Danfoss PAH 2, PAH 4, PAH 6.3, PAH 10, PAH 12.5 Operating guide

Download

Operating guide

PAH pumps PAH 2-12.5 Installation, Operation and Maintenance Manual

hpp.danfoss.com.

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

Table of Contents Contents

Table of Contents ..................................................................................2

1. Introduction ............................................................................5

1.1 General .................................................................................5

1.2 Symbols ................................................................................5

1.3 Manufacturer and customer service address:.............................................6

1.4 Country specic information ............................................................6

1.4.1 United Kingdom ........................................................................6

2. Safety ..................................................................................6

2.1 General information.....................................................................6

2.2 Preferred system design.................................................................6

2.3 Commissioning and servicing the unit ...................................................7

2.4 Adhere to the following important points ...............................................7

2.5 In case of doubt .........................................................................7

3. Technical data ..........................................................................7

3.1 Approved applications and operational limits for the pumps .............................7

3.2 Application range.......................................................................7

3.3 Electric motor data......................................................................7

3.4 Noise and vibration .....................................................................7

3.5 Dimension drawings ....................................................................7

3.6 Space requirement......................................................................7

3.7 Filtration................................................................................8

3.8 Properties of water ......................................................................8

3.9 Air bubbles .............................................................................8

3.10 Chemicals...............................................................................8

4. Arrival inspection, transportation, handling, lifting and storage ..........................8

4.1 Arrival inspection .......................................................................8

4.2 Warning ................................................................................8

4.3 General safety information ..............................................................8

4.4 Transport and handling .................................................................8

4.5 Return to supplier .......................................................................9

4.6 Storage .................................................................................9

5. Installation and commissioning ........................................................10

5.1 Important dimensions .................................................................10

5.2 Cleanliness.............................................................................10

5.3 Fluid temperature......................................................................10

5.4 Electrical data..........................................................................10

5.5 Local regulations.......................................................................10

5.6 Pre mounting checklist, based on Danfoss preferred system design .....................11

5.7 Lifting and positioning .................................................................11

5.8 Mount the dierent equipment ........................................................11

5.9 Electrics ...............................................................................11

5.10 Instrumentation .......................................................................11

5.11 Connections ...........................................................................11

5.12 Ensure free ow .......................................................................12

5.13 Verify setting of safety/relief valves .....................................................12

5.14 Bleed and remove air from the pump ...................................................12

5.15 Verify direction of rotation .............................................................12

5.16 Commissioning ........................................................................12

5.16.1 Op en system ...........................................................................12

5.16.2 Closed system .................................................................... 12

5.17 Check the lter condition...............................................................12

5.18 Instruct operator and maintenance personnel ..........................................12

6. Operation of motor pump unit ........................................................13

6.1 General safety information.............................................................13

6.2 What to listen and look for .............................................................13

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

7. Maintenance and service of the pump unit .............................................13

7.1 General safety information .............................................................13

7.2 Service and inspection interval for the pump ...........................................13

7.3 Shut down of the system ...............................................................13

7.4 Disassembling and assembling the pump unit ..........................................14

7.5 Assembling the pump unit .............................................................14

7.6 Procedure for mounting the pump back onto electric motor ............................14

7.7 Getting the pump unit back into operation .............................................14

7.8 Storage of the pump ...................................................................14

8. Troubleshooting and scrapping criteria .................................................15

8.1 General safety information .............................................................15

8.2 Operational conditions which can cause pump failures..................................15

8.3 Mechanical failure......................................................................15

8.4 Electrical failure ........................................................................15

8.5 Responsibility..........................................................................15

8.6 Scrapping criteria ......................................................................15

Appendices .......................................................................................17

1. Data sheet PAH 2- 12.5 (521B0835) ......................................................19

2. Pump instruction PAH/PAHT/PAHT G 2-12.5 (180R9277 ..................................33

3. Electric motor manual (180R9230) ......................................................43

4. Parts list PAH 2-12.5 (521B1408) .........................................................49

5. Trouble shooting guide for PAH, PAHT, PAHT G, PAHT 674 and PAH F pumps .............59

6. Right and wrong - Trouble shooting guide for water hydraulic systems (180R9042).......73

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

Validity

This manual is valid for PAH pumps both non ATEX and ATEX certied versions. An ATEX certied pump is indicated by Ex in the designation - example PAH 2 Ex.

No n ATEX ATE X

PAH 2

PAH 4

PAH 6 .3

PAH 10

PAH 12.5

Code no. 180B0024

Serial no. XXXXXX04-XXX XXXXXX04-XXX

Code no. 180B0022

Serial no. XXXXXX04-XXX XXXXXX04-XXX

Code no. 180B0023

Serial no. XXXXXX04-XXX XXXXXX04-XXX

Code no. 180B0008

Serial no. XXXXXX04-XXX XXXXXX04-XXX

Code no. 180B0007

Serial no. XXXXXX04-XXX XXXXXX04-XXX

PUMP

Type PAH 12.5 Code no. 180B0007

Serial no. XXXXXX04-XXX

MADE IN DENMARK

Danfoss A/S, 6430 Nordborg, Denmark

In case the pump delivered is ATEX certied, the additional ATEX instruction maus also be read.

PAH 2 Ex

PAH 4 Ex

PAH 6.3 Ex

PAH 10 Ex

PAH 12.5 Ex

180B6124

180B6122

180B6123

180B6108

180 B6107

The serial number is referring to the Serial no. on the product label. The digits shown (04) indicate the version number of the pump. This documentation is compatible with previous pump versions.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

1. Introduction

1.1 General

The PAH 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 tap water.

In case the pump delivered is ATEX certied, the additional ATEX instruction must also be read.

The PAH pumps must not be used for other purposes than those recommended and specied without rst consulting your local pump distributor.

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.

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 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

Indicates a situation which will or could

result in personal injury and/or damage to the pump

Electrical hazard - Indicates a high-

voltage warning

Safety glasses required

Hearing protection required

Safety shoes required

Safety helmet required

Protective garments must be wor n

Protective garments

must be worn

It is the responsibility of the safety ocer or the chief operator to assure compliance with all local regulations that are not taken into account in this manual.

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 specications requires a written approval from Danfoss High Pressure Pumps.

• If any changes are made without written approval the warranty will automatically become void.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Electrical

hazard

Danger HOT.

Do not touch

Electrical hazard

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

2. Safety

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: highpressurepumps@danfoss.com Web: hpp.danfoss.com

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

Electrical

hazard

All electrical installation work must only be carried out by authorized personnel in accordance with EN60204-1 and/or local regulations.

Your local Danfoss pump distributor can be found on our homepage.

1.4 Country specic information

1.4.1 United Kingdom

UK importer:

Danfoss Ltd. Oxford road UB9 4LH Denham United Kingdom

Under certain operational conditions the surface of the pump can be above 60°C / 140°F. Under these conditions the pump must be labelled with a “Danger Hot” sign.

When using an electric motor, the motor must always be supplied with adequate cooling ventilation.

When using an electric motor together with a VFD (Variable Frequency Drive), the motor must be 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.

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 certied, the additional ATEX instruction must also be read.

Protective garments

must be wor n

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.

Before start-up, the settings for all protective devices, such as sensors/switches and safety valves must be veried and free ow 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.

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.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

3. Technical data

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.

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.

• Do not try to lift the pump unit manually; most of the pumps weigh more than 20 kilos, see specic 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 exible coupling.

• Do not try to start the unit before the system components are mounted, bleeded and adjusted.

• Flush the system throughly before connecting the pump or pump unit.

• Check rotation direction of the motor before mounting the pump.

2.5 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.

3.2 Application range

See appendix 1, 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 tap water.

The PAH pumps must not be used for other purposes than those recommended and specied without rst consulting your local pump distributor.

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.

3.3 Electric motor data

See recommended motor in appendix 1, Data sheet or appendix 3, IOM for motors. The motors mentioned are the most common used motors by Danfoss High Pressure Pumps.

3.4 Noise and vibration

Noise level for a pump unit with a ”standard” motor measured according to EN ISO 3744:2010, see appendix 1, Data sheet. Possibilities to reduce noise and vibration are described in the same Data sheet.

3.5 Dimension drawings

Dimensions of the dierent 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 sucient space available around the pump in order to ensure easy access. Sucient 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.

