Reservoir
PI
User manual
5. Installation and commissioning
Installation, Operation and Maintenance Manual for PAHT / PAHT G 2-12.5 pumps
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!
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 .
Open system design
PI
PI
2
Closed system design (not applicable for PAHT/PAHT G 256-308)
1
System
PI
Reservoir
PI PI
1
System
PI
2
11
PI
System
User manual
12
Installation, Operation and Maintenance Manual for PAHT / PAHT G 2-12.5 pumps
5.6 Pre mounting checklist, based on Danfoss preferred system designs
Table 1: Check points when assembling and commissioning system
CP1
CP2
Check points
Ensure that the environmental conditions are safe .
Minimum and maximum start-up temperature for fluid and pump .
CP3
Filtration condition (10µm absolute (β
10
≥ 5000)
Comment
See Arrival inspection, transportation, handling, lifting and storage, chapter 4 .
See Data sheet or Instruction, appendices 1 and 2 .
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 .
180R9287 / IOM PAHT /PAHT G 2-12.5 pumps - v01 / 06.2013
User manual Installation, Operation and Maintenance Manual for PAHT / PAHT G 2-12.5 pumps
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/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 .
180R9287 / IOM PAHT /PAHT G 2-12.5 pumps - v01 / 06.2013
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