternatively the system may be flushed by running the unit without the return hose while continuously filling up water The flushing should continue until there is no trace of cleaning agent in the return water 10 Change the return filter element fill cold water through the return filter and bleed the pump during start up 11 The system is now ready for operation Starting procedure EREEEEEEEI 000000000 999999999 Observing the starting procedure will If the system is not cleaned before ensure problem free operation starting the filter will clog Trouble shooting Open ended water systems No water supply s the water supply ok s water supplied to the pump Lower inlet Yes temperature or provide better cooling s the water in the tank very hot le above 50 e Is the electric motor of the pump unit rotating e s water coming out of the tap Are all taps open e s the control light for low pump suction pressure on e ls
28. 05 2013 Wrong lifting When lifting the pump unit one sling must be attached to the electric motor and one sling around the pump Only some motors and pumps have specific lifting eyes Do not use connections nozzles for lifting Do not use only one sling Make sure that the unit load is balanced before lifting The centre of the mass varies from pump pump unit size to pump pump unit How to mount the pump and the electric motor correctly see appendix 1 Data sheet or appendix 2 Instruction A Incorrect lifting can result in personal injury and or damage to the pump unit see appendix 2 Instruction 4 5 Return to supplier Please see maintenance chapter 7 4 6 Storage Each pump is tested before shipment and will therefore contain water For storage temperature and frost protection see appendix 2 Instruction The pumps are NOT delivered frost protected from the factory User manual 5 Installation and commissioning A 5 1 Important dimensions Physical dimensions and connections of the pump unit are described in appendix 1 Data sheet A 5 2 Cleanliness It is very important that the tubes and pipes are completely clean no dirt chips or burrs are allowed Flush all piping before connecting the high pressure pump to ensure the system is clean Internal surfaces of the piping must not be corroded If dirt or rust is not removed the pump and the valves can be damaged In
29. 13 G Drop in flow and or pressure may indicate wear on one or more parts inside the pump The pump must be stopped immediately and inspected before it is restarted Contact the maintenance department H Other observations or troubles please see appendix 7 Right and Wrong or appendix 6 Trouble shooting guide Both appendices give good advises on design installation wiring and troubleshooting If the pump is not stopped for inspection as recommended it can lead to damage of the pump or break down See also service and warranty section in appendix 1 Data sheet and appendix 2 Instruction Danfoss offers service of the pump at the system manufacturer s location as well as we offer training in how to service the pump Quotes are offered upon request Danfoss recommends simultaneously to check the filter and membrane condition and to evaluate contamination filter and membrane elements must be replaced if necessary Danfoss offers service of the pump at the system manufacturer s location and training in how to service the pump Quotes are offered upon request 7 3 Shutdown of the system A Stopthe high pressure pump B Release the pressure C Stop the feed pump if used D Switch off the safety circuit breaker for both the high pressure pump feed pump and VFD and lock them Only personnel servicing the pump unit should be able to unlock activate the switch again E Open bleeding and drain plugs Wait until
30. 4 49 Outlet Parallel key msxsxm 0 DIN 6885 n 0 20 x 0 20 x 0 79 Bleeding M6 hex key 4 mm Outlet port G 4 BSPP depth 11 mm Mounting flange ISO 3019 2 63A2HW 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Bleeding port 77 5 3 05 5 2 SECTION B B B 20 79 SECTION A A 15 99 63 a 35 36 Data sheet PAHT 2 308 and PAHT G 2 308 pumps 8 2 PAHT 10 12 5 62 975 2 479 160 6 3 Outlet Bleeding port 102 4 02 Description Parallel key DIN 6885 Bleeding Outlet port Mounting flange 129 5 08 PAHT 10 12 5 m in 0 20 x 0 20 x 0 79 G 4 BSPP hex key 6 mm G 34 BSPP depth 17 mm G 34 BSPP depth 15 mm ISO 3019 2 63A2HW 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 95 5 3 76 5 2 SECTION B B B li 8 20 79 SECTION A A 15 99 63 Bleeding port Data sheet PAHT 2 308 and PAHT G 2 308 pumps 8 3 PAHT 20 32 252 9 9 99 97 3 94 65 2 559 Bleeding port Gauge port inlet 159 6 3 Description PAHT 20 32 Parallel key mm 8x7x32 DIN 6885 0 31 x 0 28 x 1 26 Bleeding M6 hex key 5mm G 1 BSPP depth 16 mm Outlet port G 34 BS
31. All rights reserved 50 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Electric Motors Motor Manual hoyermotors com HOYER MOTORS 180R9230 HOVER MOTORS 1 General This manual concerns the following types of standard induction motors from Hoyer HMA2 HMC2 HMD HMT MS Y2E1 Y2E2 YDT These motors are manufactured in accordance with IEC EN 60034 4 and IEC EN 60072 Motors are rated for the ambient temperature range 20 C to 40 C and site altitudes 1000 m above sea level Low voltage motors are components for installation in machinery They are CE marked according to the Low Voltage Directive 2006 95 EC 2 Transport and storage Check the motor for external damage immediately upon receipt and if found inform the forwarding agent right away Check all rating plate data and compare it with the requirement of the motor Turn the shaft by hand to check free rotation remove transport locking if used Transport locking must be used again for internal transport also It is also important that transport locking is used when motors are transported mounted on equipment All motors should be stored indoors in dry vibration and dust free conditions Lif ng eyebolts must be tightened before use Damaged eyebolts must not be used check before use Lifting eyes at motor must not be used to lift the motor when it is attached to other equipment Before commissioning measure the insulation i
32. Guideline Trouble shooting fish bone chart q lv dWAd U0 8 8ISUI WO4 S ON S dund woJdj asion r 1030UJ 311323 3 au Jadwep uoneJqiA S S 10310UJ uo nb 10 YBIH ldu p ds uone101 ubiH Sy uo An lip p unoul sedid sesoH be 55 115 SOH Ce Gu s3A31 duing r r eJnssoJd J9 UI Jeuruou XELU U W Ek eui 19 3n0 39 U1 yo suoisueuuip u16ue Z S dune Jo suonipuo 2 sedid sesou suonoeuuo 3 nno lul Le piny ul aly b Wd 2 eJnssaJd 3e ui MO ez anssa1d Mo PIINPIY Z piny ubiH 8 L T piny jo ad L leul ul duind ul sea LZ uoneEniu urew OU jueuneeJ3 9eJd q Uz dois 14e3s 3JOS Cp ainssaid anno 977 ainssaid ysuiebe s31e3s duing ee abewep dwnd 133eM Ge 3uv3suo ee dwnd wo eJnssaJd anno ufu ool Le 3jeus dund uo 2210J JeIXV s L abewep dung 9 1 duund jo uone3041 ON vi e1nsseJd Mop ON L 4030UI 21112 JO UOHE201 ON Cl Gu s3A34 duing SL C Gu uunu Aig nj 71 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Guideline 1 Noflow no pressure Danfoss Trouble shooting guide for PAH PAHT PAHT G PAHT 674 and PAH F pumps 1 1 Dry running
33. MAKING MODERN LIVING POSSIBLE User manual Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps A PAHT PAHTG20and S PAHT PAHTG8O 4 danfoss high pressurepumps com Danfoss User manual Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps Table of Contents ie tit da iu IA 4 EU Declaration or CONDI lt O neh DP E v wes 5 1 Idee Zelt te EEN 6 1 1 General EEN 6 1 2 s npo sotiei aa ae a e U 6 1 3 Manufacturer and customer service address 7 2 SC A cea 7 7 2 1 ace ue Eden RR d or 7 2 2 Preferred system design 7 2 3 Commissioning and servicing the Unit sey sehe kp CERRAR AAA AAA 8 2 4 Adhere to the following important points 8 2 5 000 n a d 8 4 Cai EE 8 3 1 Approved applications and operational limits for the pumps 8 3 2 Applicaton TANG HU rapa ia 8 3 3 k H C Moto dates 8 3 4 ir og d inu st tata 8 a5 Bil 1011 EE 8 3 0 Space requirement nadar eu ee roc cbe da n ddd il ta e alea t 8 3 7 BI ET 9 3 8 Properties of E LEI ocna na da sat da be ta 9 3 9 QMOUDDU E 9 3 10 EG m a i tit Pt oi AS pa pe A ai d 0000000000 9 4 Arrival inspection transpor
34. PAHT PAHT G pumps are designed for long periods of service free operation to provide customers with low maintenance and life cycle costs Provided that the pumps are installed and operated according to Danfoss specifications the Danfoss PAHT PAHT G pumps typically run 8 000 hours between service routines However the service schedule for your PAHT PAHT G pump may vary according to the application and other factors The life of a pump may be greatly shortened if Danfoss recommendations concerning system design and operation are not followed In our experience poor filtration is the number one cause of pump damage 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 4 Empty the tank of the anti freeze medium Empty the pump through the lower bleeding plug The pump is now protected against internal corrosion and frost 5 6 2 Open ended systems with water supply from tank 1 Emptythe tank of water and empty the pump housing through the lower bleeding plug When the pump is empty retighten the plug 2 Through the upper bleeding plug fill the pump housing with anti freeze medium Pour anti freeze medium into the tank Connect a hose to the outlet of the pump and lead the other end of the hose back to tank 3 Quickly start and stop the pump Make sure that the pump does not run dry The pump is now protected against internal corrosion and frost 5 6 3 Open ended systems with direct water supply 1 Disconne
