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Operation guide
User manual
Installation (WEG Motor, Operation and
Maintenance Manual for
PAHT / PAHT G 20-90 pumps
PAHT/PAHT G 20 to
PAHT/PAHT G 80
Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps - WEG motor
Table of Contents Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2 Symbols
1.3 Manufacturer and customer service address:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1
2.2
2.3
2.4
2.5
General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Preferred system design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Commissioning and servicing the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Adhere to the following important points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
In case of doubt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.
3.1
3.2
3.3
3.4
3.5
Noise and vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.6 Space requirement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.7 Filtration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.8
3.9
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Approved applications and operational limits for the pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Application range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Electric motor data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Properties of water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Air bubbles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.10 Chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.
4.1
Arrival inspection, transportation, handling, lifting and storage . . . . . . . . . . . . . . . . . . . . . . . . . .8
Arrival inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.2 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.3
4.4
4.5
General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Transport and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Return to supplier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5.
5.1
5.2 Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
5.3
5.4
5.5
5.6
5.7
5.8
Installation and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Important dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Fluid temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Local regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Pre mounting checklist, based on Danfoss preferred system designs . . . . . . . . . . . . . . . . . . . .11
Lifting and positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Mount the different equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.9 Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.10 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.11 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.12
5.13
Ensure free flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Verify setting of safety/relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Bleed and remove air from the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Verify direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.14
5.15
5.16 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.16.1
5.16.2
5.17
5.18
Open system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Closed system (not applicable for PAHT G 256-308) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Check the filter condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Instruct operator and maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
6.
6.1
6.2
Operation of motor pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
What to listen and look for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps - WEG motor
7.
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
Maintenance and service of the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Service and inspection interval for the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Shut down of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Disassembling and assembling the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Assembling the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Procedure for mounting the pump back onto electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Getting the pump unit back into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Storage of the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
8.
8.1
8.2
8.3
Troubleshooting and scrapping criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Operational conditions which can cause pump failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Mechanical failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
8.4 Electrical failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
8.5 Responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
8.6 Scrapping criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.
6.
3.
4.
1.
2.
Appendices
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Data sheet PAHT G 2-308 / ATEX PAHT G pumps (521B1407) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Pump instruction PAHT G 256-308 (180R9385) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Electric motor manual (WEG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Parts list PAHT G (521B1410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Trouble shooting guide for PAH, PAHT, PAHT G, PAHT 674 and PAH F pumps . . . . . . . . . . . . .59
Right and wrong - Trouble shooting guide for water hydraulic systems (180R9042). . . . . . .71
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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps - WEG motor
Validity This manual is valid for PAHT G pumps both non
ATEX and ATEX certified versions. An ATEX certified pump is indicated by Ex in the designation - example PAHT G 256 Ex.
In case the pump delivered is ATEX certified, the additional ATEX instruction must also be read.
PAHT G 256
PAHT G 308
Code no.
Serial no.
Code no.
Serial no.
Non ATEX
180B6090
XXXXXX02-XXX
180B6091
XXXXXX02-XXX
ATEX certified
PAHT G 256 Ex 180B6190
XXXXXX02-XXX
PAHT G 308 Ex 180B6191
XXXXXX02-XXX
MADE IN DENMARK
Pump
Type PAHT G
Serial no.
Code no.
The serial number is referring to the Serial no. on the product label. The digits shown (02) indicate the version number of the pump.
This documentation is compatible with previous pump versions.
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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps - WEG motor
1. Introduction 1.1 General
The 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 G pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor.
• If 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
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.
Indicates a situation which will or could result in personal injury and/or damage to the pump
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
• Lifting the unit
• Installing the pump unit
• Connecting the pump unit to the water system
• Connecting the electric motor and instrumentation
• Commissioning the unit
• Servicing the motor pump unit, mechanical and electrical parts
• 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.
!
Electrical hazard - Indicates a high- voltage warning
Safety glasses required
Hearing protection required
Safety shoes required
Safety helmet required
Protective garments must be worn
Protective garments must be worn
Danger HOT.
Do not touch
Electrical hazard
Electrical hazard
Changing the pumps’ or pump units’ operational 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.
• Operation outside the Danfoss specifications requires a written approval from Danfoss
High Pressure Pumps.
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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps - WEG motor
1.3 Manufacturer and customer service address:
Danfoss A/S
High Pressure Pumps
Nordborgvej 81,
DK-6430 Nordborg
Denmark
Telephone: +45 7488 2222
Fax: +45 7445 3831
Email: [email protected]
Web: hpp.danfoss.com
Your local Danfoss pump distributor can be found on our homepage.
1.3 Country specific information
1.4.1 United Kingdom
UK importer:
Danfoss Ltd.
Oxford road
UB9 4LH Denham
United Kingdom
2. Safety
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:
• Death or fatal injuries
• Costly damages and claims
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 equipment from overloads with suitable equipment.
In case the pump delivered is ATEX certified, the additional ATEX instruction must also be read.
!
Electrical hazard
Protective garments must be worn
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 ( V ariable F requency D rive), the motor must be designed 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.
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.
All pipe and hose connections must be stressfree 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 responsibility of applying good judgment when operating and maintaining the pump and its components.
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.
2.2 Preferred system design
Danfoss recommends to build systems with a high degree of safety. Danfoss preferred system design and P&ID are found in appendix 1, Data sheet, and appendix 2, Instruction.
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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps - WEG motor
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 shutdown devices as well as high-pressure protection equipment is essential.
•
•
•
•
2.3 Commissioning and servicing the unit
It is recommended that commissioning and servicing are carried out by a minimum of two people, where one is acting as a supervisor.
•
•
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.
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.
2.4 Adhere to the following important points
• Before using the pump/pump unit it is very important to read and understand this user manual.
2.5 In case of doubt
Please contact Danfoss A/S in case of doubt.
Contact information are listed in section 1.3,
Manufacturer and customer service address.
3. Technical data 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.
3.1 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 G pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor.
3.5 Dimension drawings
Dimensions of the different pumps can be found in appendix 1, Data sheet.
3.6 Space requirement
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.
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.
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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps - WEG motor
3.7 Filtration
(10µm absolute [β
10
≥ 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 should 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.
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.
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. Arrival inspection, transportation, handling, lifting and storage
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.
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.
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.
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Pumps which have a weight above 20 kilos (see appendix 1, Data sheet) must be handled by using lifting eyes and slings.
Wrong lifting:
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:
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.
Incorrect lifting can result in personal injury and/or damage to the pump unit, see appendix
2, Instructi on.
Once the lifting is done the lifting eye must be removed from the pump.
4.5 Return to supplier
Please see maintenance chapter 7.
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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.
9
11
Reservoir
2
1
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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps - WEG motor
5. Installation and commissioning
5.1 Important dimensions
Physical dimensions and connections of the pump unit are described in appendix 1, Data sheet.
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.
5.2 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 worst case the pump can be damaged beyond repair!
Open system design
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.
5.5 Local regulations
Commissioning must always be done in
accordance with valid regulations and local standards.
4
1
4 PI
2
1
PI PI
System
3
3
2
5 5
6
7
1
Closed system design (not applicable for PAHT/PAHT G 256-308)
2
11 4
Reservoir
6
5
6 7
PI PI
5
2
5
PI
7
6
System
PI
10
6
5
6
9
10
7
PI
1
System
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8
3 2
9
10
8
1
System
3
Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps - WEG motor
5.6 Pre mounting checklist, based on Danfoss preferred system designs
Table 1: Check points when assembling and commissioning system
Check points
CP1 Ensure that the environmental conditions are safe.
Comment
See Arrival inspection, transportation, handling, lifting and storage, chapter 4.
CP2 Minimum and maximum start-up temperature for fluid and pump.
See Data sheet or Instruction, appendices 1 and 2.
CP3 Filtration condition (10µm absolute (β
10
≥ 5000) See Danfoss requirements in
Data sheet and Instruction, appendices 1 and 2
CP4 Power supply for electric motor and VFD.
CP5 Safety circuit / breaker must be sized for the motor and environment (corrosion and humidity)
CP6 Bolts and screws must conform to environmental conditions as well as fluid and torque requirements.
CP7 Instrumentation, pressure switch should be designed to conform to the environment (corrosion and humidity).
See Data sheet for the used motor and VFD.