For system integration of the pumps, please see appendix 1, Data sheet and appendix 2, Instruction.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

4. Arrival inspection, transportation, handling, lifting and storage

3.7 Filtration

(10µm absolute [β10 ≥ 5000])

Requirements are specied in appendix 1, Data sheet and appendix 2, Instruction.

Danfoss recommends not to build a lter bypass function or use lters 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 lter via the dierential/delta pressure across the lter.

Using insucient ltration or a lter 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 specied in the Data sheet.

4.1 Arrival inspection

The pump is packed in a cardboard or wood box with plugs in the port connections to protect the pump from damage during transportation.

When the shipment has arrived it is important to check the pump for any damages. The name plate/type designation must be in accordance with the delivery note and your order.

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 lowpressure and high-pressure side before the system is pressurised. Special consideration should be given in order to minimize air bubbles in the feed ow. 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.

4.4 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.

In case of damage and/or missing parts, a report should be documented and presented to the carrier at once.

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.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

appendix 1, Data sheet) must be handled by using lifting eyes and slings.

Wrong lifting:Pumps which have a weight above 20 kilos (see

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 specic 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, Instruction.

4.5 Return to supplier

Please see maintenance chapter 7.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

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.

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

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 uid and pump housing temperature must be within the specied 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 highpressure 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

1 4 5 5 6

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.

SYSTEM

Closed system design

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

5.6 Pre mounting checklist, based on Danfoss preferred system design

Check points Comment OK ?

CP1 Ensure that the environmental conditions are safe. See Arrival inspection,

CP2 Minimum and maximum start-up temperature for uid and

pump.

CP3 Filtration condition (10µm absolute (β10 ≥ 5000) See Danfoss requirements in

CP4 Power supply for electric motor and VFD. See Data sheet for the used

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 uid and torque requirements.

CP7 Instrumentation, pressure switch should be designed to

conform to the environment (corrosion and humidity).

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.

CP10 Check that all pressure indicators (PI) are selected to be able

to measure the system pressure range.

CP 11 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.

transportation, handling, lifting and storage, chapter 4.

See Data sheet or Instruction, appendices 1 and 2.

Data sheet and Instruction, appendices 1 and 2

motor and VFD.

See Data sheet for the used safety circuit.

See Data sheet for the used equipment.

See Data sheets for the used valves.

See Data sheet or Instruction, appendices 1 and 2.

Scaling should at least be 1 barg or more precise.

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 dierent equipment

(connections, pipes, tubes, check and safety/relief valves, etc.)

• The hard piping and exible 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 o 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 specied.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

5.12 Ensure free ow

Ensure free ow 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.

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 specications, 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.

• Check the temperature switch/controls. The high-pressure pump must stop if temperature is above specied set point.

• Check the pressure switch/controls. The high-pressure pump must stop if pressure is below specied set point.

• If the system is running within the system design limits, the system is released for operation.

5.16.2 Closed system

• Check if the reservoir is clean.

• Check if lter element is present and

mounted correctly.

• Fill water at the reservoir using the lling

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 specied set point.

• Check the lter pressure switch/controls. A

warning must be given if pressure is above specied set point.

• If the system is running within the system

design limits, the system is released for operation.

When the motor is turning in the right direction, the pump can be mounted.

5.17 Check the lter condition

Evaluate contamination found in lter, replace

5.16 Commissioning

lter elements, if necessary.

5.16.1 Open system

• Check if lter 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.

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.

• Adjust pressure relief valve to minimum setting.

• Check rotation of the high-pressure pump by description in 5.15.

Danfoss oers commissioning and service at system manufacturer’s location. Rate quotes are oered upon request.

• 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 ttings for leakage.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

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 specied 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.

G) Drop in ow 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 oers service of the pump at the system manufacturer’s location as well as we oer training in how to service the pump. Quotes are oered upon request.

Danfoss recommends simultaneously to check the lter condition and to evaluate contamination; lter elements must be replaced if necessary.

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.

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.

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 ltration of the water.

See the section Service and warranty in the appendix 1, Data sheet and appendix 2, Instruction.

Danfoss oers service of the pump at the system manufacturer’s location and training in how to service the pump. Quotes are oered upon request.

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 o 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.

For spare parts and service tools, please see appendix 4, Parts list.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

E) Open bleeding and drain plugs. Wait until

the pump and system are emptied for water.

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

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.

I) Carefully pull the pump out of the bell

housing by using lifting equipment, if necessar y.

J) Hold the pump in dierent positions above

a drip tray; this should allow most of the water trapped in the pump to drain. Clean and dry the pump surface and plug the bleeding and draining plugs.

K) Move the pump to a clean and safe location

where the pump can be inspected/ serviced.

7.4 Disassembling and assembling the pump unit

A) Remove all connections from the pump.

B) Disassemble the pump according to the

Disassembling and Assembling Instruction (available at www. danfoss.high-pressurepumps.com). Clean all the parts and surfaces with a uid compatible with the materials found in the pump. Wipe the parts clean and dry with a lint-free clothing.

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).

7.6 Procedure for mounting the pump back onto electric motor

Mount the exible 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.

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.

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 ll 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.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

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 uid 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 specication.

• The pump is running with a non-specied/ approved uid.

• The pump is running in the wrong direction.

• The ltration is insucient.

• There is excessive mechanical load on the shaft coupling and piping.

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, re 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.

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 ooding, which can cause slipping, tripping or falling.

If water is dripping into the electric motor; it can cause electric shock, re, 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.

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.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Operation guide

PAH pumps

PAH 2-12.5 Appendices for Operation, Installation and Maintenance Manual

hpp.danfoss.com

Operation guide | Installation, Operation and Maintenance Manual for PAH 2-12.5 pumps

Table of Contents

1. Data sheet PAH 2- 100 (521B0835) ......................................................19

2. Pump instruction PAH/PAHT/PAHT G 2-12.5 (180R9277 ..................................33

3. Electric motor manual (180R9230) ......................................................43

4. Parts list PAH 2-12.5 (521B1408) .........................................................49

5. Trouble shooting guide for PAH, PAHT, PAHT G, PAHT 674 and PAH F pumps .............59

6. Right and wrong - Trouble shooting guide for water hydraulic systems (180R9042).......73

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Data sheet

PAH pumps

PAH 2/4/6.3, PAH 10/12.5,

PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and

PAH 20/25/32 and

PAH 50/63/70/80/100

PAH 50/63/70/80/100 pumps

danfoss.high-pressurepumps.com

hpp.danfoss.com

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

Table of Contents

Contents

1. Introduction ...........................................................................20

2. Benets................................................................................21

3. Application examples ..................................................................21

4. Technical data .........................................................................22

4.1 PAH 2-12.5 .............................................................................22

5. Flow ...................................................................................23

5.1 PAH 2-6.3 typical ow curves at max pressure ..........................................23

5.2 PAH 10-12.5 typical ow curves at max pressure.........................................24

6. Motor requirements....................................................................25

7. Installation.............................................................................26

7.1 Filtration ..............................................................................26

7.2 Noise ..................................................................................26

7.3 Open-system design ...................................................................27

7.4 Closed-system design .................................................................28

8. Dimensions and connections...........................................................29

8.1 PAH 2-6.3 ..............................................................................29

8.2 PAH 10-12.5 ............................................................................30

9. Service.................................................................................31

1. Introduction

The data sheet is valid for PAH pumps both non ATEX and ATEX certied. The ATEX certied versions are indicated with Ex in the designation.

The Danfoss range of PAH high-pressure pumps is designed to supply water ow under highpressure for a varity of tap water applications.

Danfoss PAH pumps are positive displacement pumps, with axial pistons that move a xed amount of water in each cycle. Flow is proportional to the number of input shaft revolutions (rpm). Unlike centrifugal pumps, they produce the same ow at a given speed no matter what the discharge pressure.

All components are designed to provide long service life with a constantly high eciency and minimum service required.

In the following all pumps are named PAH.

20 | 180R9379 | IOM PAH 2-12.5 pumps - v06

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

Below sectional drawing is an example of a PAH pump.