35. PP depth 18 mm Gauge ports G YA BSPP depth 15 mm Mounting flange ISO 3019 2 100A2HW 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 24 99 98 137 8 5 4 8 3 SECTION B B 32 126 F B SECTION A A 37 Data sheet PAHT 2 308 and PAHT G 2 308 pumps 8 4 PAHT 50 90 315 12 4 Outlet 124 97 4 92 Bleeding port Gauge port outlet 168 5 6 6 Gauge port inlet 79 5 3 13 SECTION B B 4 2 208 8 2 V V NOILO3S act 661 38 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Data sheet PAHT 2 308 and PAHT G 2 308 pumps 8 5 PAHT 256 308 357 14 07 47 3 1 86 83 5 3 29 D 279 10 98 128 5 04 Bleeding 42 94 1 69 4x M12x1 75 13mm depth 39 99 sot 1 57 2 004 72 272D Wily 7 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 39 Data sheet 9 Service Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark PAHT 2 308 and PAHT G 2 308 pumps Danfoss PAHT pumps are designed for long periods of service free operation to provide customers with low maintenance and life cycle costs
36. T G 20 32 and PAHT PAHT G 50 90 5 4 Dryrunning When running the pump must always be connected to the water supply in order to avoid damage if it should run dry In systems with water tank it is recommended to build in a level gauge in the tank to avoid the risk of running dry In systems with a boost pump it is strongly recommended to have a low pressure switch mounted on the water inlet side set at minimum 2 barg 29 psig 5 5 Disconnection If the inlet line is disconnected from the water supply the pump will be emptied of water through the disconnected inlet line When starting up again follow the bleeding procedure described under section 4 Initial start up 5 6 Storage When preparing the pump for long term storage or for temperatures below the freezing point flush the pump with an anti freeze medium type monopropylene glycol to prevent internal corrosion or frost in the pump For further information on anti freeze media please contact the Danfoss High Pressure Pumps sales organization Recommended procedure 5 6 1 Water hydraulic systems water recircu lated 1 Disconnect the power pack from the system 2 Empty the tank of water Fill up the tank with anti freeze medium to a level well above the suction line 3 Startup the power pack and for a couple of minutes in a closed loop system let the anti freeze medium run back to tank through the pressure relief valve or the bypass valve The Danfoss
37. a temperature Q Ambient temperature o 22 Sound pressure level Weight li O UN Measurements according to EN ISO 3744 2010 dB A L values are calculated Measured at max pressure and rpm for a motor pump unit 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Data sheet PAHT 2 308 and PAHT G 2 308 pumps 5 Flow The flow Q at less than max pressure p can be calculated with the following equation Theoretical flow l min Flows at max pressure l min see 4 1 4 4 Q ar Q HQ an Z O P mad X PP ma Max pressure bar Pressure bar Displacement ccmv rev Motor speed rpm The theoretical flovv can be calculated vvith the follovving equation Vxn Q i 1000 At zero pressure the true flow equals the theoretical flow Q 5 1 PAHT 2 6 3 flow curves at max pressure PAHT 6 3 PAHT 4 PAHT 3 2 PAHT 2 o d SS DO CO O CO SS cO PW cQ Q AS AS AB PO SAS oi SO SON E wi a AR QUOS o4 rpm PAHT 6 3 PAHT 4 PAHT 3 2 PAHT 2 rpm 26 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Data sheet PAHT 2 308 and PAHT G 2 308 pumps 5 2 PAHT 10 12 5 flow curves at max pressure PAHT 12 5 PAHT 10 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 PAHT 12 5 PAHT 10 27 Data sheet 28 PAHT 2 308 and PAHT G 2 308 pumps 5 3 PAHT 20 32 flow curves
38. at max pressure PAHT 32 PAHT 25 PAHT 20 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 PAHT 32 PAHT 25 PAHT 20 Data sheet PAHT 2 308 and PAHT G 2 308 pumps 5 4 PAHT 50 90 flow curves at max pressure 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 PAHT 90 PAHT 80 PAHT 70 PAHT 63 PAHT 50 PAHT 90 PAHT 80 PAHT 70 PAHT 63 PAHT 50 29 Data sheet 30 PAHT 2 308 and PAHT G 2 308 pumps 5 5 PAHT 256 308 flow curves at max pressure PAHT 308 OQ DB CO DG LC QOO LC GD O Ss GS GQ O LC o DOG S Q 0 Q OD Qo S dg di NL LP rpm PAHT 308 A ma S dS IS Oo 2 9 OO OQ 67 H q i di S HM KM OQ CO QO SORS Bg rpm 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Data sheet 6 Motor requirements PAHT 2 308 and PAHT G 2 308 pumps The required motor power can be calculated by using the following equation nxVxp 600 000 x n Power kW Torque Nm Mechanical efficiency Pressure bar Motor speed rpm Displacement ccm rev From the flow curves in item 5 you can deter mine the rpm of the pump at the desired flow The required torque is calculated as follows Vxp M 62 8xn To determine the correct motor size both the power and torque requirement must be verified The mechanical efficiency of the pump at max pressure
39. ation damper below the When no damper is installed below the electric motor pump motor vibrations from the motor and pump may be transferred to the frame and the rest of the system plant 76 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Guideline 6 Typical signs of wear 6 1 Valve plate Picture 1 Picture 2 Scratches Picture 3 pu Trouble shooting guide for PAH PAHT PAHT G PAHT 674 and PAH F pumps A normally worn valve plate has no marks scratches but only a slightly polished surface No scratches or marks should be felt The surface must be flat and level A worn valve plate has scratches and or a polished surface Even small scratches will give a loss of flow A good way to identify a worn valve plate is to hold a straight knife edge over the valve plate When holding it up to the light it will be possible to see any space between the knife edge and the valve plate See picture 3 If any light can be seen between the two arrows on the picture the valve plate is worn If any scratches or marks can be felt by running a fingernail over the surface the valve plate is worn The valve plate on picture 3 is highly damaged 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 77 Guideline Trouble shooting guide for PAH PAHT PAHT G PAHT 674 and PAH F pumps 6 2 Port plate Picture 1 6 UE C If the port plate has scratches level differences or both between the arrows i the por
40. cated bearings 50 160 40 000h 180 2 35 000h 200 2 27 000h 225 2 23 000h 1807 225 4 8 40 000h Motors with a re greasing system must be lubricated with high quality lithium complex grease NLGI grade 2 or 3 with a temperature range of between 40 G to 150 C Motors are normal fitted with a data plate with greasing information if it is missing use the following re greasing intervals Frame Grease 2 pole 4 pole 6 pole 8 pole size 2 h h h h 160 20 4200 7000 8500 8500 180 20 4200 7000 8500 8500 200 25 3100 6500 8500 8500 225 25 3100 6500 8500 8500 250 55 2000 6000 7000 7000 280 35 2000 6000 7000 7000 315 50 1500 5500 6500 6500 355 60 1000 4000 5000 6000 400 80 800 3000 4000 6000 Grease the motor while running open the grease outlet plug and let the motor run 1 2 hours before the outlet grease plug is closed again Grease the motor for the first time during commissioning The following applies in general for both lifetime lubricated and re lubricated bearings At 60Hz the time will be reduced by app 20 Data for vertically mounted motors are half of the above values Motor Manual The table values are based on an ambient temperature of 25 C The values must be halved for every 15K increase in bearing temperature Higher speed operations e g frequency converter drive will require shorter greasing intervals Typically doubling the speed will reduce the values by 50 6 Special note for A
41. ches on the surface facing the port plate Minor wear on valve plate can cause large internal leakage See Index 6 1 Check port plate Port plate has marks scratches on the surface facing the valve plate Minor wear on port plate can cause large internal leakage See Index 6 2 Check cylinder barrel Liners in cylinder barrel may be scratched or worn Insert a piston in the liner and check the fit If there is any space clearance between liner and piston liner or piston is worn Pre treatment Analyse fluid for content of particles Check that filters are OK and working correctly Main filtration Check that the correct filter type is used particles in fluidmust not exceed 10 um Danfoss High Pressure Pumps supplies filters please contact the sales office Fluid type The PAH PAH F tapwater and PAHT PAHT G ultra pure water pumps are designed for water operation for any other fluid please contact Danfoss High Pressure Pumps sales office for further help High fluid temperature If fluid temperature is above 50 C stop the pump immediately Check internal parts see above 2 2 1 Check that booster pump supplies the right pressure flow 2 2 2 Check if filters require replacement 2 3 1 If VFD operated check frequency 2 3 2 Check that rotation speed of the electric motor is as stated on name plate on electric motor Check that the motor rotor winding is not damaged 180R9288 IOM PAHT PAHT G 20 90 pum
42. cified torque s B Leakage if a small leakage from the bell housing is observed Contact the mainte nance department C Leakage if there is a large leak the unit should be stopped immediately Contact the maintenance department D High frequency tones safety relief valves are either damaged or running very close to their design pressure stop the unit immediately Contact the maintenance department E Increased noise or vibration requires the unit to be stopped immediately Contact the maintenance department F Very high temperatures may indicate that one or more parts are damaged inside the pump The pump must be stopped immediately and inspected before it is restarted Contact the maintenance department A 7 1 General safety information Before servicing the pump unit it is necessary to read and understand this user manual especially the Safety chapter 2 Remember to wear suitable safety equipment according to Safety chapter 2 7 2 Service and inspection interval for the pump Maintenance and service intervals are depending on the cleanliness level of the water hydraulic load and temperature of the pump unit The most important parameter is the filtration of the water See the section Service and warranty in the appendix 1 Data sheet and appendix 2 Instruc tion For spare parts and service tools please see appendix 4 Parts list 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 20