See Data sheet for the used safety circuit.
CP8 Check the factory settings of the safety/relief valves or pressure relief valves (1).
CP9 Check the settings of the pressure transmitter/switch (2) set at min. inlet pressure.
See Data sheet for the used equipment.
See Data sheets for the used valves.
See Data sheet or Instruction, appendices 1 and 2.
CP10 Check that all pressure indicators (PI) are selected to be able to measure the system pressure range.
CP11 Check coupling distance ( air gab – movement of the spider ) 3 – 5 mm
CP12 Check correct connections on the pump ( in & outlet)
CP13 Check piping for possible air gaps.
Scaling should at least be 1 Bar or more precise.
OK ?
5.7 Lifting and positioning
Lift the pump unit onto base (Remember vibration dampers, if needed). Fasten the motor to the base.
See also chapter 4, Arrival inspection, transportation, handling, lifting and storage.
5.8 Mount the different equipment
(connections, pipes, tubes, check and safety/relief valves, etc.)
• The hard piping and flexible hoses used must be of proper design and must be installed in accordance with the manufacturer’s recommendations.
• Misalignment of the hard pipes may give unintended stress on the pump port connection and may damage the pump.
• Prevent excessive external pipe load.
• Do not connect piping by applying external force (use of wrenches, crane, etc.) Piping must be aligned without residual stress.
• Do not mount expansion joints so that their force applies internal pressure on the pump connections.
5.9 Electrics
All electrical installation work must be carried out by authorized personnel in accordance with
EN60204-1 and/or local regulations. (see also
Safety, chapter 2)
Turn off the safety circuit breaker and lock it.
Mount the power cable on the electric motor.
If a VFD is used, adjust the protective motor switch/VFD to the current limits found on name plate of the electric motor.
5.10 Instrumentation
The pressure switch/sensor should be mounted as close to the pump as possible. It is recommended to test the pressure/sensor switch via an instrumentation manifold.
Mount the pressure switch/sensors according to the manufacturer’s instructions.
5.11 Connections
Mount and tighten connections and check valve(s) as specified.
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5.12 Ensure free flow
Ensure free flow from relief 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.
• Check the temperature switch/controls. The high-pressure pump must stop if temperature 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.
5.13 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 specifications, 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.
•
•
5.16.2 Closed system (not applicable for
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.
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.
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.
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.
Check the filter pressure switch/controls. A warning must be given if pressure is above specified set point.
If the system is running within the system design limits, the system is released for operation.
5.17 Check the filter condition
Evaluate contamination found in filter, replace filter elements, if necessary.
5.16 Commissioning
5.16.1 Open system
• Check if filter element is present and mounted correctly.
• Switch on the circuit breaker for both motor(s) and VFD(s).
• Check rotation of the 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.
• Adjust pressure relief valve to minimum setting.
• 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.
• Check all fittings for leakage.
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.
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6. Operation of motor pump unit
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 specified torque(s).
B) Leakage – if a small leakage from the bell housing is observed. Contact the maintenance 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.
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.
7. Maintenance and service of the pump unit 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.
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.
7.2 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, Instruction.
For spare parts and service tools, please see appendix 4, Parts list.
7.3 Shut down of the system
A) Stop the 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 the pump and system are emptied for water.
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F) Slowly 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) For the 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.
Returns without a return number will be rejected !!!
7.5 Assembling the pump unit
Assemble the pump according to the Disassembling and Assembling Instruction (available at www. danfoss.high-pressurepumps.com).
I) 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.
7.4 Disassembling and assembling the
A) pump unit
Remove all connections from the pump.
7.6 Procedure for mounting the pump back onto electric motor
K) Move the pump to a clean and safe location where the pump can be inspected/ serviced.
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 inspection, transportation, handling, lifting and storage and Installation and commissioning, chapter 5.
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 pump. Wipe the parts clean and dry with a lint-free clothing.
C) Inspect all parts including shaft seal and if necessary, replace them; see appendix 4,
Parts list.
D) If the 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.
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.
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8. Troubleshooting and scrapping criteria
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.
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 wrong 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 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.
Electrical hazard
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 temperatures 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 temperatures and shall not be liable for any consequential 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 good advises regarding design, installation, wiring and troubleshooting.
In case the pump needs to be scrapped, please follow your local environmental rules.
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Operation guide
Appendices
PAHT G 256-308
Installation, Operation and
Maintenance Manual
hpp.danfoss.com
Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps - WEG motor
Table of Contents
3.
4.
1.
2.
5.
6.
Data sheet PAHT G 2-308 / ATEX PAHT G pumps (521B1407) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Pump instruction PAHT G 256-308 (180R9385) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Electric motor manual (WEG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Parts list PAHT G (521B1410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Trouble shooting guide for PAH, PAHT, PAHT G, PAHT 674 and PAH F pumps . . . . . . . . . . . . .59
Right and wrong - Trouble shooting guide for water hydraulic systems (180R9042). . . . . . .71
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Data sheet
Data sheet
PAHT 2-308 pumps /
PAHT G 2-308 pumps /
ATEX PAHT G pump
Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
Table of Contents Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2. Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3. Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.4 PAHT G 256-308. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
5. Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5.5 PAHT G 256-308 typical flow curves at max pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6. Motor requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
7. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
7.1 Filtration
7.2 Noise
7.3
7.4
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Open-system design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Closed-system design (not applicable for PAHT G 256-308). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.
8.5
Dimensions and connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
PAHT G 256-308. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
9. Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
1. Introduction
•
•
•
The Danfoss range of PAHT G high-pressure pumps is specifically designed for use with technical water such as:
Ultra-pure water that has undergone multiple reverse osmosis processes
De-ionized water
Demineralized water
Danfoss PAHT G pumps are positive displacement pumps, with axial pistons that move a fixed amount of water in each cycle. Flow is proportional to the number of input shaft revolutions
(rpm). Unlike centrifugal pumps, they produce the same flow at a given speed independently of no matter what the discharge pressure.
The range of PAHT G pumps is based on the standard PAHT pump series. The PAHT G pumps are made with extra coatings that reduce the wear of the pump. This coating is particularly important for pumps used in gas turbine applications or other similar applications where the wear of the pumps is higher due to the ultra pure water quality.
The next pages will cover both PAHT G and PAHT
G ATEX pumps.
ATEX certified pumps are indicated by Ex in the type designation - example PAHT G 12.5 Ex.
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Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
Below sectional drawing is an example of a PAHT G pump.
1: Mounting flange
2: Shaft seal
3: Connecting flange
4: Port plate
5: Valve plate
6: Retainer plate
7: Swash plate
8: End cap
9: Spring
10: Piston
11: Cylinder barrel
12: Housing with bearing
2. Benefits
•
•
- Oil lubricants are replaced with the pumped medium, water, so there is no
• contamination risk from the pump.
Low maintenance costs:
- Efficient design and all-stainless steel construction ensure exceptionally long
• lifetime. When Danfoss specifications are met, service intervals of up to 8,000 hours can be expected. Service is easy, and can be carried out on site due to the simple design and few parts.
Low energy costs:
- The highly efficient axial piston design provides the lowest energy consumption of any comparable pump on the market.
Easy installation:
- The lightest and most compact design available.
•
- Pump can be installed horizontally or vertically.
- No pulsation dampeners necessary due to extremely low-pressure pulsation.
- Powered by electric motors or combustion engines.
- Suitable for both boosted inlet pressure and water supply from a tank.
- No need for cooling circuits due to very high mechanical efficiency.
Certified quality:
- Fulfills the stringent hygiene requirements, VDI 6022, HACCP.
- Certificates:
ISO 9001, ISO 14001
ATEX available
API available on request
3. Application examples •
•
•
High-pressure cleaning with ultra-pure water, as used in the manufacturing of flat-panel displays and many 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.
•
•
•
Humidification in office buildings, electronic 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 and gas turbines.
• Gas turbine by inlet fogging and fuel wash
systems.
