Danfoss PAHT 2, PAHT 3.2, PAHT 4, PAHT 6.3, PAHT 10 Operating guide
...
Operation guide
User manual
Installation, Operation and
PAHT pumps
PAHT 2/3.2/4/6.3/10 and 12.5
Maintenance Manual for
Operation, Installation and
Maintenance Manual
PAHT / PAHT G 20-90 pumps
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Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
Table of Contents Contents
Table of Contents .......................................................................2
Validity .................................................................................4
1. Introduction ............................................................................6
1.1 General.................................................................................6
1.2 Symbols ................................................................................6
1.3 Manufacturer and customer service address:.............................................7
1.4 Country specific information ............................................................7
1.4.1 United Kingdom ........................................................................7
2. Safety ..................................................................................7
2.1 General information.....................................................................7
2.2 Preferred system design.................................................................7
2.3 Commissioning and servicing the unit ...................................................8
2.4 Adhere to the following important points ...............................................8
2.5 In case of doubt .........................................................................8
3. Technical data ..........................................................................8
3.1 Approved applications and operational limits for the pumps .............................8
3.2 Application range .......................................................................8
3.3 Electric motor data......................................................................8
3.4 Noise and vibration .....................................................................8
3.5 Dimension drawings ....................................................................8
3.6 Space requirement......................................................................8
3.7 Filtration................................................................................9
3.8 Properties of water ......................................................................9
3.9 Air bubbles .............................................................................9
3.10 Chemicals...............................................................................9
4. Arrival inspection, transportation, handling, lifting and storage ..........................9
4.1 Arrival inspection .......................................................................9
4.2 Warning ................................................................................9
4.3 General safety information ..............................................................9
4.4 Transport and handling .................................................................9
4.5 Return to supplier ......................................................................10
4.6 Storage ................................................................................10
5. Installation and commissioning.........................................................11
5.1 Important dimensions .................................................................11
5.2 Cleanliness.............................................................................11
5.3 Fluid temperature......................................................................11
5.4 Electrical data..........................................................................11
5.5 Local regulations.......................................................................11
5.6 Pre mounting checklist, based on Danfoss preferred system designs ....................12
5.7 Lifting and positioning .................................................................12
5.8 Mount the different equipment ........................................................12
5.9 Electrics ...............................................................................12
5.10 Instrumentation .......................................................................12
5.11 Connections ...........................................................................12
5.12 Ensure free flow .......................................................................13
5.13 Verify setting of safety/relief valves .....................................................13
5.14 Bleed and remove air from the pump ...................................................13
5.15 Verify direction of rotation .............................................................13
5.16 Commissioning ........................................................................13
5.16.1 Op en system...........................................................................13
5.16.2 Closed system (not applicable for PAHT G 256-308) .................................13
5.17 Check the filter condition...............................................................13
5.18 Instruct operator and maintenance personnel ..........................................13
6. Operation of motor pump unit ........................................................14
6.1 General safety information.............................................................14
6.2
What to listen and look for .............................................................14
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Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
7. Maintenance and service of the pump unit .............................................14
7.1 General safety information .............................................................14
7.2 Service and inspection interval for the pump ...........................................14
7.3 Shut down of the system ...............................................................14
7.4 Disassembling and assembling the pump unit ..........................................15
7.5 Assembling the pump unit .............................................................15
7.6 Procedure for mounting the pump back onto electric motor ............................15
7.7 Getting the pump unit back into operation .............................................15
7.8 Storage of the pump ...................................................................15
8. Troubleshooting and scrapping criteria ................................................16
8.1 General safety information .............................................................16
8.2 Operational conditions which can cause pump failures..................................16
8.3 Mechanical failure......................................................................16
8.4 Electrical failure ........................................................................16
8.5 Responsibility..........................................................................16
8.6 Scrapping criteria ......................................................................16
Appendices
Table of Contents .................................................................................18
1. Data sheet PAHT 2-308 pumps (AI106586503085en-000901) . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2. Pump instruction PAHT 2-12.5 (180R9277)...............................................33
3. Electric motor manual (180R9230) ......................................................43
4. Parts list PAHT (AX322445815902en-000201) ............................................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).......71
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Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
This manual is valid for PAHT pumps with the following code numbers/serial numbers:Validity
PAHT 2.0 Code no. 180B 0031
Serial no. XXXXXX08-XXX
PAHT 3.2 Code no. 180 B0077
Serial no. XXXXXX03-XXX
PAHT 4.0 Code no. 180B0030
Serial no. XXXXXX08-XXX
PAHT 6.3 Code no. 180B 0029
Serial no. XXXXXX08-XXX
PAHT 10 Code no. 180 B0032
Serial no. XXXXXX07-XXX
PAH T 12. 5 Code no. 180 B0033
Serial no. XXXXXX07-XXX
The serial number is referring to the Serial no. on
Serial
T
the product label. The digits shown (07) indicate
the version number of the pump.