43. claims AN se All electrical installation work must only be carried out by authorized personnel in accordance with EN60204 1 and or local regulations It is recommended to install a lockable circuit breaker to avoid inadvertent starting and or electrical hazard The lockable circuit breaker must be used during installation operation and maintenance It is recommended to place a local safety switch nearby the pump enabling service personnel to cut power for the electric motor Protect the motor and other electrical equip ment from overloads with suitable equipment In case the pump delivered is ATEX certified the additional ATEX instruction must also be read Protective garments must be worn Always wear suitable safety clothing when handling the pump When working near the pump system safety shoes safety glasses hearing protection and safety helmet must always be worn 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Your local Danfoss pump distributor can be found on our homepage CE Declaration of Conformity can be found on page 5 Under certain operational conditions the surface of the pump can be above 60 C 140 F Under these conditions the pump must be labelled with a Danger Hot sign When using an electric motor the motor must always be supplied with adequate cooling ventilation When using an electric motor together with a VFD Variable Frequency Drive the motor must be d
44. ct the water supply to the pump 2 Through the lower bleeding plug empty the pump housing of water and close it again 3 Connect the pump to a tank of eg 25 litre 6 gal of anti freeze additive Connect a hose to the inlet port of the pump and via another hose return the flow from the outlet port port to the tank with anti freeze additives 4 Quickly start and stop the pump Make sure that the pump does not run dry The pump is now protected against internal corrosion and frost Other factors that affect pump performance and lifetime include running the pump at speeds outside specifications supplying the pump with water at temper atures higher than recommended o running the pump at inlet pressures outside specifications running the pump at outlet pressures outside the specifications 49 Instruction 7 Recommended service intervals Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danfoss Pump instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 7 1 General information This guideline provides information on the recommended service intervals for the PAHT PAHT G pumps The recommendation is based upon good engineering practice and on experience gained from operation even under extreme conditions The recommendation is for guidance only 7 2 Inspection of pump parts Danfoss recommends to inspect the pumps after 8 000 hours Typical signs of wear are seen on the contact sliding
45. d advises regarding design installation wiring and troubleshooting In case the pump needs to be scrapped please follow your local environmental rules MAKING MODERN LIVING POSSIBLE User manual Appendices for Installation Operation and Maintenance Manual PAHT PAHT G 20 90 pumps A PAHT PAHTG20and S PAHT PAHTG8O 4 danfoss high pressurepumps com User manual Table of Contents Danfoss Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps Data sheet PAHT PAHT G 2 308 pumps 521B1247 19 Pump instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 180R9283 41 Electric motor manual 180R9230 aaa ud ONE do 51 Parts 57 Trouble shooting guide for PAH PAHT PAHT G PAHT 674 and PAH F pumps 69 Right and wrong Trouble shooting guide for water hydraulic systems 180R9042 79 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 MAKING MODERN LIVING POSSIBLE Data sheet PAHT 2 308 pumps PAHT G 2 308 pumps danfoss high pressurepumps com Data sheet Table of Contents Data sheet PAHT PAHT G 2 308 pumps 521B1247 1 Introduction 20 PAHT 2 308 and PAHT G 2 308 pumps Introduction 2 Benefits En Application examples 4 Technical data 4 1 PAHT 2 12 5 4 2 PAHT 20 32 4 3 PAHT 50 90 4 4 PAHT 256 308 5 Flow 5 1 PAHT 2 6 3 flow curves
46. e Manual for PAHT PAHT G 20 90 pumps A 3 9 Air bubbles Large bubbles in a pressurised system can result in damage to piping equipment and the pump All air must be bleeded from both the low pressure and high pressure side before the system is pressurised Special consideration should be given in order to minimize air bubbles in the feed flow Air bubbles can cause cavitation A 3 10 Chemicals The pumps should not be exposed to any chemicals that can result in damage to piping equipment and internal parts of the pump 4 4 Transport and handling Small pumps which have a weight below 20 kilos weight can be found in appendix 1 Data sheet can be handled by hand if they are not mounted together with an electric motor The weight of a small pump with a motor will be above 20 kilos User manual Danfoss Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps Pumps which have a weight above 20 kilos see appendix 1 Data sheet must be handled by using lifting eyes and slings Never use only one sling and make sure the slings does not slip off the pump When the pump is mounted together with an electric motor the pump unit always weigh more than 20 kilos and must be handled by using slings around the pump unit See below examples of where to not to attach the lifting slings on the pump unit Correct lifting with 2 separate slings 180R9288 IOM PAHT PAHT G 20 90 pumps v01
47. electric motor and VFD See Data sheet for the used motor and VFD 5 Safety circuit breaker must be sized for the motor and See Data sheet for the used environment corrosion and humidity safety circuit CP6 Bolts and screws must conform to environmental conditions as well as fluid and torque requirements i 7 CP4 p C CP7 1 Instrumentation pressure switch should be designed to See Data sheet for the used conform to the environment corrosion and humidity equipment CP8 Checkthe factory settings of the safety relief valves or See Data sheets for the used pressure relief valves 1 valves P9 Checkthe settings of the pressure transmitter switch 2 set See Data sheet or Instruction at min inlet pressure appendices 1 and 2 CP10 Check that all pressure indicators Pl are selected to be able Scaling should at least be 1 Bar to measure the system pressure range or more precise CP11 Check coupling distance air gab movement of the spider i 12 Check correct connections on the pump in amp outlet 777 CP13 Check piping for possible air gaps d C O gt 5 7 Lifting and positioning 5 9 Electrics Lift the pump unit onto base Remember All electrical installation work must be carried vibration dampers if needed Fasten the motor out by authorized personnel in accordance with to the base EN60204 1 and or local regulations see also Safety chapter 2 See also chapter 4 Arrival inspect
48. erator and maintenance personnel 13 6 Operation of motor pump unit ca secte ca ae na ded eee ate doe 14 6 1 General safety information uses acri ac p HIERO CET tace a e N pi nr 14 6 2 What to listen and look for Re S a eine aut ek aos 14 2 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 User manual Danfoss Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps 7 Maintenance and service of the pump unit 14 7 1 General safety information ince ae ar TERN ORC OE aa 14 7 2 Service and inspection interval for the pump 14 7 3 SUP down of THe SV stalls s sco aera n ERR no IER I het ama Optra i ada d pa RE 14 7 4 Disassembling and assembling the pump unit 15 7 5 Assembling the pump unit raras EE EE 15 7 6 Procedure for mounting the pump back opntoelectrtcmotor 15 ra Getting the pump unit back into operation se I Oa Re n ees 15 7 8 Storage OF hE DUN ss Ehe 777 r r 15 8 Troubleshooting and scrapping criteria uses nasa amanata RS 16 8 1 General safety information Ra d a A cab EX e RR E I CARET e 16 8 2 Operational conditions which can cause pump 5 22222222 16 8 3 Mechanical dll FE se i 16 8 4 Electrical lift sa anana aba aa o aman ba
49. esigned for operation with VFD VFD operation may increase the temperature inside the electric motor if the motor is not designed for VFD operation This can damage the motor and cause unintended breakdown A Before start up the settings for all protective devices such as sensors switches and safety valves must be verified and free flow from safety valves must be ensured A All pipe and hose connections must be stress free mounted securely fastened to the pump and well supported Improper installation will or could result in personal injury and or damage to the pump Use of this manual does not relieve operation and maintenance personnel of the responsibil ity of applying good judgment when operating and maintaining the pump and its compo nents 2 2 Preferred system design Danfoss recommends to build systems with a high degree of safety Danfoss preferred system design and P amp ID are found in appendix 1 Data sheet and appendix 2 Instruction User manual 3 Technical data pu Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps A It is always the system builders responsibility that the system design does not cause any kind of hazard and is adapted to local regulations and standards Proper installation proper start up and shut down devices as well as high pressure protection equipment is essential 2 3 Commissioning and servicing the unit It is recommended that commissio