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Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
4.4 PAHT G 256-308
Pump size
Code number PAHT G
256
180B6090
308
180B6091
Code number ATEX PAHT G 180B6190 180B6191
Housing material AISI 316 or higher
AISI 316 or higher
Geometric displacement cm³/rev in³/rev
256
15.6
308
18.8
Pressure
Min. outlet pressure barg psig
30
435
30
435
Max. outlet pressure
Inlet pressure, continuous barg psig barg psig
120
1740
2-6
29-87
120
1740
2-6
29-87
Max inlet pressure, peak 1) barg psig
10
145
10
145
Speed
Min. speed
1250 rpm at max. pressure
450 rpm at max. pressure rpm l/min gpm
450 450
Min. speed, continuous
Max. speed rpm 700 700 rpm 1250 1250
Typical flow - Flow curves available in section 5
450 rpm at max. pressure l/min 89.6
107.8
294.4
23.3
354.2
28.0
1250 rpm at max. pressure
Typical motor size
1000 rpm at max. pressure kW
50 Hz
1200 rpm at max. pressure
Torque at max. outlet pressure gpm hp
60 Hz
Nm lbf-ft
Media temperature
Ambient temperature
°C
°F
°C
°F
Sound pressure level 2)
Weight dB(A) kg lbs
76.5
55
100
549.6
405.6
2-50
37-122
0-50
32-122
82
105
231
92.1
75
125
87
105
231
661.3
448.0
2-50
37-122
0-50
32-122
1)
2)
1% per minute peak, 10% per minute during start up.
Measurements according to EN ISO 3744: 2010 / dB(A) [L
PA, 1m
] values are calculated.
Measured at max pressure and rpm for a motor pump unit.
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Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
5. Flow The flow (Q eff
) at various pressure (p max
) can be calculated with the following equation:
Q eff
= Q
(th)
– [(Q
(th)
– Q (p max
)) x (p / p max
)]
The theoretical flow can be calculated with the following equation:
Q
(th)
=
V x n
1000
At zero pressure the true flow equals the theoretical flow Q
(th)
.
p:
V: n:
Q
(th)
Q (p p max
: max
Theoretical flow (l/min / gpm)
): Flows at max. pressure (l/min and gpm), see 4.1-4.4
: Max pressure (barg / psig)
Pressure (barg / psig)
Displacement (cm 3 / rev.)
Motor speed (rpm)
5.5 PAHT G 256-308 typical flow curves at max pressure l/min
250
200
200
150
150
100
100
50
50
0
0
400
350
350
300
300
250
45
0
45
0
55
0
0
55
65
0
0
65
75
0
75
0
PAHT 308
PAHT 256
PAHT 256
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
85
0
85
0
95
0
95
0
10
50
10
50
11
11
50
50
12
50
12
50 rpm rpm gpm
70
60
60
50
50
40
40
30
30
20
20
10
10
0
0
100
90
90
80
80
70
45
0
45
0
55
0
55
0
65
0
65
0
75
0
75
0
PAHT 308
PAHT 256
85
0
85
0
95
0
95
0
10
10
50
50
11
50
11
50
12
12
50
50 rpm rpm
23
Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
6. Motor requirements The required motor power can be calculated by using the following equation:
P = n x V x p
600.000 x η
P: Power (kW)
M: Torque (Nm)
η: Mechanical efficiency p: Pressure (barg) n: Motor speed (rpm)
V: Displacement (cm 3 /rev.)
From the flow curves in item 5, you can determine the rpm of the pump at the desired flow.
The required torque is calculated as follows:
M =
V x p
62.8 x η
To determine the correct motor size, both the power and torque requirement must be verified.
The mechanical efficiency of the pump, at max pressure, is as follows:
PAHT G 256, 308 0.95
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Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
7. Installation See the figure below for instructions on how to mount the pump and connect it to an electric motor or combustion engine.
A B C D
A: Pump
B: Bell housing
C: Coupling
D: 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.
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
521B1009).
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 filtration specifications are met, and by always changing filter cartridges according to schedule.
Since water has very low viscosity, Danfoss
PAHT G 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 99.98% at 10 μm. We strongly recommend that you always use precision depth filter cartridges rated 10 μm abs. β
10
≥ 5,000.
Please note that we do not recommend bag filters or string-wound filter cartridges , which typically have only 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.
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:
• Pump speed:
High rpm makes more fluid/structure-
• borne pulsations/vibrations than low rpm.
Discharge pressure:
High pressures make more noise than low pressures.
•
•
•
Pump mounting:
Rigid mounting makes more noise than flexible mounting because of the structureborne vibrations. Be sure to use dampers when mounting.
Connections to pump:
Pipes connected directly to the pump make more noise than flexible hoses because of structure-borne vibrations.
Variable frequency drives (VFDs):
Motors regulated by VFDs can produce more noise if the VFD does not have the right settings.
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Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
7.3 Open-system design
A Inlet line:
Dimension the inlet line to obtain minimum pressure loss (large flow, minimum pipe length, minimum number of bends/ connections, fittings with small pressure losses and restrictions).
B Inlet filter:
Install the inlet filter (1) in front of the
PAHT G pump (2). Please consult the
Danfoss filter data sheet for guidance on how to select the right filter.
C 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.
D 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 according to technical data, item 4. The monitoring temperature switch stops the pump if inlet temperature is higher than the set value.
E
F
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 maintained according to specifications described in item 4, technical data.
G Non-return valve (6):
Should be installed after the outlet to prevent pump backspin, which may ruin the pump.
H Pressure relief valve:
As the Danfoss PAHT G 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 recommended between the non-return valve
(8) and the pump to protect against high-pressure peaks.
1 4 5 2 5 6
PI PI
SYSTEM
8 3 7
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Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
7.4 Closed-system design (not applicable for PAHT G 256-308)
A Inlet line:
Dimension the inlet line to obtain minimum pressure loss (large flow, minimum pipe length, minimum number of bends/ connections, fittings with small pressure losses and restrictions).
B Inlet filter:
Install the filter (1) in front of the tank (2).
Please consult the Danfoss filter data sheet for guidance on how to select the right filter.
C Monitoring pressure switch:
Install the monitoring pressure switch (3) in front of the filter (1). Set the maximum inlet pressure to 2 barg (29.0 psig). The monitoring pressure switch will stop the pump (5) if inlet pressure is higher than 2 barg (29.0 psig), indicating that the filter element must be changed.
D Monitoring temperature switch:
Install the monitoring temperature 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.
E Hoses:
Always use flexible hoses (6) to minimize vibrations and noise.
F 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.
G Non-return valve (7):
Should be installed after the outlet to prevent pump backspin, which may ruin the pump.
H Pressure relief valve:
As the Danfoss PAHT G 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: I
To ensure proper filtration of new water
(10) supplied to the system, always use the filling valve (9).
J 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.
PI
3
4
5
2
5
PI
7
6
System
2
11 4
Reservoir
PI
6
5
6
PI
7
System
1
9
10
8
3
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Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
8. Dimensions and connections
8.5 PAHT G 256-308
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Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
9. Service Danfoss PAHT G pumps are designed for long periods of service-free operation to ensure low maintenance and life cycle costs. Provided that the pump is installed and operated according to
Danfoss specifications, Danfoss PAHT G pumps typically run up to 8,000 hours. However, the service schedule for your Danfoss 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.
•
•
•
•
running the pump at speeds outside specifications
supplying the pump with water at temperatures 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 if 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.
Other factors that affect pump performance and lifetime include:
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Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
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Data sheet | PAHT G 2-308 and ATEX PAHT G pumps
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31
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.
© Danfoss | DCS (im) | 2020.08
521B1407 | AI106586503089en-000701| 32
Instruction
Instruction
Pump instruction
PAHT 256-308 and
PAHT G 256-308
Instruction | PAHT 256-308
Table of Contents Table of Contents
1. Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
2.
2.1
2.2
2.3
2.4
System design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Open-ended systems with direct water supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Preferred system design and P&ID Inlet line: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Reversible pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
General comments on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3. Building up the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
3.2 Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
3.3 Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
3.4 Protection from too high pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
3.5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
3.6 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
4. Initial start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.1 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.2 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.3 Dry running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.4 Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
6. Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
7.
7.1
7.2
7.3
Recommended service intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Inspection of pump parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
How to inspect the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
1. Identification
PUMP
Type PAHT 256
Code no. 180BXXXX
Serial no. XXXXXX02-XXX
MADE IN DENMARK
Danfoss A/S, 6430 Nordborg, Denmark
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Instruction | PAHT 256-308
2. System design The design of the system must ensure that self-emptying of the pump during standstill is avoided.
The inlet pressure of the pump must never exceed the outlet pressure. This may typically occur in boosted or open-ended systems with direct water supply.