This documentation is compatible with previous
pump versions.
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Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
1. Introduction
1.1 General
The PAHT pumps and pump units are manufactured by Danfoss A/S, and are sold and marketed
by a net of authorized distributors world wide.
This manual contains the necessary instructions
for the installation, operation and service of the
pumps used for technical water.
In case the pump delivered is ATEX certified, the
additional ATEX instruction must also be read.
The PAHT pumps must not be used for other
purposes than those recommended and
specified without first 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 officer or
Danger HOT.
the chief operator to assure compliance with all
local regulations that are not taken into
account in this manual.
Electrical
hazard
Electrical hazard
Changing the pumps’ or pump units’ operational limits and hardware:
• Changes to the delivered pump or motor
pump system may only be done with a
written approval from Danfoss High Pressure
Pumps.
• Operation outside the Danfoss specifications
requires a written approval from Danfoss
High Pressure Pumps.
• If any changes are made without written
approval the warranty will automatically
become void.
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Do not touch
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Operation guide | Installation, Operation and Maintenance Manual for PAHT 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 specific information
1.4.1 United Kingdom
UK importer:
Danfoss Ltd.
22 Wycombe End
HP9 1NB Beaconsfield
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 certified, 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 verified and free flow from safety
valves must be ensured.
All pipe and hose connections must be stressfree mounted, securely fastened to the pump
and well supported. Improper installation will or
could result in personal injury and/or damage to
the pump.
Use of this manual does not relieve operation
and maintenance personnel of the responsibility of applying good judgment when operating
and maintaining the pump and its components.
2.2 Preferred system design
Danfoss recommends to build systems with a
high degree of safety. Danfoss preferred system
design and P&ID are found in appendix 1, Data
sheet, and appendix 2, Instruction.
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Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
• Do not try to lift the pump unit manually;
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.
most of the pumps weigh more than
20 kilos, see specific weight for the pump
in the appendix 1, Data sheet.
• Always bleed the pump prior to initial
start-up.
• Do not mount the pump without the bell
housing and a flexible coupling.
• Do not try to start the unit before the
system components are mounted, bleeded
and adjusted.
• Flush the system throughly before
connecting the pump or pump unit.
• Check rotation direction of the motor
before mounting the pump.
3. Technical data
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.
3.1 Approved applications and operational
limits for the pumps
The pump and the pump units are designed for
the use in systems with technical water.
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.
3.3 Electric motor data
See recommended motor in appendix 1, Data
sheet or appendix 3, IOM for motors. The motors
mentioned are the most common used motors
by Danfoss High Pressure Pumps.
3.4 Noise and vibration
Noise level for a pump unit with a ”standard”
motor measured according to EN ISO 3744:2010,
see appendix 1, Data sheet. Possibilities to
reduce noise and vibration are described in the
same Data sheet.
3.5 Dimension drawings
Dimensions of the different pumps can be found
in appendix 1, Data sheet.
The PAHT G pumps must not be used for other
purposes than those recommended and
specified without first 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.
For system integration of the pumps, please
see appendix 1, Data sheet and appendix 2,
Instruction.
180R9287 |AQ073186503097en-001001 | IOM PAHT 2-12.5 pumps | 01.2022
3.6 Space requirement
When doing service or replacing the complete
pump unit, it is recommended to have sufficient
space available around the pump in order to
ensure easy access. Sufficient space means at
least 1 meter/40 inches around the pump. When
working with high pressures, it is important to
have the right space available around the pump
as stated in the safety requirements.
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Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
4. Arrival inspection,
transportation,
handling, lifting and
storage
3.7 Filtration
(10µm absolute [β
Requirements are specified in appendix 1, Data
≥ 5000])
10
sheet and appendix 2, Instruction.
Danfoss recommends not to build a filter bypass
function or use filters with an integrated bypass.
If the above recommendation is not followed the
warranty for the pump will automatically
become void.