50. esponsible for changing parts in accordance with the lifetime of parts in particular bearings grease and lubrication of shaft sealing Maintenance repairs and replacement on zone 22 motors must only be carried out by qualified specialists 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 53 EC Declaration of Conformity The Manufacturer SVEND HOYER A S Over Hadstenvej 42 DK 8370 Hadsten Denmark Hereby declares that The products HOYER MOTORS 3 phased induction motors Aluminium motors MS A22 MS 56 180 HMA A22 HMA 56 180 Cast iron motors Y2E A22 Y2E 80 400 HMC A22 HMC 80 400 Are in conformity with the following Standards EN 60 034 1 and EN 60 072 Directive Low Voltage Directive 2006 95 EC Year of CE marking CE Signed by N NN er 2 lanaging Director Date December 2010 Page 1 1 Svend Hoyer A S Over Hadstenvej 42 DK 8370 Hadsten VAT no DK 21 96 23 09 Bank Danske Bank SWIFT DABADKKK IBAN EUR 2X6630003617176718 USD DK8330003785071190 T 45 86 98 21 11 F 45 86 98 17 79 svendhoyerGsvendhoyer com svendhoyer com m ra a 5 Wi ka 2 mi a E H mn a m BA a 2 HOYER MOTORS Motor Manual 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 55 HOYER Svend Hoyer A S Over Hadstenvej 42 DK 8370 Hadsten T 45 86 98 21 11 F 45 86 98 17 79 svendhoyer svendhoyer
51. feed pump Start feed pump Bleed high pressure pump until only water leaves the high pressure pump Remember to close all bleeding and draining plugs e Adjust pressure relief valve to minimum setting e Check rotation of the high pressure pump by description in 5 15 Start high pressure pump for 2 minutes to make sure all air is out of the system Adjust pressure relief valve to working pressure e Check all fittings for leakage 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 e Check the temperature switch controls The high pressure pump must stop if tempera ture is above specified set point Check the pressure switch controls The high pressure pump must stop if pressure is below specified set point If the system is running within the system design limits the system is released for operation 5 16 2 Closed system not applicable for PAHT PAHT G 256 308 Check if the reservoir is clean Check if filter element is present and mounted correctly Fill water at the reservoir using the filling valve Inspect immediately for leakage o Bleed high pressure pump until only water leaves the high pressure pump Remember to close all bleeding and draining plugs Adjust pressure relief valve to minimum setting o Check rotation of the high pressure pump by description in 5 15 Start high pressure pump for 2 minutes to make sure all air is out of the system Check reservoir low level switch controls
52. flooding which can cause slipping tripping or falling If water is dripping into the electric motor it can cause electric shock fire short of circuit or even death When mounting the pump vertically always mount the motor above the pump to avoid water leaking into the electric motor 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 ANS 8 4 Electrical failure If the wiring of the electric motor is incorrect or the ground connection is missing it can cause electric shock burn damages fire or even death If a VFD is used and wrongly programmed it can damage the pump and lead to high tempera tures or other dangers All electrical installation must be carried out by authorized personnel in accordance with EN60204 1 and or local regulations 8 5 Responsibility Danfoss takes no responsibility for any abnormal injuries risks or damages that could arise caused by abnormal conditions vibrations corrosion abrasives foreign objects or excessive tempera tures and shall not be liable for any consequen tial or incidental damages 8 6 Scrapping criteria Whether the pump can be repaired or need to be scrapped depends on in which conditions the internal parts are or how damaged the whole unit is Please use appendix 5 Trouble shooting guide as guideline or send the pump to Danfoss headquarter in Denmark for evaluation For other observations or troubles please see appendix 6 Right and Wrong which gives goo
53. ing code numbers serial numbers EC Declaration of Conformity Danfoss A S Danfoss High Pressure Pumps Nordborgvej 81 6430 Nordborg Denmark EG Konformit tserkl rung gem EG Richtlinie 2006 42 EG Hiermit erkl ren wir dass die Maschine gem 2006 42 EG entwickelt ist Beschreibung der Maschine Hochdruck Pumpe Maschinentyp PAH 2 6 3 PAH 10 12 5 PAH 20 32 PAH 50 100 PAH 25 32 tech PAH 50 80 tech PAHT 2 6 3 PAHT 10 12 5 PAHT 20 32 PAHT 50 90 PAHT 256 308 PAHT G 2 6 3 PAHT G 10 12 5 PAHT G 20 32 PAHT G 50 90 PAHT G 256 308 Seriennummer N A Technisches Dossier Kontaktperson Leiter Qualit tsabteilung Angewandte harmonisierte Normen DS EN ISO 12100 2011 Hersteller Unterschrift Titel 11 OSES EES 2012 12 21 Datum Welm Friedrichsen Leiter F amp E EC Declaration of Conformity according to Directive 2006 42 EC We hereby declare that the machine is designedaccording to the directive 2006 42 EC Machine description High pressure pump Machine designation PAH 2 6 3 PAH 10 12 5 PAH 20 32 PAH 50 100 PAH 25 32 tech PAH 50 80 tech PAHT 2 6 3 PAHT 10 12 5 PAHT 20 32 PAHT 50 90 PAHT 256 308 PAHT G 2 6 3 PAHT G 10 12 5 PAHT G 20 32 PAHT G 50 90 PAHT G 256 308 Serial number N A Technical dossier Contact person Manager Quality Department Used harm
54. ion transporta tion handling lifting and storage Turn off the safety circuit breaker and lock it Mount the power cable on the electric motor 5 8 Mount the different equipment connections pipes tubes check and safety relief If a VFD is used adjust the protective motor valves etc switch VFD to the current limits found on name plate of the electric motor The hard piping and flexible hoses used must be of proper design and must be installed in accordance with the manufacturer s recom 5 10 Instrumentation mendations The pressure switch sensor should be mounted Misalignment of the hard pipes may give as close to the pump as possible It is recom unintended stress on the pump port mended to test the pressure sensor switch via an connection and may damage the pump instrumentation manifold e Prevent excessive external pipe load e Do not connect piping by applying external Mount the pressure switch sensors according to force use of wrenches crane etc Piping the manufacturer s instructions must be aligned without residual stress e Do not mount expansion joints so that their force applies internal pressure on the pump 5 11 Connections connections Mount and tighten connections and check valve s as specified 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 User manual Danfoss Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps 5 12 Ensure free flow Ensure free flow from relief
55. m 4 6 Outlet pressure 4 7 Soft start stop 4 1 1 Ensure that the entire inlet line is bled before starting up the system 4 1 2 Ensure that air cannot enter into the inlet line 4 2 1 Follow the instructions Initial start up supplied with the new pump 4 2 2 Ensure that the pump is completely bled before start up 4 3 1 Ensure that inlet pressure is between the limits specified in the Data sheet 4 3 2 Check the pump for internal damage 4 4 1 Dismantle pump and check if anything is broken or worn See 1 No flow item 1 2 Pump reversing WARNING The pump must not run without water for more than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure and will eventually be damaged If electric motor rpm is too high dismantle pump and check for damage If the rpm is within the specified range of the pump data sheet and abnormal noise remains dismantle pump and check for damage If outlet pressure is too low check set point of outlet pressure valve If outlet pressure is lower than mentioned in the pump data sheet please contact Danfoss High Pressure Pumps technical support If outlet pressure has exceeded its maximum check set point of outlet pressure valve Check internal parts for wear damage 4 71 Checkif noise is normal when the pump is running at operation speed 4 7 2 f noise is abnormal at operation speed check internal parts see above
56. mpedance If values are lt 10M at 25 C the winding must be oven dried The insulation resistance reference is halved for each 20 C rise in motor temperature It is recommended that shafts are rotated periodically by hand to prevent grease migration 3 Installation The motor must be fixed on a stable clear and flat founda tion It must be sufficiently rigid to withstand possible short circuit forces It is important to ensure that the mounting conditions do not cause resonance with the rotational frequency and the doubled supply frequency Only mount or remove drive components pulley coupling etc using suitable tools never hit the drive components with a hammer as this will cause damage to the bearing The motor are balancing with half key ensure that the drive components are also the same Motor Manual Correct alignment is essential to avoid bearing vibration and shaft failure Use appropriate methods for alignment Re check the alignment after the final tightening of the bolts or studs Check that drain holes and plugs face downwards We recommend opening the drain hole for motors placed outdoors and not running 24 hours day so that the motor can breathe thus ensuring a dry motor 4 Electrical connection Work is only permitted to be carried out by qualified specialists and must to be carried out in accordance with local regulations Before work commences ensure that all power is switched off and canno
57. mum pressure loss large flow area minimum length of pipe minimum number of bends connections fittings with small pressure losses 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Protective cap must be removed and thrown away before usage 2 2 Open ended systems water supply from tank The numbers 1 3 refer to the drawing below In order to eliminate the risk of cavitation always ensure a minimum inlet pressure of O barg 0 psig 1 barg 14 5 psig abs by observing the following guidelines 1 Place the tank above the pump water level in the tank should always be above the pump 2 Place the inlet filter before the tank 3 Dimension the inlet line to obtain mini mum pressure loss large flow area minimum pipe length minimum number of bends connections fittings with small pressure losses 43 Instruction 44 Pump instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 2 3 Open ended systems with direct water supply The pump is supplied with water direct from the water supply or from a booster pump Recomended normal boost pressure is 2 6 barg 29 87 psig 3 7 barg 43 5 101 5 psig abs The inlet line connection must be properly tightened as possible entrance of air will cause cavitation The suction conditions can be optimized according to below guide lines General guidelines for calculation of pressure losses bar m psi ft In smooth