1: Shaft sealing 2: Mounting ange/ housing with bearing 3: Retaining ring 4: Piston/shoe 5: Valve trust plate 6: Swash plate 7: Cylinder barrel8: 8: Spring 9: Port plate 10: Connecting ange

2. Benets • Zero risk of lubricant contamination:

- Oil lubricants are replaced with the

pumped medium, water, so there is no contamination risk from the pump.

• Low maintenance costs:

- Ecient design and all-stainless steel

construction ensure exceptionally long lifetime. When Danfoss specications 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 ecient axial piston design

provides the lowest energy consumption of any comparable pump on the market.

• Easy installation:

- The lightest and most compact design

available.

3. Application examples • Stationary and mobile hydraulic systems

• High-pressure systems

• Fire ghting

- 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 eciency.

• Certied quality:

Certicates:

ISO 9001, ISO 14001, ITF 16949

ATEX available on request ABS and DNV GL certications on request

• Flushing and cleaning processes

• Humidication systems

180R9379 | IOM PAH 2-12.5 pumps - v06 |

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

4. Technical data

4.1 PAH 2-12.5

Pump size 2 4 6.3 10 12.5

Code number 180B0024 180B0022 180B0023 180B0008 180B0007

Code number ATEX

Housing material AISI 304 AISI 304 AISI 304 AISI 304 AISI 304

Geometric displacement

Pressure

Min. outlet pressure

Max. outlet pressure

Inlet pressure, continuous

Speed

Min. speed, continuous

Max. speed rpm 1800 1800 180 0 18 00 1800

Typical ow - Flow curves available in section 5

1000 rpm at max. pressure

1500 rpm at max. pressure

1200 rpm at max. pressure

1800 rpm at max. pressure

Typical motor size

1500 rpm at max. pressure

1800 rpm at max. pressure

Torque at max. spec.

Media temperature

Ambient temperature

Sound pressure level

Weight kg 4.4 4.4 4.4 7.7 7.7

For certied pumps specications on inlet and outlet pressure is stated on the 3.1 inspection certicate and may vary from generic specications stated above.

180B6124 180B6122 180 B6123 180B6108 180B6107

cm³/rev 2 4 6.3 10 12 .5

in³/r ev 0.12 0.24 0.38 0.60 0.75

barg 30 30 30 30 30

psig 435 435 435 435 435

barg 140 140 140 160 160

psig 2030 2030 2030 2320 2320

barg 0-4 0-4 0-4 0-4 0-4

psig 0-58 0-58 0-58 0-58 0-58

rpm 700 700 700 700 700

l/min 1.0 3.2 5.6 8.4 11.0

l/min 2.0 5.2 8.7 13 .4 17.2

gpm 0.4 1.0 1.8 2.7 3.5

gpm 0.7 1.7 2.8 4.3 5.5

0.9 1.7 2.6 4.5 5.6

1.5 2.7 4.2 7. 3 9.0

Nm 5.9 10.9 16.7 29.0 35.8

lbf-ft 4.4 8.0 12 .3 21.4 26.4

°C 2-50 2-50 2-50 2-50 2-50

°F 36 -122 36 -122 36-122 3 6-122 36 -122

°C 0-50 0-50 0-50 0-50 0-50

°F 32-122 32-122 32-122 32-122 32-122

dB(A) 76 76 76 75 75

lbs 9.7 9.7 9.7 17. 0 17.0

Measurements according to EN ISO 3744: 2010 / dB(A) [L

Measured at max pressure and rpm for a motor pump unit.

Category 2, Zone 1 or Category 3, Zone 2.

22 | 180R9379 | IOM PAH 2-12.5 pumps - v06

] values are calculated.

PA, 1m

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

l/min

1100

1300

1500

1700

1800

0 rpm

PAH 2.0

PAH 4.0

PAH 6.3

l/min

700

900

1100

1300

1500

1700

1800

gpm

5. Flow

The ow (Q e) at various pressure (p calculated with the following equation:

Q e = Q

(th)

– [(Q

– Q (p

(th)

)) x (p / p

max

) can be

max

)]

max

The theoretical ow can be calculated with the following equation:

V x n Q

(th)

1000

At zero pressure the true ow equals the theoretical ow Q

: Theoretical ow (l/min / gpm)

(th)

Q (p

): Flows at max. pressure (l/min and

max

gpm), see 4.1-4.4

: Max pressure (barg / psig)

max

p: Pressure (barg / psig)

(th)

V: Displacement (cm3 / rev.) n: Motor speed (rpm)

5.1 PAH 2-6.3 typical ow curves at max pressure

PAH 6.3

PAH 4.0

PAH 2.0

0 rpm

700

2.5

1.5

0.5

0 rpm

700

900

PAH 6.3

PAH 4.0

PAH 2.0

900

180R9379 | IOM PAH 2-12.5 pumps - v06 |

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

l/min

1100

1300

1500

1700

1800

PAH 12.5

l/min

gpm

1100

900

1300

1500

1700

1800

700

rpm

PAH 12.5

PAH 10

PAH 12.5

5.2 PAH 10-12.5 typical ow curves at max pressure

700

900

PAH 10

rpm

PAH 10

24 | 180R9379 | IOM PAH 2-12.5 pumps - v06

700

900

rpm

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

6. Motor requirements

The required motor power can be calculated by using the following equation:

n x V x p P =

600.000 x η

P: Power (kW) M: Torque (Nm) η: Mechanical eciency p: Pressure (barg) n: Motor speed (rpm) V: Displacement (cm3/rev.)

From the ow curves in item 5, you can determine the rpm of the pump at the desired ow.

The required torque is calculated as follows:

V x p M =

62.8 x η

To determine the correct motor size, both the power and torque requirement must be veried.

The mechanical eciency of the pump, at max pressure, is as follows:

PAH 2, 4, 6.3 0.82 PAH 10, 12.5 0.9

180R9379 | IOM PAH 2-12.5 pumps - v06 |

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

7. Installation See the gure below for instructions on how to mount the pump and connect it to an electric motor or combustion engine.

A: Flexible coupling B: Bell housing C: Motor shaft

If alternative mounting is required, please contact your Danfoss sales representative for further information.

Note: Do not add any axial or radial loads to the pump shaft.

7.1 Filtration

Proper ltration 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 ltration specications are met, and by always changing lter cartridges according to schedule.

Since water has very low viscosity, Danfoss PAH pumps have been designed with very narrow clearances in order to control internal leakage rates and improve component performance. To

minimize wear in the pump, it is therefore essential to lter inlet water properly.

The main lter must have a ltration eciency of 99.98% at 10 μm. We strongly recommend that you always use precision depth lter cartridges rated 10 μm abs. β10 ≥ 5,000.

Please note that we do not recommend bag lters or string-wound lter cartridges, which

typically have only 50% ltration eciency. This means that out of 100,000 particles that enter such lters, 50,000 particles pass right through them; compare this to precision depth lters that are 99.98% ecient, and only allow 20 of the same 100,000 particles to pass through.

For more information on the importance of proper ltration, including explanation of ltration principles, denitions, and guidance on how to select the right lter for your pump, please consult our Filtration information and specications (Danfoss document number 521B1009).

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 exible hoses rather than metal pipes where possible.

The noise level is inuenced by:

• Pump speed: High rpm makes more uid/structureborne pulsations/vibrations than low rpm.

• Discharge pressure: High pressures make more noise than low pressures.

• Pump mounting: Rigid mounting makes more noise than exible 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 exible 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.

26 | 180R9379 | IOM PAH 2-12.5 pumps - v06

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

7.3 Open-system design

A Inlet line:

Dimension the inlet line to obtain minimum pressure loss (large ow, minimum pipe length, minimum number of bends/ connections, ttings with small pressure losses and restrictions).

B Inlet lter:

Install the inlet lter (1) in front of the PAH pump (2). Please consult the Danfoss lter data sheet for guidance on how to select the right lter.

C Monitoring pressure switch:

Install the monitoring pressure switch (3) between the lter and the pump inlet. Set the minimum inlet pressure according to specications 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 lter 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 Hoses:

Always use exible hoses (5) 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 specications 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 PAH pump begins to create pressure and ow 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 5 6

SYSTEM

180R9379 | IOM PAH 2-12.5 pumps - v06 |

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

7.4 Closed-system design

A Inlet line:

Dimension the inlet line to obtain minimum pressure loss (large ow, minimum pipe length, minimum number of bends/ connections, ttings with small pressure losses and restrictions).