It should be possible to monitor the condition of
the filter via the differential/delta pressure across
the filter.
Using insufficient filtration or a filter bypass
can cause a failure or decreased service life of
the pump.
3.8 Properties of water
It is recommended NOT to use the pump for
other media than specified in the Data sheet.
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 flow. Air bubbles can cause cavitation.
3.10 Chemicals
The pumps should not be exposed to any
chemicals that can result in damage to piping,
equipment and internal parts of the pump.
e.g. an overhead crane or industrial truck to be
used as minimum.
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;
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Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
Pumps which have a weight above 20 kilos (see
appendix 1, Data sheet) must be handled by
using lifting eyes and slings.
Wrong lifting:
When the pump is mounted together with an
electric motor, the pump unit always weigh more
than 20 kilos and must be handled by using
slings around the pump unit.
See below examples of where to/not to attach
the lifting slings on the pump unit:
Correct lifting with 2 separate slings:
When lifting the pump unit, one sling must be
attached to the electric motor and one sling
around the pump.
Only some motors and pumps have specific
lifting eyes.
Do not use connections/nozzles for lifting!
Do not use only one sling!
Make sure that the unit/load is balanced before
lifting. The centre of the mass varies from pump/
pump unit size to pump/pump unit.
How to mount the pump and the electric motor
correctly, see appendix 1, Data sheet or appendix
2, Instruction.
Incorrect lifting can result in personal injury
and/or damage to the pump unit, see appendix
2, Instruction.
4.5 Return to supplier
Please see maintenance chapter 7.
4.6 Storage
Each pump is tested before shipment, and will
therefore contain water. For storage temperature
and frost protection see appendix 2, Instruction.
The pumps are NOT delivered frost protected
from the factory.
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Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
PI
System
PI
M
5. Installation and
commissioning
5.1 Important dimensions
Physical dimensions and connections of the
pump unit are described in appendix 1, Data
sheet.
5.3 Fluid temperature
Before start-up, the fluid and pump housing
temperature must be within the specified
temperature range listed in appendix 1, Data
sheet.
5.2 Cleanliness
It is very important that the tubes and pipes are
completely clean: no dirt, chips or burrs are
allowed.
Flush all piping before connecting the 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
PI
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.
M
2
PI
SYSTEM
8
73
Closed system design (not applicable for PAHT/PAHT G 256-308)
Reservoir
M
PI
2
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PI
System
1
Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
5.6 Pre mounting checklist, based on Danfoss preferred system designs
Table 1: Check points when assembling and commissioning system
Check points Comment OK ?
CP1 Ensure that the environmental conditions are safe. See Arrival inspection,
CP2 Minimum and maximum start-up temperature for fluid 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 fluid 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 Bar
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 different equipment
(connections, pipes, tubes, check and safety/relief
valves, etc.)
• The hard piping and flexible hoses used must
be of proper design and must be installed in
accordance with the manufacturer’s recommendations.
• Misalignment of the hard pipes may give
unintended stress on the pump port
connection and may damage the pump.
• Prevent excessive external pipe load.
• Do not connect piping by applying external
force (use of wrenches, crane, etc.) Piping
must be aligned without residual stress.
• Do not mount expansion joints so that their
force applies internal pressure on the pump
connections.
5.9 Electrics
All electrical installation work must be carried
out by authorized personnel in accordance with
EN60204-1 and/or local regulations. (see also
Safety, chapter 2)
Turn off the safety circuit breaker and lock it.
Mount the power cable on the electric motor.
If a VFD is used, adjust the protective motor
switch/VFD to the current limits found on name
plate of the electric motor.
5.10 Instrumentation
The pressure switch/sensor should be mounted
as close to the pump as possible. It is recommended to test the pressure/sensor switch via an
instrumentation manifold.
Mount the pressure switch/sensors according to
the manufacturer’s instructions.
5.11 Connections
Mount and tighten connections and check
valve(s) as specified.
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Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
5.12 Ensure free flow
Ensure free flow from relief valve (table 1, item
5.6, CP 8). A blocked relief valve can cause
excessive build-up of pressure and thereby cause
dangerous situations and damage to the whole
system.
5.13 Verify setting of safety/relief valves
Make sure, the relief valve is placed correctly (see
open system design, item 1).
Check the pressure settings on the name plate
of the relief valve. If they are within specifications, you can continue.