58. n and commissioning chapter 5 7 8 Storage of the pump If the pump has to be shut down for a longer period instructions can be found in appendix 2 Instruction 15 User manual 8 Troubleshooting and scrapping criteria Danfoss Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps A 8 1 General safety information Before inspecting the pump unit it is necessary to read and understand this user manual especially the Safety chapter 2 Remember to wear suitable safety equipment according to Safety chapter 2 8 2 Operational conditions which can cause pump failures The following conditions can cause a pump failure The pump is running dry The inlet pressure is too high The inlet pressure is too low The temperature of the fluid is too high The ambient temperature is too high The pump is running against a blocked port closed manual valve o The pump is operating at a pressure out of specification The pump is running with a non specified approved fluid The pump is running in the vvrong direction The filtration is insufficient There is excessive mechanical load on the shaft coupling and piping 8 3 Mechanical failure If the pump is running dry the temperature will quickly increase which can cause burns If there is any leakage at start up or during operation a high pressure jet can cause eye or skin damage Leakage can result in
59. ncy drives VFDs Motors regulated by VFDs can produce more noise if the VFD does not have the right settings Data sheet PAHT 2 308 and PAHT G 2 308 pumps 7 3 Open system design A Inlet line Dimension the inlet line to obtain mini mum pressure loss large flow minimum pipe length minimum number of bends connections and fittings with small pressure losses Inlet filter Install the inlet filter 1 in front of the PAHT pump 2 Please consult the Danfoss filter data sheet for guidance on how to select the right filter Monitoring pressure switch Install the monitoring pressure switch 3 between the filter and the pump inlet Set the minimum inlet pressure according to specifications described in item 4 technical data The monitoring pressure switch stops the pump if inlet pressure is lower than the set minimum pressure Monitoring temperature switch Install the monitoring temperature switch 4 between the filter and the pump on either side of the monitoring pressure switch Set the temperature value accord ing to technical data item 4 The monitor ing temperature switch stops the pump if inlet temperature is higher than the set value 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Danfoss Hoses Always use flexible hoses 5 to minimize vibrations and noise Inlet pressure In order to eliminate the risk of cavitation and other pump damage pump inlet pressure must be mai
60. ning and servicing are carried out by a minimum of two people where one is acting as a supervisor 2 4 Adhereto the following important points Before using the pump pump unit it is very important to read and understand this user manual A 3 1 Approved applications and operational limits for the pumps The pump and the pump units are designed for the use in systems with technical water The PAHT pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor A Use of the pump in other applications not suitable for the pump unit can cause damages to the pump unit with risk of personal injury For system integration of the pumps please see appendix 1 Data sheet and appendix 2 Instruction 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Do not try to lift the pump unit manually most of the pumps weigh more than 20 kilos see specific weight for the pump in the appendix 1 Data sheet Always bleed the pump prior to initial start up o Do not mount the pump without the bell housing and a flexible coupling Do not try to start the unit before the system components are mounted bleeded and adjusted Flush the system throughly before connecting the pump or pump unit Check rotation direction of the motor before mounting the pump 2 5 Incase of doubt Please contact Danfoss A S in case of doubt Contact information are
61. ntained according to specifications described in item 4 technical data Non return valve 6 Should be installed after the outlet to prevent pump backspin which may ruin the pump Pressure relief valve As the Danfoss PAHT pump begins to create pressure and flow immediately after start up regardless of any counter pressure a pressure relief valve 7 should be installed to prevent system damage Note If a non return valve is mounted in the inlet line a low pressure relief valve is also required between the non return valve and the pump to protect against high pressure peaks 33 Data sheet 34 PAHT 2 308 and PAHT G 2 308 pumps 7 4 Closed system design not applicable for PAHT PAHT G 256 308 Inlet line Dimension the inlet line to obtain mini mum pressure loss large flow minimum pipe length minimum number of bends connections and fittings with small pressure losses Inlet filter Install the inlet filter 1 in front of the tank 2 Please consult the Danfoss filter data sheet for guidance on how to select the right filter Monitoring pressure switch Install the monitoring pressure switch 3 in front of the filter 1 Set the maximum inlet pressure to 2 bar 29 0 psi The monitoring pressure switch will stop the pump 5 if inlet pressure is higher than 2 bar 29 0 psi indicating that the filter element must be changed Monitoring temperature switch Install the monitoring tempera
62. onised standards DS EN ISO 12100 2011 2012 12 21 Date Welm Friedrichsen Director R amp D 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 D claration de conformit CE conform ment la Directive 2006 42 CE Par la pr sente nous d clarons que la machine est concue conform ment la Directive 2006 42 CE Description de la machine Pompe haute pression Type de machine PAH 2 6 3 PAH 10 12 5 PAH 20 32 PAH 50 100 PAH 25 32 tech PAH 50 80 tech PAHT 2 6 3 PAHT 10 12 5 PAHT 20 32 PAHT 50 90 PAHT 256 308 PAHT G 2 6 3 PAHT G 10 12 5 PAHT G 20 32 PAHT G 50 90 PAHT G 256 308 Num ro de s rie N A Personne de contact pour le dossier technique Manager d partement qualit Normes harmonis es appliqu es DS EN ISO 12100 2011 Pon du fabricant Titre A LLL ied 2012 12 21 Date Welm Friedrichsen Directeur R amp D User manual 1 Introduction pu Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps 1 1 General The PAHT and PAHT G pumps and pump units are manufactured by Danfoss A S and are sold and marketed by a net of authorized distributors world wide This manual contains the necessary instructions for the installation operation and service of the pumps used for technical water In case the pump delivered is ATEX certified the additional ATEX instruction must also be read The PAHT pumps must not be used fo
63. or PAHT 20 32 15 WNE UNOE 61 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Parts list PAHT and PAHT G pumps 16 Spare parts list for PAHT G 20 32 180B4323 Swash plate set PAHT G 20 180B4324 Swash plate set PAHT G 25 180B4325 Swash plate set 180B4335 Cylinder barrel set PAHT G 32 PAHT G 20 32 180B4337 Valve plate set 180B4333 Seal set PAHT G 20 32 PAHT G 20 32 180B4336 Piston set PAHT G 20 32 en em uu vjemees pm BI moen em wore pem lam sl lm s 0 l 1 Le lo 1 lil o l m 1 lil lm ST ree 0 e ei r mwee 0 l S wmm ise 0 T INC lt l m 3 allem ene neg ell al reng le TT Te eme qw T TT TT em T E TTT el l s ELE LL Cw r ememn s lm T TTTT el reum eem III ei nen ene a rose l m O TT Cw epeeme las T TTT al rpesmem moe T TTT ec 1 L TT TT 62 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 PAHT and PAHT G pumps Parts list o Un AN m 1 592 g N DU o o LI x e N WNE UNOE
64. ould be possible to monitor the condition of the filter via the differential delta pressure across the filter Using insufficient filtration or a filter bypass can cause a failure or decreased service life of the pump 3 8 Properties of water It is recommended NOT to use the pump for other media than specified in the Data sheet 4 1 Arrival inspection The pump is packed in a cardboard or wood box with plugs in the port connections to protect the pump from damage during transportation When the shipment has arrived it is important to check the pump for any damages The name plate type designation must be in accordance with the delivery note and your order In case of damage and or missing parts a report should be documented and presented to the carrier at once A 4 2 Warning Before any lifting operation is performed environmental conditions must be taken into consideration Ex rated areas wind speed wet dry conditions lifting height etc 4 3 General safety information Personnel involved in lifting and transporting the equipment see Safety chapter 2 must be trained in handling and safety procedures when lifting heavy loads Many of the pumps and pump units weigh more than 20 kilos which requires lifting slings and suitable lifting devices e g an overhead crane or industrial truck to be used as minimum 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Danfoss Installation Operation and Maintenanc
65. out use of tools Elastic coupling Bell housing Motor shaft 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Pump suction line should be placed relatively high above the tank bottom in order to prevent settled particles from being led into the pump We recommend a separation wall to separate the inlet from the outlet end of the tank Monitoring It is recommended to continuously monitor the following conditions Water level if a tank is used o Filter contamination 9 Pressure inlet side of the pump Temperature inlet side of the pump Please take care to observe the recommended length tolerances of the chosen coupling as an axial force on the pump shaft will prevent the pump from generating pressure and over time damage the pump max 0 25mm max 0 01 inch m x 45 Instruction 46 Pump instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 3 2 Direction of rotation The direction of rotation is indicated by means of an arrow at the label of the pump 777 E ST 2 o LU X CW clock wise 3 3 Orientation The pump can be mounted orientated in any horizontal position and it can be mounted orientated in the vertical position with the shaft upwards The pump cannot be vertically mounted orientated with the shaft facing downwards Danfoss 3 4 Protection from too high system The valve sho