2.1 Open-ended systems with direct water supply
The pump is supplied with water direct from a feed pump.
The inlet pressure for PAHT 256/308 must be at least 3 barg (43 psig) and it must not exceed
6 barg (87 psig) continuously.
monitoring switch stop the pump at pressures lower than minimum pressure.
Monitoring temperature switch:
D Place a monitoring temperature switch (4) set between filter and pump, on either side of the monotoring pressure switch. Set the temperature value according to specifications described in item 5 .The monitoring switch stops the pump at temperatures higher than set value.
Hoses
E Always use flexible hoses (5) to minimize vibrations and noise.
Inlet pressure:
F In order to eliminate the risk of damage and cavitation, a positive pressure at the inlet is always to be maintained at min. inlet pressure and max. inlet pressure.
PI
Optrional
If it is unknown what the peak inlet pressure can be, then there should be a 10 barg (145 psig) safety valve on the inlet side of the pump.
2.2 Preferred system design and P&ID
Inlet line:
A Dimension the inlet line to obtain minimum pressure loss (large flow, minimum pipe length, minimum number of bends/ connections, and fittings with small pressure losses).
Inlet filter:
B Place an inlet filter (1) in front of the PAHT pump (2). Please consult Danfoss filter datasheet for guidance on how to select the right filter. Thoroughly clean pipes and flush system prior to start-up.
Monitoring pressure switch:
C Place a monitoring pressure switch (3) between filter and pump inlet. Set the minumum inlet presssure according to specifications described in item 5. The
Non-retrun valve
G A non-return valve (6) after the outlet can be installed in order to avoid backspin of the pump.
Pressure relief valve:
H A pressure relief valve (7)) can be installed in order to avoid system damage as the
Danfoss PAHT pump creates pressure and flow immediately after start-up, regardless of any counter pressure.
Note: If a non-return valve is mounted in the inlet line, a low pressure relief valve is also required between non return valve (8) and pump as protection against high pressure peaks.
1 4 5 6
PI
2 5
PI
SYSTEM
8 3
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35
Instruction | PAHT 256-308
3. Building up the pump unit
2.3 Reversible pumps
If exposed to high pressure in the outlet while the electric motor is not energized, the pumps will start spinning backwards. This will not harm the pumps as long as the pressure in the inlet does not exceed the max. pressure peak of
10 barg (145 psig).
If a non-return valve is mounted in the inlet line, a low-pressure relief valve is also required as protection against high-pressure pulses and high pressure in general.
Alternatively a high-pressure check valve can be mounted in the pump discharge line to prevent the pump from reversing.
The dotted setup ensures that the inlet pressure does not exceed 10 barg (145 psig), when a non-return valve is mounted in the inlet.
In order to avoid the risk of cavitation, the inlet pressure at the pump must be min. 3 barg
(43 psig).
The inlet line connection must be properly tightened, as possible entrance of air will cause cavitation.
2.4 General comments on
Filtration
A good filtration is vital to ensure a long and trouble free life of the pump.
As water has very low viscosity, the PAHT pumps have been designed with very narrow clearance in order to control internal leakage rates and improve component performance. Therefore it is important that the inlet water is filtered properly to minimize the wear of the pump.
The main filter must have a filtration efficiency of
99.98% at 10 µm. We recommend to use precision depth filter cartridges rated 10 µm abs.
β10 ≥ 5000 (equivalent to a filtration efficiency of
99.98%). Bag filters and string wound filter cartridges typically have only 50% filtration efficiency. This means that for each 100,000 particles reaching the filter, 50,000 particles pass through it compared to only 20 particles in a filter with an efficiency of 99.98%.
For more information on the importance of proper filtration, please consult our publication
“Filtration” (code number 521B1009), which also will provide you with an explanation of filtration definitions and a guidance on how to select the right filter.
Monitoring
It is recommended to continuously monitor the following conditions:
•
• filter clogging
pressure (inlet- and outlet side of the pump)
3.1 Mounting
A: Elastic coupling
B: Bell housing
C: Motor shaft
D: Pump flange
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Instruction | PAHT 256-308
C
B
A
1. Mount the coupling flush or maximum
1mm offset from the pump shaft end.
Ensure an air gap between coupling and pump flange of min. 4 mm (0.16 in).
2. Mount the bell housing on pump. Secure nuts with the right torque.
3. Measure the longest distance “A” from top of bell housing to the button of coupling claw.
4. Mount the coupling on motor shaft. Ensure the coupling and motor flange are not in contact with each other.
5. Measure from motor flange to the top of the coupling. That measurement “B” shall be 3-5 mm (0.12 - 0.2 inch) shorter than the measurement “A”.
6. Adjust respectively, verify the measurement, and secure both couplings with the right torques on the locking screws (see coupling operation & mounting instruction).
7. Mount the elastic gear ring and mount the bell housing/pump on the motor. After mounting it must be possible to move the elastic gear ring 3-5mm (0.12 - 0.2 in) axial
“C”. The check can be done through the inspection hole of bell housing. Secure flange bolts with the right torque.
If alternative mounting is desired, please contact the Danfoss Sales Organization.
Choose proper tolerances to ensure an easy mounting of the elastic coupling without use of tools.
Please take care to observe the recommended length tolerances of the chosen coupling, as an axial force on the pump will damage the pump.
3.2 Direction of rotation
Is indicated by means of an arrow on the pump label.
PUMP
Type PAHT 256
Code no. 180BXXXX
Serial no. XXXXXX02-XXX
MADE IN DENMARK
Danfoss A/S, 6430 Nordborg, Denmark
3.3 Orientation
The pump can be mounted/orientated in any horizontal direction with the inlet and the outlet pointing upwards, downwards or to either side.
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Instruction | PAHT 256-308
4. Initial start-up
5. Operation
38
3.4 Protection from too high pressures
The pump should be protected against too high pressure by means of a safety valve or a pressure relief valve.
The valve should be placed as close to the pump as possible.
The opening characteristics of the valve must not result in peak pressures higher than 100 barg
(1450 psig).
Both the inlet and outlet lines must be flexible soft hoses.
The valve outlet must not be connected directly to the pump suction line. It must be connected directly to the drain.
3.5 Connections
I: Inlet
O: Outlet
C: Bleeding
D:
C
Parallel key
C I
O
D
3.6 Grounding
To prevent stray current corrosion we recommend grounding of the pump and all other parts in the system. All parts in the system must be electrical potential equalized to a single reference point (grounding point).
It is recommended that the electrical resistance in the grounding cable is equal to or below 0.25
Ohm towards the grounding point.
1. Flush inlet line before connecting the pump, to remove possible impurities from pipes, hoses etc.
2. Loosen top bleeding plug “C” (see item 3.5) using an allen key (only plugs with internal hexagan sockets). Retighten the plug, when water appears from the bleeding plug.
3. Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump (see label on pump).
4. Now the pump is ready for start-up.
WARNING:
Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump (see label on pump).
Otherwise the pump will be damaged if a check valve is placed between pump and feed pump.
5.1 Temperature
Fluid temperature:
Min. +2°C to max. +50°C
(Min. +35.6°F to max. +122°F)
Ambient temperature:
Min. +2°C to max. +50°C
(Min. +35.6°F to max. +122°F)
Storage temperature:
Min. -40°C to max. +70°C
(Min. -40°F to max. +158°F)
In case of lower operating temperatures, please contact the Danfoss Sales Organization.
NB: The pump unit should include a pressure gauge on the high pressure side.
5.3 Dry running
When running, the pump must always be connected to the water supply in order to avoid damage if it should run dry.
5.4 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.
5.2 Pressure
The inlet pressure for PAHT 256/308 must be min.
3 barg (43 psig) and max. 6 barg (87 psig). At lower pressures the pump will cavitate, resulting in damage of the pump.
Max. inlet pressure peak (e.g. in case the pump stops momentarily) up to 10 barg (145 psig) are acceptable. Max. pressure on the pump’s outlet line should be limited at 120 barg (1740 psig) continuously.
5.5 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 Sales Organization.
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Instruction | PAHT 256-308
Recommended procedure:
1. Disconnect 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 containing 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.
6. Service The Danfoss PAHT 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 pumps typically run 8,000 hours between service routines. However, the service schedule for your 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.