5.14 Bleed and remove air from the pump
Open bleeding plugs. Keep the plugs open until
the high-pressure pump is bleeded.
If the pump is submerged, remove all bleeding
plugs before mounting in reservoir.
5.15 Verify direction of rotation
The direction of rotation must always follow the
arrow. The arrow is placed on the pump or pump
unit.
Check the direction of rotation before mounting
the pump.
Unlock the safety circuit breaker. Start the motor
for 1 second and observe the direction of
rotation either looking on the fan of the motor or
on the coupling through the hole in the bell
housing (not available on all bell housings). If the
motor is turning the wrong direction, switch two
phases in the connection box of the motor or
reprogram the direction in VFD.
• Check the temperature switch/controls. The
high-pressure pump must stop if temperature is above specified set point.
• Check the pressure switch/controls. The
high-pressure pump must stop if pressure is
below specified set point.
• If the system is running within the system
design limits, the system is released for
operation.
5.16.2 Closed system
• Check if the reservoir is clean.
• Check if filter element is present and
mounted correctly.
• Fill water at the reservoir using the filling
valve. Inspect immediately for leakage.
• Bleed high-pressure pump until only water
leaves the high-pressure pump. Remember
to close all bleeding and draining plugs.
• Adjust pressure relief valve to minimum
setting.
• Check rotation of the high-pressure pump
by description in 5.15.
• Start high-pressure pump for 2 minutes, to
make sure all air is out of the system.
• Check reservoir low level switch/controls.
The high-pressure pump must stop if low
level switch is activated.
• Adjust pressure relief valve to working
pressure.
• Check the temperature switch/controls.
The high-pressure pump must stop if
temperature is above specified set point.
• Check the filter pressure switch/controls. A
warning must be given if pressure is above
specified set point.
• If the system is running within the system
design limits, the system is released for
operation.
When the motor is turning in the right direction,
the pump can be mounted.
5.16 Commissioning
5.16.1 Open system
• Check if filter element is present and
mounted correctly.
• Switch on the circuit breaker for both
motor(s) and VFD(s).
• Check rotation of the feed pump.
• Start feed pump.
• Bleed high-pressure pump until only water
leaves the high-pressure pump. Remember
to close all bleeding and draining plugs.
• Adjust pressure relief valve to minimum
setting.
• Check rotation of the high-pressure pump
by description in 5.15.
• Start high-pressure pump for 2 minutes, to
make sure all air is out of the system.
• Adjust pressure relief valve to working
pressure.
• Check all fittings for leakage.
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5.17 Check the filter condition
Evaluate contamination found in filter, replace
filter elements, if necessary.
5.18 Instruct operator and maintenance
personnel
Before using the pump/pump unit, the personnel
must be instructed in using the pump/pump
unit, its function, components, documentation
and safety.
Danfoss offers commissioning and service at
system manufacturer’s location. Rate quotes are
offered upon request.
Operation guide | Installation, Operation and Maintenance Manual for PAHT 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 specified torque(s).
B) Leakage – if a small leakage from the bell
housing is observed. Contact the maintenance department.
C) Leakage – if there is a large leak, the unit
should be stopped immediately. Contact
the maintenance department.
D) High frequency tones – safety/relief valves
are either damaged or running very close
to their design pressure, stop the unit
immediately. Contact the maintenance
department.
E) Increased noise or vibration – requires the
unit to be stopped immediately. Contact
the maintenance department.
G) Drop in flow and/or pressure – may indicate
wear on one or more parts inside the
pump. The pump must be stopped
immediately and inspected before it is
restarted. Contact the maintenance
department.
H) Other observations or troubles, please see
appendix 7, Right and Wrong or appendix
6, Trouble shooting guide. Both appendices
give good advises on design, installation,
wiring and troubleshooting.
If the pump is not stopped for inspection as
recommended, it can lead to damage of the
pump or break-down. See also service and
warranty section in appendix 1, Data sheet and
appendix 2, Instruction.
Danfoss offers service of the pump at the system
manufacturer’s location as well as we offer
training in how to service the pump. Quotes are
offered upon request.
Danfoss recommends simultaneously to check
the filter and membrane condition and to
evaluate contamination; filter and membrane
elements must be replaced if necessary.
7. Maintenance and
service of the pump
unit
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.
7.1 General safety information
Before servicing the pump unit, it is necessary to
read and understand this user manual, especially
the Safety, chapter 2. Remember to wear suitable
safety equipment according to Safety, chapter 2.