B Inlet lter:

Install the lter (1) in front of the tank (2). Please consult the Danfoss lter data sheet for guidance on how to select the right lter.

C Monitoring pressure switch:

Install the monitoring pressure switch (3) in front of the lter (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 lter 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 exible 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 specications 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 PAH pump begins to create pressure and ow immediately after start-up regardless of any counter pressure, a pressure relief valve (8) should be installed to prevent system damage.

I System water lling:

To ensure proper ltration of new water (10) supplied to the system, always use the lling 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.

28 | 180R9379 | IOM PAH 2-12.5 pumps - v06

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

8. Dimensions and connections

8.1 PAH 2-6.3

180R9379 | IOM PAH 2-12.5 pumps - v06 |

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

8.2 PAH 10-12.5

30 | 180R9379 | IOM PAH 2-12.5 pumps - v06

Data sheet PAH 2/4/6.3, PAH 10/12.5, PAH 20/25/32 and PAH 50/63/70/80/100 pumps

9. Service Danfoss PAH 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 specications, Danfoss PAH pumps typically run 8,000 hours between service. However, the service schedule for your Danfoss PAH 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 ltration is the number one cause of pump damage.

Other factors that aect pump performance and lifetime include:

• running the pump at speeds outside specications

• supplying the pump with water at temperatures higher than recommended

• running the pump at inlet pressures outside specications

• running the pump at outlet pressures outside the specications.

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 eciently and to prevent breakdown. If worn parts are not replaced, then our guidelines recommend more frequent inspection.

180R9379 | IOM PAH 2-12.5 pumps - v06 |

Danfoss A/S

Nordborgvej 81 High Pressure Pumps DK-6430 Nordborg Denmark

Danfoss ca n accept no respons ibility for pos sible errors in ca talogues, bro chures and other pr inted material. Da nfoss reserves t he right to alter its p roducts with out notice. This also a pplies to produc ts already on ord er provided that su ch alterations ca n be made without su bsequential cha nges being nece ssary in speci cations alread y agreed. All trade marks in this mate rial are proper ty of the respec tive companies . Danfoss and the Dan foss logotyp e are trademark s of Danfoss A/S. Al l rights reserv ed.

AI073186502976en- 001501 | 32

Instruction

PAH, PAHT pumps

PAH / PAHT 2-12.5

Instruction

PAH / PAHT / PAHT G 2-6.3 pumps/ PAH / PAHT / PAHT G 10-12.5 pumps

danfoss.high-pressurepumps.com

hpp.danfoss.com

Instruction Pump instruction PAH / PAHT 2-12.5

Table of Contents

Contents

1. Identication ..........................................................................34

2. System design .........................................................................35

2.1 Closed-system design .................................................................35

2.2 Open-system design ...................................................................36

2.3 General guidelines for calculation of pressure losses ....................................37

2.4 General comments on..................................................................37

3. Building up the pump unit .............................................................38

3.1 Mounting..............................................................................38

3.2 Direction of rotation ...................................................................38

3.3 Orientation ............................................................................38

3.4 Protection from too high pressures .....................................................39

3.5 Connections ...........................................................................39

4. Initial start-up..........................................................................40

5. Operation..............................................................................40

5.1 Water quality ..........................................................................40

5.2 Temperature...........................................................................40

5.3 Pressure ...............................................................................40

5.4 Dry running............................................................................40

5.5 Disconnection .........................................................................40

5.6 Storage ................................................................................40

5.6.1 Water hydraulic systems, water recirculated.............................................40

5.6.2 Open-ended systems with water supply from tank. .....................................41

5.6.3 Open-ended systems with direct water supply. .........................................41

1. Identication

6. Service.................................................................................41

7. Recommended service intervals........................................................41

7.1 General information....................................................................41

7.2 Inspection of pump parts ..............................................................41

7.3 How to inspect the pump ..............................................................41

34 |

180R9379 | IOM PAH 2-12.5 pumps - v06

Instruction Pump instruction PAH / PAHT 2-12.5

System

5 5

2. System design

2.1 Closed-system design

A Inlet line:

Dimension the inlet line to obtain minimum pressure loss (large ow, minimum pipe length, minimum number of bends/ connections, and ttings with small pressure losses).

B Inlet lter:

Install the inlet lter (1) in front of the tank (2). Please consult the Danfoss lter data sheet for guidance on how to select the right lter.

C Monitoring pressure switch:

D Monitoring temperature switch:

E Hoses:

Always use exible 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 specications 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 pump begins to create pressure and ow immediately after start-up regardless of any counter pressure, a pressure relief valve (8) should be installed to prevent system damage.

I System water lling:

To ensure proper ltration of new water (10) supplied to the system, always use the lling 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.

Reservoir

6 6 7

System

180R9379 | IOM PAH 2-12.5 pumps - v06 |

Instruction Pump instruction PAH / PAHT 2-12.5

2.2 Open-system design

A Inlet line:

Dimension the inlet line to obtain minimum pressure loss (large ow, minimum pipe length, minimum number of bends/ connections, and ttings with small pressure losses).

B Inlet lter:

Install the inlet lter (1) in front of the PAHT pump (2). Please consult the Danfoss lter data sheet for guidance on how to select the right lter.

C Monitoring pressure switch:

D Monitoring temperature switch:

E Hoses:

Always use exible hoses (5) 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 specications 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 pump begins to create pressure and ow immediately after start-up regardless of any counter pressure, a pressure relief valve (7) should be installed to prevent system damage.

Note: If a non-return valve is mounted in the inlet line, a low-pressure relief valve is also required between the non-return valve (8) and the pump to protect against high-pressure peaks.

1 4 5 5 6

SYSTEM

36 |

180R9379 | IOM PAH 2-12.5 pumps - v06

Instruction Pump instruction PAH / PAHT 2-12.5

2.3 General guidelines for calculation of pressure losses

The suction conditions can be optimized according to below guidelines.

In smooth pipes and hoses

In 90° bends

2.4 General comments on

Filtration

A good ltration is vital to ensure a long and trouble free life of the pump.

When selecting a lter or strainer, please note that lter materials should be compatible with water, i.e. should neither corrode or dissolve. Also be aware of the electrochemical series of the applied materials.

• Main lter must have a neness of 10 µm abs. β10 ≥ 5,000.

• The pressure loss across the lter should be monitored.

• Please contact the Danfoss Sales Organization for further lter details.

Water tank

Must be made of corrosion-proof material such as stainless steel or plastic and must be sealed to prevent entrance of impurities from the environment.

Automatic pressure equalization between tank and surroundings must be ensured.

Inlet from the water supply (the return line) and inlet to the pump should be placed in opposite ends of the tank to calm and deaerate the water, and to ensure optimum opportunity for particles to settle.

Pump suction line should be placed above the tank bottom in order to prevent settled particles from being led into the pump.

180R9379 | IOM PAH 2-12.5 pumps - v06 |

Instruction Pump instruction PAH / PAHT 2-12.5

unit

We recommend a separation (“wall”) to separate the inlet from the outlet end of the tank.

3.1 Mounting3. Building up the pump

Monitoring

It is recommended to continuously monitor the following conditions:

• Water level in the tank

• Filter contamination

• Pressure (inlet- and outlet side of the pump)

A: Elastic coupling B: Bell housing C: Motor shaft

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 shaft must be avoided.

3.3 Orientation

The pump can be mounted/orientated in any direction.

3.2 Direction of rotation

Is indicated by means of an arrow at the label of the pump.

38 |

180R9379 | IOM PAH 2-12.5 pumps - v06

Instruction Pump instruction PAH / PAHT 2-12.5

3.4 Protection from too high pressures

The pump should be protected against too high pressure by means of a pressure relief valve or a bypass/unloading valve placed on the pressure side.

The valve should be placed as close to the pump as possible.

3.5 Connections

The opening characteristics of the valve must not result in peak pressures higher than 200 bar (2900 psi).

The valve outlet must not be connected directly to the pump suction line. It shall be connected directly to the tank.