•
•
•
•
Other factors that affect pump performance and lifetime include:
running the pump at speeds outside specifications
supplying the pump with water at temperatures higher than recommended
running the pump at inlet pressures outside specifications
running the pump at outlet pressures outside the specifications.
7. Recommended service intervals
7.1 General information
This guideline provides information on the recommended service intervals for the PAHT 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 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 wear 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 following 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 How to inspect the pump
Service manuals are available on the internet hpp.danfoss.com
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
39
Danfoss A/S
High Pressure Pumps
Nordborgvej 81
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.
© Danfoss | DCS (im) | 2020.08
180R9257 | AN228286503049en-000501 | 40
Extract
WEG motors
Extract from Installation, Operation and Maintenance Manual from WEG www.weg.net
Operation guide | WEG motors
Introduction This extract is based on information in the Installation, Operation and Maintenance Manual of
Electric Motors from WEG:
“Cod: 50033244 | Rev: 02 | Date (m/y): 11/2011”.
If you have any questions concerning the IOM or need further information, please contact your local WEG branch.
Contact Details can be found at: www.weg.net
2.2. Receiving Inspection
All motors are tested during the manufacturing process.
The motor must be checked when received for any damage that may have occurred during the transportation.
All damages must be reported in writing to the transportation company, to the insurance company and to WEG. Failure to comply with such procedures will void the product warranty.
You must inspect the product:
• Check if nameplate data complies with the purchase order;
• Remove the shaft locking device (if any) and rotate the shaft by hand to ensure that it rotates freely.
• Check that the motor has not been exposed to excessive dust and moisture during the
transportation.
Do not remove the protective grease from the shaft, or the plugs from the cable entries. These protections must remain in place until the installation has been completed.
4.1. Lifting
Before lifting the motor ensure that all eyebolts are tightened properly and the eyebolt shoulders are in contact with the base to be lifted, as shown in Figure 4.1.
Figure 4.2 shows an incorrect tightening of the eyebolt.
Ensure that lifting machine has the required lifting capacity for the weight indicated on the motor nameplate.
Figure 4.1 - Correct tightening of the eyebolt
42 180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Figure 4.2 - Incorrect tightening of the eyebolt
Operation guide | WEG motors
4.1.1 Horizontal motors with one eyebolt
The center-of-gravity may change depending on motor design and accessories. During the lifting procedures the maximum allowed angle of inclination should never be exceeded as specified below.
For horizontal motors fitted with only one eyebolt, the maximum allowed angle-of-inclination during the lifting process should not exceed
30º in relation to the vertical axis, as shown in
Figure 4.3.
30° Max.
Figure 4.3 - Maximum allowed angle-of-inclination for motor with one eyebolt
4.1.3 Vertical motors
For vertical mounted motors, as shown in Figure
4.7, the use of a spreader bar is required for maintaining the lifting element (chain or rope) in vertical position and thus preventing damage to the motor surface.
Always use the eyebolts mounted on the top side of the motor, diametrically opposite, considering the mounting position. Figure 4.7- Lifting of vertical mounted motors
5. Storage
If the motor is not installed immediately, it must be stored in a dry and clean environment, with relative humidity not exceeding 60%, with an ambient temperature between 5 ºC and 40 ºC, without sudden temperature changes, free of dust, vibrations, gases or corrosive agents. The motor must be stored in horizontal position, unless specifically designed for vertical operation, without placing objects on it. Do not remove the protection grease from shaft end to prevent rust.
If the motor are fitted with space heaters, they must always be turned on during the storage period or when the installed motor is out of operation. Space heaters will prevent water condensation inside the motor and keep the winding insulation resistance within acceptable levels. Store the motor in such position that the condensed water can be easily drained. If fitted, remove pulleys or couplings from the shaft end.
The space heaters should never be energized when the motor is in operation.
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43
Operation guide | WEG motors
6. Installation
The insulation resistance must be measured in a safe environment.
1. Insulation resistance: must be within the acceptable limits.
2. Bearings: a. Rolling bearings: oxidized bearings must
be replaced. If no oxidation is detected,
lubricate the bearings. If the motor is
stored for a period of over two years, the
bearings must be replaced before
starting the motor.
b. Sleeve bearing: if sleeve bearing motors
are stored longer than the
recommended oil change interval, the
oil must be changed before machine
starting. Don’t forget to remove the
dehumidifiers when you drain the
oil from the motor and to fill it again
with new oil before starting the
machine.
3. Operating conditions of the start capacitors: If single-phase motors are stored for a period of over two years, it is recommended to change the start capacitors before motor starting since they lose their operating characteristics.
4. Terminal box: a. the inside of the terminal box must be
clean and dry.
b. the contacts must be correctly
connected and corrosion free. c. the cable entries must be correctly
sealed and the terminal box cover
properly mounted in order to ensure
the degree of protection indicated on
the motor nameplate.
5. Cooling: the cooling fins, air inlet and outlet openings must be clean and unobstructed. The distance between the air inlet openings and the wall should not be shorter than ¼ (one quarter) of the diameter of the air inlet. Ensure sufficient space to perform the cleaning services. See
Figure 7.1.
6. Coupling: remove the shaft locking device
(where fitted) and the corrosion protection grease from the shaft end and flange just before installing the motor.
7. Drain hole: the motor must always be positioned so the drain hole is at the lowest position
(If there is any indication arrow on the drain, the drain must be so installed that the arrow points downwards). Motors supplied with rubber drain plugs leave the factory in the closed position and must be opened periodically to allow the exit of condensed water. For environments with high water condensation levels and motor with degree of protection IP55, the drain plugs can be mounted in open position (see Figure 6.1).
For motors with degree of protection IP56, IP65 or IP66, the drain plugs must remain at closed position (see Figure 6.1), being opened only during the motor maintenance procedures.
The drain system of motors with Oil Mist lubrication system must be connected to a specific collection system.
44
Closed position Open position
Figure 6.1 - Detail of the rubber drain plug mounted in closed and open position
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Operation guide | WEG motors
6.9. Electrical connection
Consider the rated motor current, service factor, starting current, environmental and installation conditions,maximum voltage drop, etc. to select appropriate power supply cables and switching and protection devices.
All motors must be installed with overload protection systems. Three-phase motors should be fitted with phase fault protection systems.
If motors are supplied without terminal blocks, insulate the cable terminals with suitable insulation material that meets the power supply voltage and the insulation class indicated on the motor nameplate.
Ensure correct tightening torque for the power cable and grounding connections.
The clearance distance (see Figure 6.12) between non-insulated live parts with each other and between grounded parts must be as indicated in
Table 6.2.
Before connecting the motor, check if the power supply voltage and the frequency comply with the motor nameplate data. All wiring must be made according to the connection diagram on the motor nameplate. To prevent accidents, check if motor has been solidly grounded in accordance with the applicable standards.
Clearance distance
Clearance distance
Figure 6.12 - Clearance distance representation
Voltage
U ≤ 440 V
Minimum clearance distance (mm)
4
440 < U ≤ 690V
Tabel 6.2 - Minimum clearance distance (mm) x supply voltage
Even when the motor is off, dangerous voltages may be present inside the terminal box used for the space heater supply or winding energization when the winding is used as heating element.
Motor capacitors will hold a charge even after the power has been cut off. Do not touch the capacitors and/or motor terminals, before discharging the capacitors completely.
After the motor connection has been completed, ensure that no tool or foreign body has been left inside the terminal box.
Unused cable inlet holes in the terminal box must be properly closed to ensure the degree of protection indicated on the motor nameplate.
The cable inlets used for power supply and control must be fitted with components (for example, cableglands and conduits) that meet the applicable standards and regulations in each country.
5.5
If the motor is fitted with accessories, such as brakes and forced cooling systems, these devices must be connected to the power supply according to the information provided on their nameplates and with special care as indicated above.
All protection devices, including overcurrent protection, must be set according to the rated machine conditions. These protection devices must protect the machine against short circuit, phase fault or locked rotor condition.
The motor protection devices must be set according to the applicable standards.
Check the direction of rotation of the motor shaft. If there is no limitation for the use of unidirectional fans, the shaft rotation direction can be changed by reversing any two of the phase connections. For single-phase motor, check the connection diagram indicated on the motor nameplate.