66. pressure 37 122 37 122 37 122 37 122 37 122 37 122 32 122 32 122 32 122 32 122 32 122 32 122 Sound dB A 76 76 76 76 75 75 pressure level w r l o o mil we Measurements according to EN ISO 3744 2010 dB A LA m values are calculated Measured at max pressure and rpm for a motor pump unit 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Data sheet PAHT 2 308 and PAHT G 2 308 pumps 4 2 PAHT 20 32 Code number PAHT 180B0019 Code number PAHT G 180B1009 Housing material AISI 316 or higher Geometric 20 displacement 122 Min outlet 30 ps g 435 Max outlet pressure continuous 1160 Inlet pressure 36 continuous psig 43 87 Max inlet 15 ps g Speed PAHT 25 180B0020 180B1010 AISI 316 or higher PAHT 32 180B0021 180B1011 AISI 316 or higher N 1 53 1 95 N UN UJ UJ O A UJ UN UJ 6 2321 2321 3 6 43 87 O UN UN N Min speed continuous rpm 700 700 Max speed 2400 2400 continuous rpm Typical flow Flow curves available in item 5 1000 rpm at l min max pressure 1500 rpm at l min 27 7 max pressure 1200 rpm at 5 7 gpm max pressure 1800 rom at max pressure Typical motor size 1500 rpm at kW max pressure UN o 15 0 1800 rpm at 20 0 20 0 max pressure N N Xe UI SS N 69 2 51 1 2 50 37 122 0 50 32 122 89 0 65 7 2
67. ps v01 05 2013 Typical signs of wear Polished surface all over the swash plate Normally only half of the swash plate the pressure side is polished See index 6 3 If the ring is missing the piston is very worn The filters can be bypassed even if they are correctly mounted Some filters can create channelling where particles can pass trough the filter in tunnels String wound filters are typically channelling filters A string wound filter may have a filtration efficiency of only 5096 which will cause internal wear and must always be followed by a main filter Insufficient filtration means that too many or too large hard particles can pass the main filter because it is damaged bypassed or simply too poor Filtration efficiency must be 99 9896 Beta 5000 at 10 um to prevent abnormal wear of the pump Temperature gt 50 C will cause wear on internal pump parts Mount a temperature switch and check its set point function The temperature switch will ensure that the pump stops at fluid temperatures gt 50 C If the pressure drop across the filters is too high the booster pump does not deliver sufficient flow pressure No pressure or low pressure results in cavitation and insufficient internal lubrication causing wear on internal pump parts Mount a low pressure switch in front of the pump and check its set point function The low pressure switch ensures that the pump does not start until the inlet pressure ha
68. r other purposes than those recommended and specified without first consulting your local pump distributor In the following text Installation Operation and Maintenance Manual the PAHT and PAHT G pumps will be called PAHT pumps A Use of the pump in other applications not suitable for the pump unit can cause damages to the pump unit with risk of personal injury A All personnel being responsible for operation and maintenance of the pump unit must read and fully understand these instructions especially the section Safety before Transportation of the pump unit e Lifting the unit e Installing the pump unit e Connecting the pump unit to the water system e Connecting the electric motor and instru mentation e Commissioning the unit Servicing the motor pump unit mechanical and electrical parts e Decommissioning the motor pump unit The pump must always be installed and used in accordance with existing national local sanitary safety regulations and laws It is the responsibility of the safety officer or the chief operator to assure compliance with all local regulations that are not taken into account in this manual A Changing the pumps or pump units opera tional limits and hardware Changes to the delivered pump or motor pump system may only be done with a written approval from Danfoss High Pressure Pumps 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 e Operation outside
69. rease m e iN Correctly limited quantities of grease Too much grease may develop prevent seizing biofilm causing operational failures Assembly of coupling The coupling must be easy and simple Never use force when assembling the to assemble see product instruction coupling parts as this will damage the motor pump Coupling Ensure always to have 3 mm distance Insufficient distance and or misalign between coupling flanges ment between the coupling flanges will damage the pump Water supply Fill system with water before starting Starting without water will cause to ensure lubrication and cooling damage Level indicator Level and temperature indicators Missing or incorrectly connected level must be fitted Follow installation and temperature indicators cause instructions damage Rotation direction Check pump drive motor rotation Incorrect rotation direction will direction matches that of the pump damage the pump prior to installation Bleeding Bleeding the pump will ensure correct Insufficient bleeding may cause dam cooling and lubrication age not applicable to Power Packs Starting procedure Cleaning procedure 1 Fill cold water into the system via the return filter and bleed the pump Power Packs PPH 4 6 3 10 and 12 5 are self bleeding 2 Start and bleed the system without pressure by opening the bypass valve 3 Add the cleaning agent to give 396 agent water solution 4 Runthe system for 6
70. s 31 N Nameplate 9 11 12 13 73 Noise 8 14 32 33 34 71 75 76 L E se e ee ri eee I e n 16 Ego ace ee er EE 6 9 10 12 15 52 Local regulations 6 7 8 11 12 16 52 O Open system design 11 33 Operation 6 7 9 13 14 15 16 40 48 2021777 49 50 53 73 75 81 82 Operational conditions 7 16 P ql 57 Danfoss Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps PIPING e oar a td diede 9 11 12 16 48 Positioning RE 12 Preferred system design 7 12 Pre mounting 3 33 ae a e od Sed 12 Protection 6 7 8 10 46 R Recommended service intervals 50 Reliefvalve 12 13 14 33 34 43 a a 46 48 49 74 80 ET 5 n n a ate e seral e ai os 11 15 16 53 Responsibility 6 7 8 16 Return 2 523 oe 35 a 10 15 43 49 80 82 S SE semn ace e r oes 6 7 8 9 12 13 14 16 Safety valve 7 Scrapping criteria 16 Serial number eric e e Y en en 4 Service 7 8 9 13 14 15 21 40 O c de poor cdo a ae d 49 50 59 83 84 Servicings gt A 6 8 14 Shutdown e acis en de re EE 14 15 Signsofvvear 50 73 74 77 Sound pressure level 22 23 24 25 Space requilrement 8 Sparepart 57 60 62 64 66 Start up 7 8 11 12
71. s 16 8 5 RESPONSO Rm 16 8 6 SEENEN eebe 16 Appendices for Installation Operation and Maintenance Manual 17 Table OF CORTOS ccu daia act a s dd adeo e asd added edu rea dedique 18 L Data sheet PAHT PAHT G 2 308 pumps 521B1247 19 2 Pump instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 180R9283 41 Electric motor manual 180R9230 51 4 Parts list PART and PART G 52181237 p canted e pi aice ERROR ai ta dt i e Rage a 57 5 Trouble shooting guide for PAH PAHT G PAHT 674 and PAH F pumps 69 6 Right and wrong Trouble shooting guide for water hydraulic systems 180R9042 79 oo scies bio o A 86 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 3 User manual Validity PAHT 20 PAHT G 20 PAHT 25 PAHT G 25 PAHT 32 PAHT G 32 PAHT 50 PAHT G 50 PAHT 63 PAHT G 63 PAHT 70 PAHT G 70 PAHT 80 PAHT G 80 PAHT 90 PAHT G 90 03 18081009 02 18080020 04 18081010 02 18080021 04 18081011 02 18080085 04 18081012 02 18080086 04 18081013 02 18080087 04 18081014 02 18080088 04 180B1015 02 18080089 04 18081016 02 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 pu Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps This manual is valid for PAHT and PAHT G pumps with the follow
72. s reached 1 bar Speeds below minimum limit see Data sheet result in insufficient internal lubrication causing wear on the internal pump parts 73 Danfoss Guideline Trouble shooting guide for PAH PAHT PAHT G PAHT 674 and PAH F pumps 3 High torque on electric motor 3 1 Too high outlet pressure from pump 3 1 1 Check for blocked nozzles or a faulty Pressure changes due to flow restrictions This adjusted relief valve will also cause high motor torque 3 2 Pump starts against pressure 3 2 1 Check that electric motor is correctly sized Pumps run in parallel with cascade start may 3 2 2 Check internal parts see item 2 1 switch offthe motor relay due to too high 3 2 3 Systems with more than one electric torque caused by high outlet pressure motor installed Start motors simultaneously 3 3 Constant torque 3 3 1 Please contact Danfoss sales office If the electric motor is too small for the pump it cannot provide sufficient torque 3 4 Water pump damage 3 4 1 Dismantle pump and check for wear Too heavy damage in the pump will increase friction causing a high torque see item 6 Typical signs of wear 74 180R9288 IOM PAHT PAHT 20 90 pumps v01 05 2013 Guideline 4 Noise from pump Danfoss Trouble shooting guide for PAH PAHT PAHT G PAHT 674 and PAH F pumps 4 1 Air in fluid 4 2 Bleeding conditions of pump 4 3 Min max nominal inlet pressure 4 4 Pump reversing 4 5 High rotation speed rp