Thread size

Max tighten torque

P: Pressure T: Tank C: Bleeding D: Parallel key 5 x 5 x 20, DIN 6885

PAH / PAHT 2-6.3 PAH / PAHT 10-12.5

P T C P T C

G 1⁄4 x 11 G 1⁄ 2 x 15

25 Nm 25 Nm 5 Nm 25 Nm 25 Nm 15 Nm

M6; Allen key 4 mm

G 3⁄8 x 15 G 3⁄4 X 17

G 1⁄4, NV6 14 deep

Recommended torque values refer to steel washers containing a rubber sealing element.

180R9379 | IOM PAH 2-12.5 pumps - v06 |

Instruction Pump instruction PAH / PAHT 2-12.5

4. Initial start-up Before start-up, loosen the top bleeding plug “C”. When water appears from the bleeding plug, retighten the plug. With its inlet line connected to the water supply or the tank, the pump is now started with open outlet port.

At the initial start of the system, the pump should be run without pressure for about 5 minutes, thus removing possible impurities from pipes, hoses, etc. However, the system should be ushed before start-up.

Warning: Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump. Otherwise the pump will be damaged if a check valve is placed between pump and tank.

5. Operation

5.1 Water quality

Water of drinking water quality, conrming to the EEC directive 98/83/EC and without abrasive sediments. Please contact Danfoss sales organization in case of doubt.

5.2 Temperature

Fluid temperature

Ambient temperature

Storage temperature

In case of lower operating tempera tures, please contact the Danfoss Sales Organization.

5.3 Pressure

The inlet pressure must be between min. 0 barg/ 0 psig and max. 4 barg/60 psig. The use of pump outside this range damage the pump.

Max. pressure on the pump’s outlet line should be limited at 140 barg (2030 psig) continuously.

NB: The pump unit should include a pressure gauge on the high pressure side.

5.4 Dry running

When running, the pump must always be connected to the water supply in order to avoid damage if it should run dry.

In systems with water tank it is recommended to build in a level gauge in the tank to avoid the risk of running dry.

Min. +2° C to max. +50° C

Min. 0° C to max. 50° C

Min. -40° C to max. +70° C

5.5 Disconnection

If the inlet line is disconnected from the water supply, the pump will be emptied of water through the disconnected inlet line.

When starting up again, follow the bleeding procedure described under section 4: Initial start up.

5.6 Storage

When preparing the pump for long-term storage or for temperatures below the freezing point, ush 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.

Recommended procedure

5.6.1 Water hydraulic systems, water recirculated

1. Disconnect the power pack from the system.

2. Empty the tank of water. Fill up the tank with anti-freeze medium to a level well above the suction line.

3. Start up the power pack and, for a couple of minutes, in a closed loop system let the anti-freeze medium run back to tank through the pressure relief valve or the bypass valve.

4. Empty the tank of the anti-freeze medium. Empty the pump through the lower bleeding plug.

The pump is now protected against internal corrosion and frost.

40 |

180R9379 | IOM PAH 2-12.5 pumps - v06

Instruction Pump instruction PAH / PAHT 2-12.5

5.6.2 Open-ended systems with water supply from tank.

1. Empty the tank of water and empty the pump housing through the lower bleeding plug. When the pump is empty, retighten the plug.

2. Through the upper bleeding plug, ll the pump housing with anti-freeze medium. Pour anti-freeze medium into the tank. Connect a hose to the outlet of the pump and lead the other end of the hose back to tank.

3. Quickly start and stop the pump. Make sure that the pump does not run dry.

The pump is now protected against internal corrosion and frost.

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 specications, 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.

5.6.3 Open-ended systems with direct water supply.

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 of e.g. 25 litre/ 6 gal. of anti-freeze additive. Connect a hose to the inlet port of the pump and via another hose return the ow from the outlet port port to the tank with anti-freeze additives.

4. Quickly start and stop the pump. Make sure that the pump does not run dry.

The pump is now protected against internal corrosion and frost.

Other factors that aect pump performance and lifetime include:

• running the pump at speeds outside specications

• supplying the pump with water at temperatures higher than recommended

• running the pump at inlet pressures outside specications

• running the pump at outlet pressures outside the specications.

7. Recommended service intervals

In our experience, poor ltration is the number one cause of pump damage.

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 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/ow 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 www.danfoss.high-pressurepumps.com

If there are any wear marks on the parts they need to be replaced.

180R9379 | IOM PAH 2-12.5 pumps - v06 |

Danfoss A/S

High Pressure Pumps Nordborgvej 81 DK-6430 Nordborg Denmark

180R9277 | AN103586502885en-000501 | 42

Electric Motors

Motor Manual

hoyermotors.com

Motor Manual

General

This manual concerns the following types of standard induction motors from Hoyer: HMA3, HMC3, HMA2, HMC2, HMD, HMT, MS, Y2E1, Y2E2, YDT These motors are manufactured in accordance with IEC/EN 60034-4 and IEC/EN 60072. Motors are rated for the ambient temperature range -20°C to +40°C and site altitudes ≤1000 m above sea level. Low-voltage motors are components for installation in machinery. They are CE marked according to the Low Voltage Directive 2014/35/EU.

Motors not fulﬁlling the IE3 efﬁciency level must be equipped with a variable speed drive when used in EU.

Transport and storage

Check the motor for external damage immediately upon receipt and, if found, inform the forwarding agent right away. Check all rating plate data, and compare it with the requirement of the motor. Turn the shaft by hand to check free rotation, remove transport locking if used. Transport locking must be used again for internal transport also. It is also important that transport locking is used when motors are transported mounted on equipment. All motors should be stored indoors, in dry, vibration- and dust-free conditions.

Lifting eyebolts must be tightened before use. Damaged eyebolts must not be used, check before use. Lifting eyes at motor must not be used to lift the motor when it is attached to other equipment.

Before commissioning, measure the insulation impedance. If values are ≤ 10MΩ at 25°C, the winding must be oven dried. The insulation resistance reference is halved for each 20°C rise in motor temperature. It is recommended that shafts are rotated periodically by hand to prevent grease migration.

etc.) using suitable tools, never hit the drive components with a hammer as this will cause damage to the bearing. The motor are balancing with half key, ensure that the drive components are also the same. Correct alignment is essential to avoid bearing, vibration and shaft failure. Use appropriate methods for alignment. Re-check the alignment after the ﬁnal tightening of the bolts or studs. Check that drain holes and plugs face downwards. We recommend opening the drain hole for motors placed outdoors and not running 24 hours / day, so that the motor can breathe, thus ensuring a dry motor.

Electrical connection

Work is only permitted to be carried out by qualiﬁed specialists and must to be carried out in accordance with local regulations. Before work commences, ensure that all power is switched off and cannot be switched on again. This also applies to the auxiliary power circuits, e.g. anti-condense heaters. Check that supply voltage and frequency are the same as rated data. Motors can be used with a supply deviation of ± 5% voltage and ± 2% frequency, according to IEC60034-1.

Connection diagrams for main supply and accessory as PTC or heater are located inside the terminal box.

Connections must be made in such a way as to ensure that a permanently safe electrical connection is maintained, both for the main supply and the earth connection. We recommend that crimped connections are made in accordance with IEC 60352-2.

Tightening torques for terminal board screws:

Thread M5 M6 M8 M10 M12 M16 M20 M24

T.(Nm) 2.5 3.5 7 12 18 35 55 80

Installation

The motor must be ﬁxed on a stable, clear and ﬂat foundation. It must be sufﬁciently rigid to withstand possible short circuit forces. It is important to ensure that the mounting conditions do not cause resonance with the rotational frequency and the doubled supply frequency. Only mount or remove drive components (pulley, coupling,

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Ensure that the terminal box is clean and dry. Unused glands must be closed with blind caps. Check the terminal box gasket before it is remounted.

Maintenance

Inspect the motor at regular intervals, keep it clean and ensure free ventilation air ﬂow, check the condition of shaft seals and replace if necessary. Both electrical and mechanical

Motor Manual

connections must be checked and tightened if necessary. Bearing size and type are speciﬁed on the rating plate. Motor types HMA3 and HMC3 is as standard with lifetime greased bearings in motors size ≤180 for cast iron and size ≤132 for aluminium. Motor types HMA2 and HMC2 is as standard with lifetime greased bearing in motors size ≤225. Motor types MS and Y2E is as standard with lifetime greased bearing in motors size ≤160.

Typical duty hours for lifetime lubricated bearings.