7.2 Service and inspection interval for the
pump
Maintenance and service intervals are depending
on the cleanliness level of the water, hydraulic
load and temperature of the pump unit. The
most important parameter is the filtration of the
water.
See the section Service and warranty in the
appendix 1, Data sheet and appendix 2, Instruction.
Danfoss offers service of the pump at the system
manufacturer’s location and training in how to
service the pump. Quotes are offered upon
request.
7.3 Shut down of the system
A) Stop the high-pressure pump.
B) Release the pressure.
C) Stop the feed pump if used.
D) Switch off the safety circuit breaker for
both the high-pressure pump, feed pump
and VFD and lock them. Only personnel
servicing the pump unit should be able to
unlock/activate the switch again.
For spare parts and service tools, please see
appendix 4, Parts list.
180R9287 |AQ073186503097en-001001 | IOM PAHT 2-12.5 pumps | 01.2022
E) Open bleeding and drain plugs. Wait until
the pump and system are emptied for
water.
13
Operation guide | Installation, Operation and Maintenance Manual for PAHT 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
necessary.
J) Hold the pump in different positions above
a drip tray; this should allow most of the
water trapped in the pump to drain. Clean
and dry the pump surface and plug the
bleeding and draining plugs.
K) Move the pump to a clean and safe location
where the pump can be inspected/
serviced.
7.4 Disassembling and assembling the
pump unit
A) Remove all connections from the pump.
B) Disassemble the pump according to the
Disassembling and Assembling Instruction
(available at
www. danfoss.high-pressurepumps.com).
Clean all the parts and surfaces with a fluid
compatible with the materials found in the
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
hpp.danfoss.com).
7.6 Procedure for mounting the pump back
onto electric motor
Mount the flexible coupling and bell housing
according to appendix 2, Instruction.
7.7 Getting the pump unit back into
operation
Find instructions of how to put the pump unit
back into operation in chapter 4, Arrival inspection, transportation, handling, lifting and storage
and Installation and commissioning, chapter 5.
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 fill
out with product information. A copy of the
form together with contact information
and reason for returning should be sent to
the email address on the form. The same
documents should be attached to the
shipment.
14
180R9287 |AQ073186503097en-001001 | IOM PAHT 2-12.5 pumps | 01.2022
Operation guide | Installation, Operation and Maintenance Manual for PAHT 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 fluid is too high.
• The ambient temperature is too high.
• The pump is running against a blocked
port/closed manual valve.
• The pump is operating at a pressure out of
specification.
• The pump is running with a non-specified/
approved fluid.
• The pump is running in the wrong
direction.
• The filtration is insufficient.
• There is excessive mechanical load on the
shaft coupling and piping.
Electrical
hazard
8.4 Electrical failure
If the wiring of the electric motor is incorrect or
the ground connection is missing, it can cause
electric shock, burn damages, fire or even death.
If a VFD is used and wrongly programmed, it can
damage the pump and lead to high temperatures or other dangers.
All electrical installation must be carried out by
authorized personnel in accordance with
EN60204-1 and/or local regulations.
8.5 Responsibility
Danfoss takes no responsibility for any abnormal
injuries, risks or damages that could arise caused
by abnormal conditions, vibrations, corrosion,
abrasives, foreign objects or excessive temperatures and shall not be liable for any consequential or incidental damages.
8.6 Scrapping criteria
Whether the pump can be repaired or need to be
scrapped, depends on in which conditions the
internal parts are, or how damaged the whole
unit is. Please use appendix 5, Trouble shooting
guide as guideline or send the pump to Danfoss
headquarter in Denmark for evaluation.
8.3 Mechanical failure
If the pump is running dry, the temperature will
quickly increase which can cause burns.
If there is any leakage at start-up or during
operation, a high pressure jet can cause eye or
skin damage.
Leakage can result in flooding, which can cause
slipping, tripping or falling.
If water is dripping into the electric motor; it can
cause electric shock, fire, short of circuit or even
death. When mounting the pump vertically,
always mount the motor above the pump to
avoid water leaking into the electric motor.
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.