73. s being necessary in specifications already agreed 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 40 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 MAKING MODERN LIVING POSSIBLE Pump instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 danfoss high pressurepumps com Instruction Table of Contents Pump instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 180R9283 42 Pump instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 2 1 2 2 2 3 2 4 Identification System design Closed water hydraulic systems water recirculated Open ended systems water supply from tank Open ended systems with direct water supply General comments on Building up the pump unit Mounting Direction of rotation Orientation Protection from too high system pressures Connections PAHT PAHT G 20 32 PAHT PAHT G 50 90 Initial start up Operation Water quality Temperature Pressure Dry running Disconnection Storage Water hydraulic systems water recirculated Open ended systems with water supply from tank Open ended systems with direct water supply Service Recommended service intervals General information Inspection of pump parts How to inspect the pump 180R9288 IOM PAHT PAHT 20 90 pumps v01 05 2013 Instruction 1 2 Identification System design Danfoss Pump
74. sion proof materials of corrosion proof materials may cause damage Choice of filter Install a 10 micron absolute filter with Return filter with bypass valve and pressure switch poorer filterability than 10 u will damage the system Filter location looooooooo 000000000 000000000 Locate the return filter in the return line Placing the return filter upstream of the immediately before the tank final load may damage the pump Pump location Pump always to be placed below water Pump location above water surface surface level level will cause damage Suction conditions System to be dimensioned to provide Poor suction conditions will cause a suction pressure of the pump inlet of malfunction and damage the pump max 0 1 bar vacuum Pressure Relief valve 090000000 000000000 090000000 Pressure relief valve to be mounted Coupling the pressure relief valve outlet vertically or with vertical outlet and directly to the pump inlet may damage connected to return hose or tank the pump Water supply Filling system with unfiltered water causes damage System to be filled via filter Installation Impurities BRO Prior to installation burrs and chips and Chips or other impurities in the system other impurities must be removed from may cause damage pipes and hoses eg with a felt plug Fittings in screwed components to be Using teflon tape or packing yarn in sealed with O rings or bonded seals joints may cause damage G
75. ssary in specifications already agreed 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 84 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Danfoss User manual Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 85 User manual Subject index A Address emma aaa 7 Airbubbles 9 75 ADDERE S Vo swa ninn Ee E 17 Application range s Rx 8 Approval 2 1 2 sog II 6 Arrival 9 Assembling 12 15 81 A 6 7 21 53 B Benefits 21 Bleed 8 9 13 14 15 35 36 37 A 38 39 47 48 49 71 75 82 C Checklist 12 Check points x 22x x E 12 Chemicals 445406 240 b 9 Cleanliness 11 14 Closed system design 11 34 Commissioning 6 8 11 12 13 52 53 Connections 7 9 10 11 12 15 32 33 0 34 35 43 47 52 53 71 76 Corrosion 12 16 45 49 80 Coupling 8 12 13 15 16 32 CP 45 52 72 80 81 D li EC 6 7 13 16 Datasheet 19 Declaration of Conformity 5 Design 7 8 11 12 13 14 16 20 21 32 33 34 40 43 49 73 80 Distributor ec d E sk e 3 s n d 6 7 8 DIMENSIONS 2x
76. surfaces in the pumps If the pumps must run for additional 8 000 hours the following parts will have to be inspected Pistons Retainer plate ball and bearing Valve plate Port plate Sealings If there are any vvear marks on the parts they need to be replaced If service inspection due to the application is complicated the plant operator can decide to extend the service interval by evaluating the follovving deviations Sound does the pump have any unusual sounds Electric motor power consumption and speed compared with measurement made in the past Pressure flow according to measurements made in the past We advise that the above mentioned parameter during the extended service interval is inspected for every 500 2 000 hours beyond the 8 000 hours The pump must in any case be inspected after maximum 16 000 hours or 2 years 7 3 Howtoinspect the pump Service manuals are available on the internet www danfoss high pressurepumps com Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S
77. t be switched on again This also applies to the auxiliary power circuits e g anti condense heaters Check that supply voltage and frequency are the same as rated data Motors can be used with a supply deviation of 5 voltage and 2 frequency according to IEC60034 1 Connection diagrams for main supply and accessory as PTC or heater are located inside the terminal box Connections must be made in such a way as to ensure that a permanently safe electrical connection is maintained both for the main supply and the earth connection We recommend that crimped connections are made in accordance with IEC 60352 2 Tightening torques for terminal board screws Hinton 25 eG d EE ee ME ess 55 Ensure that the terminal box is clean and dry Unused glands must be closed Check the terminal box gasket before it is remounted 5 Maintenance Inspect the motor at regular intervals keep it clean and ensure free ventilation air flow check the condition of shaft seals and replace if necessary Both electrical and mechanical connections must be checked and tightened if necessary 52 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 HOVER MOTORS Bearing size and type are specified on the rating plate Motor types HMA2 and HMC2 is as standard with lifetime greased bearing with motor size lt 225 Motor types MS and Y2E is as standard with lifetime greased bearing with motor size 160 Typical duty hours for lifetime lubri
78. t plate must be replaced Even small scratches or wear will cause loss of flow To check See item 6 1 picture 3 6 3 Swash plate Picture 1 E If the swash plate is polished 3602 it is an indication of insufficient filtration The surface of the swash plate must be plane and even at same level all over To check this please see item 6 1 picture 3 If the surface has any marks scratches it is worn damaged and a new one is required Please contact Danfoss High Pressure Pumps sales office for further infor mation Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed 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 78 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 MAKING MODERN LIVING POSSIBLE Right and wrong Trouble shooting guide for water hydraulic systems SOREN ea EESNEN n hs SEEN NEUE Bu danfoss high pressurepumps com 180R9042 Choice of material Rubber Plastic Stainless steel Always use system components made Non corro
79. tation handling lifting and storage 9 4 1 Arrival inspections rac quu Tap Pd cede ptor EE 9 4 2 KU te le sis erai 0 0009000005 0000000 9 4 3 General safety Informal Over cr 9 4 4 Transport and handling d q dorso 9 4 5 Elei 10 4 6 10141 i a 3 a ee d aa 0000000090 5000007 10 5 Installation and COMMISSIONING 444000 ocio v dep cares aaro d Oo ae E A ERO KENT een 11 5 1 H dimensions ioo ab added 11 5 2 REENEN 11 5 3 PUL temperature e anca zi aaa vea aa la dad tie 11 5 4 Eu e a ai an at o PE a pg ai i la ii 11 5 5 Local regulations orar EEEn EEEREN AURRIDE a ds o e Duda 11 5 6 Pre mounting checklist based on Danfoss preferred system designs 12 57 Bette anc l l r ju olla Lo Coo ero EEG TERN 3 12 5 8 Mount the different equipment sana aaa sea bazada ERA SEES 12 5 9 Tc A 12 510 stc ERIS EE 12 5 11 CO IEC HE nb 12 5 12 Ensure hee ia sab asa s rama d 13 5 13 Verify setting of safety relief valves 13 5 14 Bleed and remove air from the pump 13 5 15 Verify direction of rotation dek reg d Oe ean ea ENTERO AUC kia CO e R 13 5 16 COMMISSION is s o s 0 13 5 16 1 o rS 13 5 16 2 CIOSCO SUSTO RO E DENDUM RED 13 5 17 Checkthe filter condition e sare n rta da e 0600006 077 0 13 5 18 Instruct op
80. tex Zone 22 motors Notice for the use of electrical equipment in areas with combustible dust Designation of motor according to EC directive Ex II 3D T125 C IP55 The dust hazardous 3 phase asynchronous motors are in accordance with European standard EN 50281 1 1 Combustible dust areas will be found in agricultural areas and in industrial environments Only one electrical installation may be installed in one specified area zone Only certificated cable glands for category 2D may be used Unused glands must be closed Connections must be made in such a way as to ensure that a permanently safe electrical connection is maintained both for the main supply and earth connection Installations must be in accordance with actual standards for installation in the Zone 22 area It is recommended that EN 50281 2 is followed according temperature and dust on the motor surface The use of motors with so much surface dust that the motor temperature increases is not permitted Regularly cleaning is recommended The radial shaft sealing ring is part of the ATEX certification It is important that the ring is always intact The shaft sealing must be regularly checked and if dry it must be lubricated It is recommended that the seal is re lubricated regularly Always use the original seal ring when replaced Replacing bearings also means replacing the seals All machines must be inspected regularly for mechanical damage The user is r
81. the power supply ok Are control lights on The filter is clogging e s the filter clogged e s the filter control light on s water coming through the filter A blown fuse or short circuit Check power supply and fuses and contact electrician Replace filter element Replace filter element Contact serviceman Turn on the tap for water supply Trouble shooting Closed water systems The system does not work e s there sufficient water in the tank e s the electric motor of the pump unit rotating s the water in the tank BG very hot le above 50 At temperatures higher than 50 the pump drive cuts out e Is the power supply ok Consequently the cooler must be checked cleaned Are control lights on A blown fuse or short circuit Check power supply s the filter clogged and fuses and contact electrician Fill water into the system e s the filter control Replace filter element light on Contact serviceman Trace leakage if any Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being nece