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
45
Operation guide | WEG motors
6.10. Connection of the thermal protection
devices
If the motor is supplied with temperature monitoring devices, such as, thermostat, thermistors, automatic thermal protectors, Pt-100 (RTD), etc., they must be connected to the corresponding control devices as specified on the accessory nameplates. The non-compliance with this procedure may void the product warranty and cause serious material damages.
Do not apply test voltage above 2.5 V on thermistors and current above 1 mA on RTDs
(Pt-100) according to IEC 60751 standard.
Figure 6.13 and Figure 6.14 show the connection diagram of the bimetal thermal protector
(thermostats) and thermistors, respectively.
46
Figure 6.13 - Connection of the bimetal thermal protectors (thermostats)
Figure 6.14 - Thermistor connection
7. Commissioning
7.1. Initial Start-up
After finishing the installation procedures and before starting the motor for the first time or after a long period without operation, the following items must be checked:
• If the nameplate data (voltage, current, connection diagram, degree of protection, cooling system, service factor, etc.) meet the application requirements.
• If the machine set (motor + driven machine) has been mounted and aligned correctly.
• If the motor driving system ensures that the motor speed does not exceed the max. allowed speed.
• Measure the winding insulation resistance, making sure it complies with the specified values.
• Check the motor rotation direction.
• Inspect the motor terminal box for damage and ensure that it is clean and dry and all contacts are rust-free,the seals are in perfect operating conditions and all unused threaded holes are properly closed thus ensuring the degree of protection indicated on the motor nameplate.
• Check if the motor wiring connections, including grounding and auxiliary equipment connection, have been carried out properly..
• Check the operating conditions of the installed auxiliary devices (brake, encoder, thermal protection device, forced cooling system, etc.).
• Check bearing operating conditions. If signs of oxidation are detected, replace the bearings. If no sign of oxidation is detected, relubricate the bearings as described in item
8.2. If the motors are stored for more than two years, the bearings must be replaced before starting the motor.
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Operation guide | WEG motors
• When motors are fitted with sleeve bearings, ensure:
- correct oil level for the sleeve bearing. The
oil level should be in the center of the
sight glass
- that the motor is not started or operated
with axial or radial loads;
- that if the motor is stored for a period
equal or longer than the oil change
interval, the oil must be changed before
starting the motor.
• Inspect the capacitor operating condition, if any. If motors are installed for more than two years, but were never commissioned, it is recommended to change the start capacitors since they lose their operating characteristics.
• Ensure that the air inlet and outlet opening are not blocked. The minimum clearance to the nearest wall (L) should be at least ¼ of the fan cover diameter (D), see Figure 7.1.
The intake air temperature must be at ambient temperature.
D
L
Figure 7.1 - Minimum clearance to the wall
Please consider the minimum distances shown in the Table 7.1 as reference value
Frame size
IEC
63
71
80
90
100
112
132
160
180
200
225
250
NEMA
-
-
-
143/5
-
182/4
213/5
254/6
284/6
324/6
364/5
404/5
• ensure that all rotating parts, such as pulleys,
couplings, external fans, shaft, etc. are
protected against accidental contact.
Distance between the fan cover and the wall (L) mm Inches
25
26
30
33
36
41
50
65
68
78
0.96
1.02
1.18
1.30
1.43
1.61
1.98
2.56
2.66
3.08
85 3.35
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
47
Operation guide | WEG motors
48
Other tests and inspections not included in the manual may be required, depending on the specific installation, application and/or motor characteristics.
After all previous inspections have been carried out, proceed as follows to start the motor:
• Start the motor on no-load (if possible) and check the motor direction of rotation. Check for the presence of any abnormal noise, vibration or other abnormal operating conditions.
• Ensure the motor starts smoothly. If any abnormal operating condition is noticed, switch off the motor, check the assembly system and connections before the motor is started again.
• If excessive vibrations are noticed, check if the motor mounting bolts are well tightened or if the vibrations are not generated and transmitted from adjacent installed equipment. Check the motor vibration periodically and ensure that the vibration limits are kept.
• Start the motor at rated load during a short time and compare the operating current with the rated current indicated on the nameplate.
• Continue to measure the following motor variables until thermal equilibrium is reached: current, voltage, bearing and motor frame temperature, vibration and noise levels.
• Record the measured current and voltage values on the Installation Report for future comparisons.
As induction motors have high inrush currents during start-up, the acceleration of high inertia load requires an extended starting time to reach full speed resulting in fast motor temperature rise. Successive starts within short intervals will result in winding temperature increases and can lead to physical insulation damage reducing the useful life of the insulation system. If the duty S1 is specified on the motor nameplate, this means that the motor has been designed for:
• two successive starts: first start from cold condition, i. e., the motor windings are at room temperature and the second start immediately after the motor stops.
• one start from hot condition, i. e., the motor windings are at rated temperature.
8. Maintenance
The purpose of the maintenance is to extend the useful life of the equipment. The noncompliance with one of these previous items can cause unexpected machine failures.
If motors with cylindrical roller or angular contact bearings are to be transported during the maintenance procedures, the shaft locking device must always be fitted. All HGF motors, regardless of the bearing type, must always be transported with the shaft locking device fitted.
All repairs, disassembly and assembly related services must be carried out only by qualified and well-trained personnel by using proper tools and techniques. Make sure that the machine has stopped and it is disconnected from the power supply, including the accessory devices (space heater, brake, etc.), before any servicing is undertaken.
The company does not assume any responsibility or liability for repair services or maintenance operations executed by non-authorized Service
Centers or by non qualified service personnel.
The company shall have no obligation or liability whatsoever to the buyer for any indirect, special, consequential or incidental loss or damage caused or arising from the company’s proven negligence
8.1. General Inspection
The inspection intervals depend on the motor type, application and installation conditions. Proceed as follows during inspection:
• Visually inspect the motor and coupling.
Check if abnormal noises, vibrations, excessive heating, wear signs, misalignment or damaged parts are noticed. Replace the damaged parts as required.
• Measure the insulation resistance.
• Clean the motor enclosure. Remove oil spills and dust accumulation from the motor frame surface to ensure a better heat transfer to the surrounding ambient.
• Check cooling fan condition and clean the air inlet & outlet openings to ensure a free air flow over the motor.
• Investigate the actual condition of the seals and replace them, if required.
• Drain the condensed water from inside the motor. After draining, reinstall the drain plugs to ensure the degree of protection as indicated on the motor nameplate. The motor must always be positioned so the drain hole is at the lowest position (see item
6).
• Check the connections of the power supply cables, ensuring the correct clearance distance between live and grounded parts, as specified in Table 6.2.
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Operation guide | WEG motors
• Check if the tightening torque of the bolted connections and mounting bolts meets the specified tightening torque.
• Check the status of the cable passages, the cable gland seals and the seals inside the terminal box and replace them, if required.
• Check the bearing operating conditions.
Check for the presence of any abnormal noise, vibration or other abnormal operating conditions, like motor temperature rise.
Check the oil level, the lube oil condition and compare the workings hours with the informed life time.
• Record and file all changes performed on the motor.
8.2.1. Grease lubricated rolling bearings
Excess grease causes bearing overheating, resulting in bearing failure.
The lubrication intervals specified in Table 8.1, consider a room temperature of 40°C, the motor running at rated speed, a motor mounted in horizontal position, greased with Mobil Polyrex
EM grease. The lubrication intervals are determined according to the standard ISO 281 and they estimate for the basic rating life that 90% of a group of identical bearings will theoretically meet or exceed the calculated value with 90% reliability. Any variation of the parameters listed above must be evaluated.
Do not reuse damaged or worn parts. Damaged or worn parts must be replaced by parts supplied by the manufacturer and must be installed as if they were the original parts.
8.2. Lubrication
Proper lubrication plays a vital role in the motor performance. Only use the grease or oil types, amounts and lubrication intervals recommended for the bearings. This information is available on the motor nameplate and the lubrication procedures must be carried out according to the type of lubricant (oil or grease).
When the motor is fitted with thermal protection devices for bearing temperature control, consider the operating temperature limits.
The grease and oil disposal should be made in compliance with applicable laws in each country.
Please contact WEG when motors are to be installed in special environments or used for special applications.