180R9287 |AQ073186503097en-001001 | IOM PAHT 2-12.5 pumps | 01.2022
15
Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
16
180R9287 |AQ073186503097en-001001 | IOM PAHT 2-12.5 pumps | 01.2022
Operation guide
Appendices
PAHT 2-12.5
Installation, Operation and
Maintenance Manual
hpp.danfoss.com
Operation guide | Installation, Operation and Maintenance Manual for PAHT 2-12.5 pumps
Table of Contents
1. Data sheet PAHT G 2-308 (AI106586503085en-000901) .................................19
2. Pump instruction PAHT 2-6.3 and PAHT 10-12.5 (180R9277) .............................33
3. Electric motor manual (180R9230) ......................................................43
4. Parts list PAHT (AX322445815902en-000201) ............................................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).......71
180R9287 |AQ073186503097en-001001 | IOM PAHT 2-12.5 pumps | 01.2022
18
Data sheet
Data sheet
PAHT pumps
PAHT 2-308 pumps /
PAHT 2-6.3/PAHT/10-12.5/PAHT 20-25/
PAHT G 2-308 pumps /
PAHT 50-90 and PAHT 256-308
ATEX PAHT G pump
danfoss.high-pressurepumps.com
hpp.danfoss.com
Data sheet PAHT 2-308 pumps
Table of Contents
Contents
1. Introduction ...........................................................................20
2. Benefits................................................................................21
3. Application examples ..................................................................21
4. Technical data .........................................................................22
4.1 PAHT 2-12.5 ............................................................................22
5. Flow ...................................................................................23
5.1 PAHT 2-6.3 typical flow curves at max pressure .........................................23
5.2 PAHT 10-12.5 typical flow 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 (not applicable for PAHT 256-308) ................................28
8. Dimensions and connections...........................................................29
8.1 PAHT 2-6.3 .............................................................................29
8.2 PAHT 10-12.5...........................................................................30
9. Service.................................................................................31
1. Introduction
The Danfoss range of PAHT high-pressure pumps
is specifically designed for use with technical
water such as:
• Ultra-pure water that has undergone
multiple reverse osmosis processes
• De-ionized water
• Demineralized water
Danfoss PAHT pumps are positive displacement
pumps, with axial pistons that move a fixed
amount of water in each cycle. Flow is proportional to the number of input shaft revolutions
(rpm). Unlike centrifugal pumps, they produce
the same flow at a given speed independently of
no matter what the discharge pressure.
20
180R9287 |AQ073186503097en-001001 | IOM PAHT 2-12.5 pumps | 01.2022
Data sheet PAHT 2-308 pumps
Below sectional drawing is an example of a PAHT pump.
1: Mounting flange
2: Shaft seal
3: Connecting flange
4: Port plate
5: Valve plate
6: Retainer plate
7: Swash plate
8: End cap
9: Spring
10: Pis ton
11: Cylinder barrel
12: Housing with bearing
2. Benefits • 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:
- Efficient design and all-stainless steel
construction ensure exceptionally long
lifetime. When Danfoss specifications
are met, service intervals of up to 8,000
hours can be expected. Service is easy,
and can be carried out on site due to
the simple design and few parts.
• Low energy costs:
- The highly efficient axial piston design
provides the lowest energy consumption of any comparable pump on the
market.
• Easy installation:
- The lightest and most compact design
available.
3. Application examples • High-pressure cleaning with ultra-pure
water, as used in the manufacturing of
flat-panel displays and many other
electronic products.
• High-pressure cleaning with ultra-pure
water, as used in the manufacturing of
parts for the automobile industry.
• Adiabatic cooling systems to replace or
supplement standard A/C systems in server
rooms and factories.
- Pump can be installed horizontally or
vertically.
- No pulsation dampeners necessary due
to extremely low-pressure pulsation.
- Powered by electric motors or combustion engines.
- Suitable for both boosted inlet
pressure and water supply from a tank.
- No need for cooling circuits due to very
high mechanical efficiency.
• Certified quality:
- Fulfills the stringent hygiene requirements, VDI 6022, HACCP.
- Certificates:
ISO 9001, ISO 14001
API available on request
• Humidification in office buildings, elec-
tronic component manufacturing, dairies,
greenhouses, etc.
• Dust suppression and odor control
systems, for example in paper, textile and
wood production.
• Reduction of NOx emissions in diesel
engines and gas turbines.
• Gas turbine by inlet fogging and fuel wash
systems.