Frame size Poles Typical lifetime

56 - 160 2 - 8 40,000h

180 2 35,000h

200 2 27,000h

225 2 23,000h

180 - 225 4 - 8 40,000h

Motors with a re-greasing system must be lubricated with high quality lithium complex grease, NLGI grade 2 or 3, with a temperature range of between -40°C to +150°C. Motors are normal ﬁtted with a data plate with greasing information; if it is missing use the following re-greasing intervals.

Frame

size

160 20 4200 7000 8500 8500

180 20 4200 7000 8500 8500

200 25 3100 6500 8500 8500

225 25 3100 6500 8500 8500

250 35 2000 6000 7000 7000

280 35 2000 6000 7000 7000

315 50 1500 5500 6500 6500

355 60 1000 4000 5000 6000

400 80 800 3000 4000 6000

Grease

(g)

2 pole

(h)

4 pole

(h)

6 pole

(h)

8 pole

(h)

Grease the motor while running, open the grease outlet plug and let the motor run 1-2 hours before the outlet grease plug is closed again. Grease the motor for the ﬁrst time during commissioning.

The following applies in general for both lifetime lubricated and re-lubricated bearings: At 60Hz the time will be reduced by app. 20%. Data for vertically mounted motors are half of the above values.

The table values are based on an ambient temperature of 25°C. The values must be halved for every 15K increase in bearing temperature. Higher speed operations, e.g. frequency converter drive will require shorter greasing intervals. Typically, doubling the speed will reduce the values by 50%.

Special note for Atex Zone 22 and nA motors

Designation of motor according to IEC standard: II 3D Ex tc IIIB T120°C II 3G Ex nA IIC T3

The hazardous 3-phase asynchronous motors are in accordance with International standard IEC 60079-31 and IEC 60079-15. Only one electrical installation may be installed in one speciﬁed area (zone).

Only certiﬁcated cable glands may be used. Unused glands must be closed. Connections must be made in such a way as to ensure that a permanently safe electrical connection is maintained, both for the main supply and earth connection. Installations must be in accordance with actual standards for installation in hazardours area.

It is recommended that the IEC standard is followed according to temperature and dust on the motor surface. The use of motors with so much surface dust that the motor temperature increases is not permitted. Regularly cleaning is recommended. The radial shaft sealing ring is part of the ATEX certiﬁcation. It is important that the ring is always intact. The shaft sealing must be regularly checked, and if dry it must be lubricated. It is recommended that the seal is relubricated regularly. Always use the original seal ring when replaced. Replacing bearings also means replacing the seals.

All machines must be inspected regularly for mechanical damage. The user is responsible for changing parts in accordance with the lifetime of parts, in particular: bearings, grease and lubrication of shaft sealing.

Maintenance, repairs and replacement on this type must only be carried out by qualiﬁed specialists.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Connection diagram Anschlußdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexión Collegamento Schemat polacsen

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Hoyer Motors, Motor Manual, April 2019

Head Ofﬁces

Over Hadstenvej 42 · DK-8370 Hadsten

T +45 86 98 21 11 · F +45 86 98 17 79

hoyermotors@hoyermotors.com

19 Jingwu Middle Road · Beilun District

T +86 574 26 28 15 77 · F + 86 574 2628 1573

hoyermotors@hoyermotors.cn

Important notice.

Denmark

CVR no. 17 63 06 95

hoyermotors.com

China

Ningbo 315821 · Zhejiang

hoyermotors.cn

Text and data in this catalogue are not binding and we reserve the right to implement changes without further notice.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Branch Ofﬁces

Germany

Landsberger Straße 155 · 80687 München

T +49 89 700 88 235 · F +49 89 543 56 333

germany@hoyermotors.com

hoyermotors.com

Sweden

Liljeholmsstranden 5 · PO box 44017

SE-100 73 Stockholm

T +46 8 446 877 13

sweden@hoyermotors.com

hoyermotors.com

Vasteland 78 · 3011 BN, Rotterdam

Benelux

Tel. +31 10 420 35 20 · Fax.+31 10 420 44 51

benelux@hoyermotors.com

hoyermotors.com

Korea

302ho · Code square · 3150-1 · Daejeo 2-dong

Gangseo-gu · Busan · Korea

T +82 51 996 0251 · F +82 51 996 0252

korea@hoyermotors.com

hoyermotors.com

Parts list

PAHC 2-6.3 pumps

PAH pumps PAH 2/4/6.3/10/12.5

hpp.danfoss.com

Parts list | PAH 2/4/6.3/10 and 12.5

Table of Contents

Contents

1. General ..............................................................................51

2. Spare parts list for PAH 2 ...............................................................52

2.1 Exploded view for PAH 2 ...............................................................53

3. Spare parts list for PAH 4-6.3 ...........................................................54

3.1 Exploded view for PAH 4-6.3 ...........................................................55

4. Spare parts list for PAH 10-12.5 .........................................................56

3.1 Exploded view for PAH 10-12.5 .........................................................57

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Parts list | PAH 2/4/6.3/10 and 12.5

1. G eneral

This parts list provides an overview of the content of the various service sets as well as exploeded views for both non ATEX and ATEX certied pumps. ATEX certied pumps are indicated by Ex in the designation.

Non ATEX ATEX PAH 2 PAH 2 Ex PAH 4 PAH 4 Ex PAH 6.3 PAH 6.3 Ex PAH 10 PAH 10 Ex PAH 12.5 PAH 12.5 Ex

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Parts list | PAH 2/4/6.3/10 and 12.5

2. Spare parts list for PAH 2

Pos. Qnt. Designation Material

180B4100 - Screw & Seal set

(PAH 2- 6.3)

180B4112 - Cylinder barrel set

(PAH 2- 6.3)

180B4101 - Valve plate set

(PAH 2- 6.3)

180B4110 - Piston set

(PAH 2)

180B4102 - Piston set

- 1 Shaft bush, torpedo - X

- 1 Press bush - X

1 1 Housing AISI 304 / PEEK

2 1 Pin AISI 316 X

5 4 Screw AISI 316 X

31 1 Swash plate AISI 431 X

32 1 Screw AISI 304 X

33 1 Washer AISI 304 X

34 1 Pin AISI 316 X

61 1 Cylinder barrel AISI 431 / PEEK X

62 1 Spring AISI 304 X X

65 1 Retainer plate AISI 431 X X

66 5 Piston AISI 431 / PEEK X X

67 1 Key AISI 316Ti X

69 1 Stop PEEK X X

91 1 Port plate AISI 304 / PEEK X

92 1 Valve plate AISI 431 X

93 5 Back up ring PTFE X X

94 5 O-ring NBR X X

121 1 Port ange AISI 304 / PEEK

122 1 O-ring NBR X

123 1 O-ring NBR X

124 1 Shaft seal AISI 304 / NBR X

125 1 End cover AISI 304

126 1 Pin AISI 316 X

127 2 Screw AISI 304 X

130 1 Usit-ring AISI 304 / NBR X

136 2 O-ring NBR X

- 1 Service instruction (180R9094) - X X X X X X

FFKM sealing material

(PAH 2)

180B4301 - Swash plate set

(PAH 2)

180Z0235 - Tool set

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Parts list | PAH 2/4/6.3/10 and 12.5

2.1 Exploded view for PAH 2

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Parts list | PAH 2/4/6.3/10 and 12.5

3. Spare parts list for PAH 4-6.3

Pos. Qnt. Designation Material

180B4100 - Screw & Seal set

(PAH 2- 6.3)

180B4112 - Cylinder barrel set

(PAH 2- 6.3)

180B4101 - Valve plate set

(PAH 2- 6.3)

180B4111 - Piston set

(PAH / 4-6.3)