IEC
Frame
NEMA
Poles
Bearing designation
Amount of grease
(g)
160
180
254/6
284/6
6
8
2
4
2
4
6
8
6309
6311
13
18
Table 8.1 - Lubrication intervals for ball bearings
ODP
(Open Drip Proof)
Lubrication intervals (hours)
W21 TEFC
(Totally enclosde
Fan Cooled)
W22 TEFC
(Totally Enclosed
Fan Cooled)
50 Hz 60 Hz 50 Hz
18100
60 Hz
15700
50 Hz
22000
60 Hz
20000
20000
20000
20000
20000
20000
13700
20000
20000
11500
20000
25000
17000
25000
25000
14000
25000
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
49
Danfoss A/S
High Pressure Pumps
Nordborgvej 81
DK-6430 Nordborg
Denmark
© Danfoss | DCS (im | 2016.11
180R9357 | IOM iSave 50-70-V03 | 50
Parts list
Parts list
PAHT 2-308 pumps
PAHT G 2-308 pumps
PAHT G 20/25/32 - PAHT G 50/63/70/80/90 -
PAHT G 256/308
Parts list | PAHT G pumps
Table of Contents Contents
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
14.
15.
16.
Spare parts list for PAHT G 256-308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Exploded view for PAHT G 256-308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Tool set for PAHT G 256-308 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
52 180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Parts list | PAHT G pumps
1. General This parts list provides an overview of the content of the various service sets as well as exploded views for both non ATEX and
ATEX certified pumps.
ATEX certified pumps are indicated by Ex in the designation.
Non Atex
PAHT G 256
PAHT G 308
ATEX
PAHT G 256 Ex
PAHT G 308 Ex
In the following the pumps will be called
PAHT G.
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
53
Parts list | PAHT G pumps
14. Spare parts list for
PAHT G 256-308
Pos.
Qty.
Designation Material
Retainer Ball
Retainer plate
Piston
Key 12 x 8 x 70
Retainer Guide
Port plate
Valve plate
Back up ring
O-ring ø30,2 x 3
Port flange
O-ring ø68 x 2
O-ring Ø228 x 4
Shaft sealing
Cover
Pin ø10,5 x 20
Housing
Pin ø6 x 10
Bleeding plug G 1/4"
O-ring ø11 x 2
Screw M8 x 30
O-ring ø228 x 4
O-ring ø9,19 x 2,62
End cover CW
Screw M8 x 16
Swash plate
Pin ø10,5 x 20
Cylinder barrel
Spring
Spring guide
Screw M6 x 16
Screw M8 x 90
Bleeding plug G 1/4"
O-ring ø11 x 2
Washer for shaft seal
Screw M8 x 16
Service instruction
64
65
66
67
71
91
92
93
94
121 1
122 1
9
9
123 1
124 1
125 1
126 2
9
1
1
1
1
1
1
34
61
62
63
10
11
13
31
1
2
3
4
5
9
127 4
128 15
132 2
133 2
142 1
147 1
1
4
1
2
1
2
1
2
1
1
2
4
4
17
1
Duplex / PEEK
AISI 316
Super duplex
NBR
AISI 316
NBR
NBR
Duplex
AISI 316
Super Duplex
Duplex
Super duplex / PEEK
Duplex
Polypropylen
Super duplex
Super duplex
Super duplex / PEEK
AISI 316
Super duplex / PEEK
Super duplex / PEEK
Super duplex
PTFE
NBR
Duplex
NBR
NBR
Hasteloy C276
Super duplex
Super duplex
AISI 316
AISI 316
Super duplex
NBR
Polypropylen
AISI 316 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
54 180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Parts list | PAHT G pumps
15. Exploded view for
PAHT G 256-308
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
55
Parts list | PAHT G pumps
16. Tool set for
PAHT G 256-308
Designation
Allen key, 6 mm
Adjustable pin wrench
Combination wrench, 10 mm
Combination wrench, 13 mm
Nut, M8 x 6.5 x 13
Guide bolt, M8 x 140
Shaft seal extractor, Ø45
Press bush, Ø45
Eye bolt, M8
Press bush for valve plate
Stop for retainer plate
Screw, M8 x 20
Screw, M8 x 70 x x x x x x x x x x x x x
56 180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Parts list | PAHT G pumps
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
57
Danfoss A/S
High Pressure Pumps
DK-6430 Nordborg
Denmark
58 | © Danfoss | DCS (im) | 2020.02
521B1410 | DKCFN.PI.012.H6.02
Guide line.
Guideline
Trouble shooting guide for
PAH / PAHT / PAHT C / PAHT G /
PAHT 674 and PAH F pumps
Guideline
Table of Contents
Validity
Trouble shooting guide for PAH, PAHT, PAHT C and PAHT G pumps
3.
4.
5.
6.
6.1
6.2
6.3
1.
2.
Table of Contents
Trouble shooting fish bone chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
No flow/no pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Reduced flow/reduced pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
High torque on electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Noise from pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Noise from installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Typical signs of wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Port plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Swash plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
This document is covering the pumps PAH, PAHT
PAHT C, PAHT G, PAHT 674 and PAH F for both non ATEX and ATEX certified. PAHT pumps are not ATEX certified.
60 180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Guideline
Trouble shooting fish bone chart
Trouble shooting guide for PAH, PAHT, PAHT C and PAHT G pumps
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
61
Guideline Trouble shooting guide for PAH, PAHT, PAHT C and PAHT G pumps
1. No flow/no pressure
Cause
1.1 Dry running
(no water supply to the pump)
1.2 Pump reversing
(electric motor is running the wrong direction, i.e. counter-clockwise)
Remedy
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.
Comments
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 reachedminimum inlet pressure (see Data sheet).
Rotation direction for the pump is shown by an arrow on the label on the pump.
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 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 C 2-308
PAHT G 2-308
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 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.
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
1.6 Pump damage
(the internal parts may be damaged)
1.6.1 Contact Danfoss sales office for guidelines in how to troubleshoot internal pump parts.
A B
Instructions on internal elements are available on www.danfoss.high-pressurepumps.com
C
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Guideline
2.2 Low inlet pressure
2.3 Rotation speed (rpm)
Trouble shooting guide for PAH, PAHT, PAHT C and PAHT G pumps
2. Reduced flow/reduced pressure
Cause
2.1 Wear on pump
Large internal leakage due to:
Remedy
2.1.1 Dismantle the pump.
2.1.2 Check valve plate.
Valve plate has marks/scratches on the surface facing the port plate. Minor wear on valve plate can cause large internal leakage. See Index 6.1.
2.1.3 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.
2.1.4 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.
2.1.5 Pre-treatment:
Analyse fluid for content of particles.
- Check that filters are OK and working
correctly.
2.1.6 Main filtration:
Check that the correct filter type is used
(particles in fluid must not exceed 10 μm).
Danfoss High Pressure Pumps supplies filters, please contact the sales office.
Comments
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.
2.1.7 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.
The filters can be bypassed, even if they are correctly mounted. Some filters can create channelling where particles can pass through the filter in tunnels. String wounded filters are typically channelling filters. A string wound filter may have a filtration efficiency of only 50%, 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 99.98%
(Beta = 5000) at 10 μm to prevent abnormal wear of the pump.
2.1.8 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.
Temperature > 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 > 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 has reached 1 bar.
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.
Speeds below minimum limit (see Data sheet) result in insufficient internal lubrication causing wear on the internal pump parts.
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Guideline Trouble shooting guide for PAH, PAHT, PAHT C and PAHT G pumps
3. High torque on electric motor
Cause
3.1 Too high outlet pressure from pump
3.2 Pump starts against pressure
3.3 Constant torque
3.4 Water pump damage
Remedy
3.1.1 Check for blocked nozzles or a faulty adjusted relief valve.
Comments
Pressure changes due to flow restrictions. This will also cause high motor torque.
3.2.1 Check that electric motor is correctly sized.
3.2.2 Check internal parts (see item 2.1).
3.2.3 Systems with more than one electric motor installed:
Start motors simultaneously.
Pumps run in parallel with cascade start, may switch off the motor relay due to too high torque caused by high outlet pressure.
3.3.1 Please contact Danfoss High Pressure
Pumps sales office.
3.4.1 Dismantle pump and check for wear.
If the electric motor is too small for the pump, it cannot provide sufficient torque.
Too heavy damage in the pump will increase friction causing a high torque (see item 6,
Typical signs of wear).