82. the pump from too high fluid temperature a temperature switch of 50 C 122 F should be mounted on the inlet side If the whole pump flow is bypassed over the relief valve then the fluid tempe rature will go up relatively fast 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 The piping hose between inlet filter and pump must be flushed prior to initial start up of the pump to ensure that impurities are removed 5 3 Pressure The inlet pressure must be min 2 barg equals 3 barg abs At lower pressures the pump run a risk of cavitating resulting in damage of the pump Short term inlet pressure peaks must not exceed 20 barg 290 psig It is recommended that the normal boost pressure is 2 6 barg 29 87 psig 3 7 barg 43 5 101 5 psig abs If itis unknown what the peak inlet pressure can be then there should be a 15 barg 218 psig safety relief valve on the inlet side of the pump Max pressure on the pump s outlet line should be limited at 160 barg 2 320 psig continuously Short term pressure peaks e g in connection with closing of a valve of up to 200 barg 2 900 psig are acceptable It is recommended to have a check valve on the outlet side of the pump to protect the pump from high pressure going backwards into the pump when it is turned off Especially when using flexible hose or more pumps are installed in the same system Instruction 6 Service Danfoss Pump instruction PAHT PAH
83. ture switch 4 in the tank Set the temperature value according to technical data item 4 The monitoring temperature stops the pump if inlet temperature is higher than the set value Danfoss Hoses Always use flexible hoses 6 to minimize vibrations and noise Inlet pressure In order to eliminate the risk of cavitation and other pump damage pump inlet pressure must be maintained according to specifications described in item 4 technical data Non return valve 7 Should be installed after the outlet to prevent pump backspin which may ruin the pump Pressure relief valve As the Danfoss PAHT pump begins to create pressure and flow immediately after start up regardless of any counter pressure a pressure relief valve 8 should be installed to prevent system damage System water filling To ensure proper filtration of new water 10 supplied to the system always use the filling valve 9 Minimum level switch Install the minimum level switch 11 above the outlet of the reservoir The level switch must stop the pump if the water in the reservoir is below the switch which indicates that the reservoir is empty 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Data sheet 8 Dimensions and connections PAHT 2 308 and PAHT G 2 308 pumps 8 1 PAHT 2 6 3 130 5 12 D 62 975 2 479 Bleeding port 114
84. uld be placed as close to the pump pressures as possible The pump should be protected against too high pressure by means of a pressure relief valve or a The opening characteristics of the valve must not bypass unloading valve placed on the pressure result in peak pressures higher than 200 barg side 2 900 psig 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 Instruction Pump instruction PAHT PAHT G 20 32 and PAHT PAHT G 50 90 3 5 Connections 3 5 1 PAHT PAHT G 20 32 Bleeding Gauge port inlet There are two 1 4 ports on the inlet side for XO Gauge port oulet optional mounting of ie switches for low pressure and temperature Parallel key There is one 1 4 port on the outlet for optional PAHT PAHT G 20 25 32 8 x 7 x 32 DIN 6885 mounting of i e pressure transducer PAHT PAHT G 20 25 32 Outlet O Inlet 1 Bleeding C Gauge 1 4 ports 3 4 BSPP with 1 1 4 BSPP with M6 width 1 4 BSPP with 16 mm long thread 20 mm long thread across flat 5mm 15 mm long thread Max tighten torque 90 Nm 150 Nm 4 Nm 15 Nm 9 q 66 Ib f ft 110 Ib Dft 3 Ib Dft 11 Ib f Ft Recommended torque values refer to steel washers containing a rubber sealing element 3 5 2 PAHT PAHT G 50 90 Bleeding Gauge port inlet There are two 1 4 ports on the inlet side for XO Gauge port oulet optional mounting of ie switches for low pressure and temperature PAHT PAHT G 50 63 70 80 90 There is one 1 4
85. us make noise Too low pressure also causes insufficient internal lubrication and wear on internal parts Pump may eventually be damaged Too high outlet pressure may damage the pump Noise frequency changes during soft start up stop 75 Danfoss Guideline Trouble shooting guide for PAH PAHT PAHT G PAHT 674 and PAH F pumps 5 Noise from installation es m Co 2 5 1 Inlet outlet connections hoses pipes 5 1 1 Use flexible hoses at inlet outlet connec Non flexible connections mounted directly on tions the frame vvill cause even small pressure pulsations from pump and create vibrations in the system plant 5 1 2 Mount the connections to the frame bya vibration damper mounting plate 5 2 Length dimension of inlet outlet line 2 1 ncrease pipe diameter and or reduce the 1 Too small pipes or too many bends may create number of bends too fast flow turbulence through the pipes and thus increase the noise level 5 3 Hose stiffness 3 1 Use a more flexible hose Too stiff hoses cannot damp the small pressure pulsations from the pump and subsequently vibrations occur in the system plant 5 4 Hoses pipes mounted directly on frame 4 1 Mount the connections to the frame by a If the hoses are mounted directly on the frame vibration damper mounting plate the small pressure pulsations from the pump can be transferred to the frame and the rest of the system plant 5 5 Vibration damper under the electric motor Mount a vibr
86. valve table 1 item 5 6 CP 8 A blocked relief valve can cause excessive build up of pressure and thereby cause dangerous situations and damage to the whole system 5 13 Verify setting of safety relief valves Make sure the relief valve is placed correctly see open system design item 1 Check the pressure settings on the name plate of the relief valve If they are within specifica tions you can continue 5 14 Bleed and remove air from the pump Open bleeding plugs Keep the plugs open until the high pressure pump is bleeded If the pump is submerged remove all bleeding plugs before mounting in reservoir 5 15 Verify direction of rotation The direction of rotation must always follow the arrow The arrow is placed on the pump or pump unit Check the direction of rotation before mounting the pump Unlock the safety circuit breaker Start the motor for 1 second and observe the direction of rotation either looking on the fan of the motor or on the coupling through the hole in the bell housing not available on all bell housings If the motor is turning the wrong direction switch two phases in the connection box of the motor or reprogram the direction in VFD When the motor is turning in the right direction the pump can be mounted 5 16 Commissioning 5 16 1 Open system e Check if filter element is present and mounted correctly e Switch on the circuit breaker for both motor s and VFD s Check rotation of the
87. worst case the pump can be damaged beyond repair Open system design Danfoss Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps A 5 3 Fluid temperature Before start up the fluid and pump housing temperature must be within the specified temperature range listed in appendix 1 Data sheet 5 4 Electrical data Check voltage current frequency and rated power on the electric motor and VFD settings on the name plate placed on both the motor and the VFD A 5 5 Local regulations Commissioning must always be done in accordance with valid regulations and local standards Closed system design not applicable for PAHT PAHT G 256 308 Reservoir 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 User manual Danfoss Installation Operation and Maintenance Manual for PAHT PAHT G 20 90 pumps 5 6 Pre mounting checklist based on Danfoss preferred system designs Table 1 Check points when assembling and commissioning system CP1 Ensure that the environmental conditions are safe See Arrival inspection transportation handling lifting and storage chapter 4 CP2 Minimum and maximum start up temperature for fluid and See Data sheet or Instruction pump appendices 1 and 2 Filtration condition 10um absolute B 5000 See Danfoss requirements in Data sheet and Instruction appendices 1 and 2 Power supply for
88. y 50 filtration efficiency This means that out of 100 000 particles that enter such filters 50 000 particles pass right through them compare this to precision depth filters that are 99 98 efficient and only allow 20 of the same 100 000 particles to pass through 180R9288 IOM PAHT PAHT G 20 90 pumps v01 05 2013 For more information on the importance of proper filtration including explanation of filtration principles definitions and guidance on how to select the right filter for your pump please consult our Filtration information and specifications Danfoss document number 52181009 7 2 Noise Since the pump unit is mounted on a frame the overall noise level can only be determined for a complete system To minimize vibrations and noise throughout the system it is therefore very important to mount the pump unit correctly on a frame with dampers and to use flexible hoses rather than metal pipes where possible The noise level is influenced by 9 Pump speed High rpm makes more fluid structure borne pulsations vibrations than lovv rpm Discharge pressure High pressure makes more noise than low pressure Pump mounting Rigid mounting makes more noise than flexible mounting because of structure borne vibrations Be sure to use dampers when mounting a Connections to pump Pipes connected directly to the pump make more noise than flexible hoses because of structure borne vibrations o Variable freque

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