- 1 Shaft bush, torpedo - X

- 1 Press bush - X

1 1 Housing AISI 304 / PEEK

2 1 Pin AISI 316 X

5 4 Screw AISI 316 X

31 1 Swash plate AISI 431 X X

32 1 Screw AISI 304 X X

33 1 Washer AISI 304 X X

34 1 Pin AISI 316 X X

61 1 Cylinder barrel AISI 431 / PEEK X

62 1 Spring AISI 304 X

63 1 Spring guide PEEK X

64 1 Retainer ball AISI 431 X

65 1 Retainer plate AISI 431 X

66 5 Piston AISI 431 / PEEK X

67 1 Key AISI 316Ti X

91 1 Port plate AISI 304 / PEEK X

92 1 Valve plate AISI 431 X

93 5 Back up ring PTFE X X

94 5 O-ring NBR X X

121 1 Port ange AISI 304 / PEEK

122 1 O-ring NBR X

123 1 O-ring NBR X

124 1 Shaft seal AISI 304 / NBR X

125 1 End cover AISI 304

126 1 Pin AISI 316 X

127 2 Screw AISI 304 X

130 1 Usit-ring AISI 304 / NBR X

136 2 O-ring NBR X

- 1 Service instruction (180R9094) - X X X X X X

FFKM sealing material

180B4303 - Swash plate set

(PAH 4)

180B4304 - Swash plate set

(PAH 6.3)

180Z0235 - Tool set

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Parts list | PAH 2/4/6.3/10 and 12.5

3.1 Exploded view for PAH 4-6.3

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Parts list | PAH 2/4/6.3/10 and 12.5

4. Spare parts list for PAH 10-12 .5

Pos. Qty. Designation Material

- 1 Shaft bush, torpedo - X

- 1 Press bush - X

1 1 Housing AISI 304 / PEEK

2 1 Pin AISI 316 X

5 4 Screw AISI 304 X

31 1 Swash plate AISI 431 X X

32 1 Screw AISI 304 X X

33 1 Washer AISI 304 X X

34 1 Pin AISI 316 X X

61 1 Cylinder barrel AISI 431 / PEEK X X

62 1 Spring AISI 316Ti X X

63 1 Spring guide PEEK X X

64 1 Retainer ball PEEK X X

65 1 Retainer plate AISI 304 X X

66 5 Piston AISI 431/ PEEK X X

67 1 Key AISI 316Ti X

91 1 Port plate AISI 304 / PEEK X

92 1 Valve plate AISI 431 X

93 5 Back up ring PTFE X X

94 5 O-ring NBR X X

121 1 Port ange AISI 304 / PEEK

122 1 O-ring NBR X

123 1 O-ring NBR X

124 1 Shaft seal AISI 304 / NBR X

125 1 End cover AISI 304

126 1 Pin AISI 316

127 2 Screw AISI 304 X

130 2 O-ring NBR X

135 1 Pin AISI 316 X

136 2 O-ring NBR X

- 1 Service instruction (180R9095) - X X X X X X X X

180B4105 - Seal set

(PA H 10-12.5)

180B4107 - Cylinder barrel set

(PA HT 10 -12. 5)

180B4113 - Cylinder barrel set

(PA H 10-12.5)

180B4108 - Valve plate set

(PA H 10-12.5)

180B4106 - Piston set

(PA HT 10 -12. 5)

180B4114 - Piston set

(PA H 10-12.5)

180B4305 - Swash plate set

(PAH 10)

180B4306 - Swash plate set

(PA H 12. 5)

180Z0235 - Tool set

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Parts list | PAH 2/4/6.3/10 and 12.5

3.1 Exploded view for PAH 10-12 .5

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Danfoss A/S

High Pressure Pumps Nordborgvej 81 DK-6430 Nordborg Denmark

AX322447719905en-000401 | 58

Guide line.

Guideline

Trouble shooting guide for

PAH / PAHT / PAHT C / PAHT G pumps

Trouble shooting guide

PAH / PAHT / PAHT C / PAHT G / PAHT 674 and PAH F pumps

hpp.danfoss.com

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

Table of Contents

Validity

Table of Contents

Trouble shooting sh bone chart .......................................................61

1. No ow/no pressure....................................................................62

2. Reduced ow/reduced pressure ........................................................63

3. High torque on electric motor ..........................................................64

4. Noise from pump ......................................................................65

5. Noise from installation .................................................................66

6. Typical signs of wear ...................................................................67

6.1 Valve plate.............................................................................67

6.2 Port plate ..............................................................................68

6.3 Swash plate............................................................................68

This document is covering the pumps PAH, PAHT PAHT C, PAHT G for both non ATEX and ATEX certied. PAHT pumps are not ATEX certied.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

Trouble shooting sh bone chart

PUMP FAILED

2. Reduced ow/pressure

(hoses/pipes)

inlet/outlet line

2.3 RPM

2.2 Low inlet pressure

2.1.5 Pre-treatment

2.1.6 Main ltration

2.1.8 High uid temperature

2.1.7 Type of uid

(internal leakage)

2.1 Wear in pump

1. No ow/pressure

5.1 Inlet/outlet connections

5.2 Length/dimensions of

4.1 Air in uid

4.2 Bleeding conditions of pump

directly on frame

5.3 Hose stiness

inlet pressure

4.3 Min/max nominal

electric motor

5.4 Hoses/pipes mounted

5.5 Vibration d amper under the

4.4 Pump reversin g

4.5 High rot ation speed (RPM)

4.6 Outlet pressure

5. Noise from installation

4. Noise from pump

4.7 Soft sta rt/stop

1.6 Pump damage

1.5 Axial force o n pump shaft

1.4 No rotation of pump

1.3 No rotation of e lectric motor

1.2 Pump reversing

1.1 Dry running

from pump

3.1 Too high outlet pressure

3.2 Pump starts against pressure

3.3 Constant torque

3.4 Water pump damage

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

3. High torque on el. motor

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

1. No ow/no pressure

Cause Remedy Comments

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)

If no water comes out of the pump:

1.1.1 Check that inlet valve is open.

1.1.2 Check that booster pump is running.

1.2.1 Change the phase on the electric motor to make it run clockwise.

WARNING:

- The pump must not run without water for

more than a few seconds.

- If the pump takes in water from the high-

pressure outlet line, it builds up pressure in pump housing and will eventually break down.

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.

1.3 No rotation of electric motor 1.3.1 Check that main switch is switched on.

1.4 No rotation of pump 1.4.1 Ensure that coupling between electric

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

1.3.2 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.

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 oce 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 exible 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 oce for guidelines in how to troubleshoot internal pump parts.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

A B C

Instructions on internal elements are available on www.danfoss.high-pressurepumps.com

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

2. Reduced ow/reduced pressure

Cause Remedy Comments

2.1 Wear on pump

Large internal leakage due to:

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 t. If there is any space (clearance) between liner and piston, liner or piston is worn.

2.1.5 Pre-treatment: Analyse uid for content of particles.

- Check that lters are OK and working correctly.

2.1.6 Main ltration: Check that the correct lter type is used (particles in uid must not exceed 10 μm). Danfoss High Pressure Pumps supplies lters, please contact the sales oce.

Typical signs of wear:

Polished surface all over the swash plate. Normally, only half of the swash plate = the pressure side is polished. See index 6.3.

If the ring is missing, the piston is very worn.

The lters can be bypassed, even if they are correctly mounted. Some lters can create channelling where particles can pass through the lter in tunnels. String wounded lters are typically channelling lters. A string wound lter may have a ltration eciency of only 50%, which will cause internal wear and must always be followed by a main lter.

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 uid, please contact Danfoss High Pressure Pumps sales oce for further help.

2.1.8 High uid temperature: If uid temperature is above 50°C, stop the pump immediately.

- Check internal parts (see above).

2.2 Low inlet pressure 2.2.1 Check that booster pump supplies the right pressure/ow.

2.2.2 Check if lters require replacement.

2.3 Rotation speed (rpm) 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.

Insucient ltration means that too many or too large hard particles can pass the main lter because it is damaged, bypassed or simply too poor. Filtration eciency must be 99.98% (Beta = 5000) at 10 μm to prevent abnormal wear of the pump.

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 uid temperatures > 50° C.

If the pressure drop across the lters is too high, the booster pump does not deliver sucient ow/pressure. No pressure or low pressure results in cavitation and insucient 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.

Speeds below minimum limit (see Data sheet) result in insucient internal lubrication causing wear on the internal pump parts.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

3. High torque on electric motor

Cause Remedy Comments

3.1 Too high outlet pressure from pump 3.1.1 Check for blocked nozzles or a faulty

adjusted relief valve.

Pressure changes due to ow restrictions. This will also cause high motor torque.