64 180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Guideline
4. Noise from pump
Cause
4.1 Air in fluid
Trouble shooting guide for PAH, PAHT, PAHT C and PAHT G pumps
4.2 Bleeding conditions of pump
4.3 Min/max nominal inlet pressure
4.4 Pump reversing
4.5 High rotation speed (rpm)
4.6 Outlet pressure
4.7 Soft start/stop
Remedy
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 within the limits specified in the Data sheet.
4.3.2 Check the pump for internal damage.
Comments
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 completely 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.
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.
4.5.1 If electric motor rpm is too high, dismantle pump and check for damage.
4.5.2 If the rpm is within the specified range of the pump data sheet and abnormal noise remains, dismantle pump and check for damage.
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.
4.6.1 If outlet pressure is too low, check set point of outlet pressure valve.
4.6.2 If outlet pressure is lower than mentioned in the pump data sheet, please contact
Danfoss High Pressure Pumps technical support.
4.6.3 If outlet pressure has exceeded its maximum, check set point of outlet pressure valve.
4.6.4 Check internal parts for wear/damage.
4.7.1 Check if noise is normal when the pump is running at operation speed.
4.7.2 If noise is abnormal at operation speed, check internal parts (see above).
At too low outlet pressure, the pump will create higher pressure pulsations and thus 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.
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
65
Guideline Trouble shooting guide for PAH, PAHT, PAHT C and PAHT G pumps
5. Noise from installation
Cause
5.1 Inlet/outlet connections (hoses/pipes)
5.2 Length/dimension of inlet/outlet line
5.3 Hose stiffness
5.4 Hoses/pipes mounted directly on frame
5.5 Vibration dampener under the electric motor
Remedy
5.1.1 Use flexible hoses at inlet/outlet connections.
5.1.2 Mount the connections to the frame by a vibration dampener mounting plate.
5.2.1 Increase pipe diameter and/or reduce the number of bends.
Comments
Non-flexible connections mounted directly on the frame will cause even small pressure pulsations from pump and create vibrations in the system/plant.
5.3.1 Use a more flexible hose.
5.4.1 Mount the connections to the frame by a vibration dampener mounting plate.
5.5.1 Mount a vibration dampener below the motor/pump.
Too small pipes or too many bends may create too fast flow/turbulence through the pipes and thus increase the noise level.
Too stiff hoses cannot dampen the small pressure pulsations from the pump, and subsequently vibrations occur in the system/ plant.
If the hoses are mounted directly on the frame, the small pressure pulsations from the pump can be transferred to the frame and the rest of the system/plant.
When no dampener is installed below the electric motor, vibrations from the motor and pump may be transferred to the frame and the rest of the system/plant.
66 180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Picture 2
Scratches
Picture 3
Guideline
6. Typical signs of wear
Picture 1
Trouble shooting guide for PAH, PAHT, PAHT C and PAHT G pumps
6.1 Valve plate
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.
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67
Guideline
6.2 Port plate
Picture 1
Trouble shooting guide for PAH, PAHT, PAHT C and PAHT G pumps
Scratc hes
If the port plate has scratches, level differences or both between the arrows, the port plate must be replaced.
Even small scratches or wear will cause loss of flow.
To check: See item 6.1, picture 3
Level d ifferenc es bet ween
6.3 Swash plate
Picture 1 If the swash plate is polished 360°, 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 information.
68 180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Guideline Trouble shooting guide for PAH, PAHT, PAHT C and PAHT G pumps
180R9408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
69
Danfoss A/S
High Pressure Pump
Nordborgvej 81,
DK-6430 Nordborg
Denmark
© Danfoss | DCS (im) | 12.2017
521B1475 | DKCFN.PI.012.R1.02 | 70
MAKING MODERN LIVING POSSIBLE
Instruction
Right and wrong
Trouble shooting guide for water hydraulic systems
4.
Pump location
Design
1.
Choice of material
.
.
Rubber
Plastic
.
Stainless steel
.
.
Iron
Copper
.
Brass
.
Aluminium
Always use system components made of corrosion proof materials
Non-corrosion proof materials may cause damage
2.
< 10 m m abs.
Choice of filter
> 10 m m
Pump always to be placed below water surface level
Pump location above water surface level will cause damage
5.
Suction conditions
6.
System to be dimensioned to provide a suction pressure of the pump inlet of max. 0.1 bar vacuum
Poor suction conditions will cause malfunction and damage the pump
Pressure Relief valve
3.
Install a 10 micron absolute filter with pressure switch
Return filter with bypass valve and poorer filterability than 10 m will damage the system
Filter location
7.
Pressure relief valve to be mounted vertically or with vertical outlet and connected to return hose or tank
Coupling the pressure relief valve outlet directly to the pump inlet may damage the pump
Water supply
Locate the return filter in the return line immediately before the tank
Placing the return filter upstream of the final load may damage the pump
System to be filled via filter
180R9 408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Filling system with unfiltered water causes damage
Installation
8.
Impurities 11.
Assembly of coupling
Prior to installation, burrs and chips and other impurities must be removed from pipes and hoses, eg with a felt plug
Chips or other impurities in the system may cause damage
9.
Sealing
The coupling must be easy and simple to assemble (see product instruction)
Never use force when assembling the coupling parts, as this will damage the motor/pump
12.
Coupling
= min. 3 mm 0 mm
Fittings in screwed components to be sealed with O-rings or bonded seals
Using teflon tape or packing yarn in joints may cause damage
10.
Grease
Ensure always to have 3 mm distance between coupling flanges
Insufficient distance and/or misalignment between the coupling flanges will damage the pump
13.
Water supply
Correctly limited quantities of grease prevent seizing
Too much grease may develop biofilm causing operational failures
Fill system with water before starting to ensure lubrication and cooling
Starting without water will cause damage
180R9 408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Wiring
14.
Level indicator
15.
1
Level and temperature indicators must be fitted. Follow installation instructions
Missing or incorrectly connected level and temperature indicators cause damage
180R9384 | IOM PAHT G 256-308 pumps - v01 |
03.2016
Rotation direction
?
2
Check pump drive motor rotation direction matches that of the pump prior to installation
Incorrect rotation direction will damage the pump
16.
Bleeding
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 3% agent/water solution
4. Run the system for 60 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
60 min.
2-3 days
Bleeding the pump will ensure correct cooling and lubrication
Insufficient bleeding may cause damage (not applicable to Power Packs)
Observing the starting procedure will ensure problem-free operation
If the system is not cleaned before starting, the filter will clog
180R9 408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Trouble shooting
Open ended water systems
No water supply
No
.
Is water coming
out of the tap?
.
Are all taps open?
Yes
Yes
.
Is the control light
for “low pump suction
pressure” on?
.
The filter is clogging
No
.
Is water coming
through the filter?
Yes
No
.
Replace filter element
No
.
Is the water supply ok?
.
Is water supplied to the pump?
Yes
.
Is the electric motor of
the pump unit rotating?
No
Yes
.
Is the water in the tank
very hot? Ie above 50 o
Yes
No
.
Lower inlet
temperature or
provide better cooling
.
Is the power supply ok?
.
Are control lights on?
Yes
No
.
Is the filter clogged?
.
Is the filter control
light on?
Yes
.
Replace filter element
Contact serviceman
No
.
A blown fuse / or short
circuit?
.
Check power supply
and fuses and contact
electrician
.
Turn on the tap for
water supply
Stamp
180R9 408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Trouble shooting
Closed water systems
The system does not work
No
.
Is there sufficient water
in the tank?
Yes
.
Fill water into the system
.
Is the electric motor of
the pump unit rotating?
No
Yes
.
Is the water in the tank
very hot? Ie above 50 o
Yes
No
.
A blown fuse/or short
circuit?
.
Check power supply
and fuses and contact
electrician
No
.
Is the power supply ok?
.
Are control lights on?
Yes
.
Is the filter clogged?
.
Is the filter control
light on?
No
Contact serviceman
Yes
.
At temperatures
higher than 50 o the
pump drive cuts out.
Consequently the
cooler must be
checked/cleaned
.
Replace filter element
.
Trace leakage, if any
Stamp
180R9 408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
180R9 408 | IOM PAHT G 256-308 pumps - v04 | 11.2020
Danfoss A/S
High Pressure Pumps
Nordborgvej 81
DK-6430 Nordborg
Denmark
© Danfoss | DCS (im) | 2020.11
180R9 408 | IOM PAHT G 256-308 pumps - v04 | 78
Public link updated
The public link to your chat has been updated.
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