180R9287 |AQ073186503097en-001001 | IOM PAHT 2-12.5 pumps | 01.2022
21
Data sheet PAHT 2-308 pumps
4. Technical data 4.1 PAHT 2-12.5
Pump size 2 3.2 4 6.3 10 12 .5
Code number PAHT 180B0031 180B0077 180B0030 180 B0029 180B0 032 180B0033
Housing material AISI 304 AISI 304 AISI 304 AISI 304 AISI 304 AISI 304
Geometric
displacement
Pressure
Min. outlet
pressure
Max. outlet
pressure
Inlet pressure,
continuous
Max. inlet
pressure, peak
Speed
Min. speed rpm 1000 1000 1000 1000 1000 1000
Min. speed,
continuous
Max. speed rpm 3000 3000 3000 3000 2400 2400
Typical flow - 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. pressurekW50 Hz
1800 rpm at
max. pressurehp60 Hz
Torque at max.
outlet pressure
Media
temperature
Ambient
temperature
Sound
pressure level
Weight kg 4.4 4.4 4.4 4.4 7. 7 7. 7
cm³/rev 2 3.2 4 6.3 10 12. 5
in³/rev 0.12 0.20 0.24 0.38 0.61 0.76
barg 30 30 30 30 30 30
psig 435 435 435 435 435 435
barg 100 100 100 100 140 140
psig 1450 1450 1450 1450 2031 2031
barg 0-4 0-4 0-4 0-4 0-4 0-4
psig 0-58 0-58 0-58 0-58 0-58 0-58
1)
barg 4 4 4 4 4 4
psig 58 58 58 58 58 58
rpm 1000 1000 1000 1000 1000 1000
l/min 0.7 2.0 3.0 5.5 7.6 10.2
l/min 1.7 3.6 5.0 8.6 12.6 16. 5
gpm 0.3 0.7 1.0 1.8 2.5 3.3
gpm 0.6 1.2 1.6 2.7 4.0 5.3
Nm 4.4 6.7 8.1 12.4 25.6 31.7
lbf-ft 3.2 4.9 6.0 9.2 18.9 23.4
°C 2-50 2-50 2-50 2-50 2-50 2-50
°F 37-122 37-122 37-122 37-122 37-122 37-122
°C 0-50 0-50 0-50 0-50 0-50 0-50
°F 32-122 32-122 32-122 32-122 32-122 32-12 2
dB(A) 76 76 76 76 75 75
2)
lbs 9.7 9.7 9.7 9.7 17. 0 17. 0
0.75 1.1 1.5 2.2 4.0 5.5
1.0 1.5 2.0 3.0 7.5 7. 5
22
1)
1% per minute peak, 10% per minute during start up.
2)
Measurements according to EN ISO 3744: 2010 / dB(A) [L
Measured at max pressure and rpm for a motor pump unit.
] values are calculated.
PA, 1m
180R9287 |AQ073186503097en-001001 | IOM PAHT 2-12.5 pumps | 01.2022
Data sheet PAHT 2-308 pumps
20
18
16
14
12
10
8
6
4
2
0 rpm
PAHT 2.0
PAHT 3.2
PAHT 4.0
PAHT 6.3
l/min
1000
1250
1500
1750
2000
2500
2250
2750
3000
5. Flow The flow (Q
calculated with the following equation:
Q
= Q
eff
) at various pressure (p
eff
– [(Q
(th)
– Q (p
(th)
)) x (p / p
max
max
max
The theoretical flow can be calculated with the
following equation:
V x n
Q
=
(th)
1000
5.1 PAHT 2-6.3 typical flow curves at max pressure
l/min
20
18
16
14
12
10
8
6
4
2
0 rpm
1000
1250
1500
) can be
)]
1750
At zero pressure the true flow equals the
theoretical flow Q
: Theoretical flow (l/min / gpm)
Q
(th)
Q (p
): Flows at max. pressure (l/min and
max
p
p: Pressure (barg / psig)
gpm), see 4.1-4.4
: Max pressure (barg / psig)
max
V: Displacement (cm
.
(th)
3
/ rev.)
n: Motor speed (rpm)
2000
2250
2500
2750
PAHT 6.3
PAHT 4.0
PAHT 3.2
PAHT 2.0
3000
gpm
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
1000
1250
1500
1750
2000
2250
2500
180R9287 |AQ073186503097en-001001 | IOM PAHT 2-12.5 pumps | 01.2022
2750
PAHT 6.3
PAHT 4.0
PAHT 3.2
PAHT 2.0
rpm
3000
23
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