3.2 Pump starts against pressure 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.

3.3 Constant torque 3.3.1 Please contact Danfoss High Pressure Pumps sales oce.

3.4 Water pump damage 3.4.1 Dismantle pump and check for wear. Too heavy damage in the pump will increase

Pumps run in parallel with cascade start, may switch o the motor relay due to too high torque caused by high outlet pressure.

If the electric motor is too small for the pump, it cannot provide sucient torque.

friction causing a high torque (see item 6, Typical signs of wear).

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

4. Noise from pump

Cause Remedy Comments

4.1 Air in uid 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 Bleeding conditions of pump 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 Min/max nominal inlet pressure 4.3.1 Ensure that inlet pressure is within the limits specied in the Data sheet.

4.3.2 Check the pump for internal damage.

4.4 Pump reversing 4.4.1 Dismantle pump and check if anything is broken or worn (See “1. No ow”, 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 High rotation speed (rpm) 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 specied range of the pump data sheet and abnormal noise remains, dismantle pump and check for damage.

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 uid 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 uid 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 insucient internal lubrication resulting in wear on internal pump parts.

Mount a low-pressure switch in front of the pump and check its set point/ function. The low-pressure switch will ensure that the pump does not start until the minimum inlet pressure has been reached.

If pump rotates in wrong direction, it will take in water from the high-pressure outlet line. Pressure will be built up inside the pump and it will eventually be damaged.

Higher rpm than specied 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.

4.6 Outlet pressure 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 Soft start/stop 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).

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

If rpm is changed, noise frequency will also change.

At too low outlet pressure, the pump will create higher pressure pulsations and thus make noise. Too low pressure also causes insucient 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.

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

5. Noise from installation

Cause Remedy Comments

5.1 Inlet/outlet connections (hoses/pipes) 5.1.1 Use exible hoses at inlet/outlet connec-

5.2 Length/dimension of inlet/outlet line 5.2.1 Increase pipe diameter and/or reduce the

5.3 Hose stiness 5.3.1 Use a more exible hose. Too sti hoses cannot dampen the small

5.4 Hoses/pipes mounted directly on frame 5.4.1 Mount the connections to the frame by a

5.5 Vibration dampener under the electric motor

tions.

5.1.2 Mount the connections to the frame by a vibration dampener mounting plate.

number of bends.

vibration dampener mounting plate.

5.5.1 Mount a vibration dampener below the motor/pump.

Non-exible connections mounted directly on the frame will cause even small pressure pulsations from pump and create vibrations in the system/plant.

Too small pipes or too many bends may create too fast ow/turbulence through the pipes and thus increase the noise level.

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.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

6. Typical signs of wear 6.1 Valve plate

Picture 1

Picture 2

Scratches

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 at and level.

A worn valve plate has scratches, and/or a polished surface. Even small scratches will give a loss of ow.

Picture 3 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 ma rks can be felt by running a  ngernail over the surface, the valve plate is worn.

The valve plate on picture 3 is highly damaged.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

6.2 Port plate

Picture 1

Scratches

Level dierences between

dull and shining PEEK

If the por t plate has scratches, level di erences or both betwee n the arrows, the port plate must be replaced.

Even small scratches or wear will cause loss of ow.

To check: See item 6.1, picture 3

6.3 Swash plate

Picture 1 If the swash plate is polished 36 0°, it is an ind ication of insucient ltratio n.

The surf ace of the swash plate must be pla ne 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 oce for further information.

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Guideline Trouble shooting guide for PAH, PAHT, PAHT C , PAHT G pumps

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Danfoss A/S

High Pressure Pump Nordborgvej 81, DK-6430 Nordborg Denmark

521B1475 | DKCFN.PI.012.R2.02 | 72

MAKING MODERN LIVING POSSIBLE

Service guide.

Right and wrong

Trouble shooting guide for water

Trouble shooting guide for water hydraulic systems

hydraulic systems

danfoss.high-pressurepumps.com

hpp.danfoss.com

Design

Pump location

. .

Choice of material

Rubber

Plastic

. Stainless steel

Always use system components made of corrosion proof materials

Non-corrosion proof materials may cause damage

Choice of lter

Iron

Copper

. Brass . Aluminium

Pump always to be placed below water surface level

System to be dimensioned to provide a suction pressure of the pump inlet of max. 0.1 bar vacuum

Suction conditions

Pressure Relief valve

Pump location above water surface level will cause damage

Poor suction conditions will cause malfunction and damage the pump

< 10 mm abs.

Install a 10 micron absolute lter with pressure switch

Locate the return lter in the return line immediately before the tank

Filter location

> 10 mm

Return lter with bypass valve and poorer lterability than 10 m will

damage the system

Placing the return lter upstream of the nal load may damage the pump

Pressure relief valve to be mounted vertically or with vertical outlet and connected to return hose or tank

System to be lled via lter

Coupling the pressure relief valve outlet directly to the pump inlet may damage the pump

Water supply

Filling system with unltered water causes damage

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Installation

Prior to installation, burrs and chips and other impurities must be removed from pipes and hoses, eg with a felt plug

Impurities

Chips or other impurities in the system may cause damage

Sealing

11.

The coupling must be easy and simple to assemble (see product instruction)

Assembly of coupling

12.

= min. 3 mm

Never use force when assembling the coupling parts, as this will damage the motor/pump

Coupling

0 mm

Fittings in screwed components to be sealed with O-rings or bonded seals

10.

Correctly limited quantities of grease prevent seizing

Using teon tape or packing yarn in joints may cause damage

Grease

Too much grease may develop biolm causing operational failures

Ensure always to have 3 mm distance between coupling anges

13.

Fill system with water before starting to ensure lubrication and cooling

Insucient distance and/or misalignment between the coupling anges will damage the pump

Water supply

Starting without water will cause damage

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Wiring

Starting procedure

Cleaning procedure

14.

Level and temperature indicators must be tted. Follow installation instructions

15.

Level indicator

Missing or incorrectly connected level and temperature indicators cause damage

Rotation direction

1. Fill cold water into the system via the return lter 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 eective ushing with the cleaning agent

5. Empty the system of the cleaning agent solution

Flushing procedure

6. Fill cold water through the return lter 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

Check pump drive motor rotation direction matches that of the pump prior to installation

16.

Bleeding the pump will ensure correct cooling and lubrication

Incorrect rotation direction will damage the pump

Bleeding

Insucient bleeding may cause damage (not applicable to Power Packs)

9. Alternatively the system may be ushed by running the unit without the return hose while continuously lling up water. The ushing should continue until there is no trace of cleaning agent in the return water

10. Change the return lter element, ll cold water through the return lter and bleed the pump during start up

11. The system is now ready for operation

Starting procedure

60 min.

Observing the starting procedure will ensure problem-free operation

If the system is not cleaned before starting, the lter will clog

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

days

2-3

Trouble shooting

Open ended water systems

No water supply

Is the water supply ok?

Is water supplied to the pump?

Yes

Is water coming

out of the tap?

Are all taps open?

Is the control light

for “low pump suction

Yes

pressure” on?

The lter is clogging

Is water coming

through the lter?

Replace lter element

Yes

Is the electric motor of

the pump unit rotating?

Yes

Is the water in the tank

very hot? Ie above 50

Is the power supply ok?

Are control lights on?

Is the lter clogged?

Is the lter control

light on?

Replace lter element

Yes

Lower inlet

temperature or provide better cooling

A blown fuse / or short

circuit?

. Check power supply

and fuses and contact electrician

Turn on the tap for

water supply

Contact serviceman

Stamp

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

Trouble shooting

Closed water systems

Is there sucient water

in the tank?

Yes

The system

does not work

Fill water into the system

Is the electric motor of

the pump unit rotating?

Yes

A blown fuse/or short

circuit?

. Check power supply

and fuses and contact electrician

Is the water in the tank

very hot? Ie above 50

Is the power supply ok?

Are control lights on?

Yes

Is the lter clogged?

Is the lter control

light on?

Contact serviceman

Yes

At temperatures

higher than 50o the pump drive cuts out. Consequently the cooler must be checked/cleaned

Yes

Replace lter element

Trace leakage, if any

Stamp

180R9379 | IOM PAH 2-12.5 pumps - v06 | 11.2020

180R9379 | IOM PAH 2-12.5 pumps - v06 | 80

Danfoss PAH 2, PAH 4, PAH 6.3, PAH 10, PAH 12.5 Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual