Danfoss PAHT G 256, PAHT G 308 Operating guide

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Operation guide

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Installation, Operation and

PAHT G pumps

PAHT G 256-308

Maintenance Manual for

Operation, Installation and Maintenance Manual

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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps

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

Validity .........................................................................................4

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

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

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

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

1.4 Country speciﬁc 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 designs ....................11

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

5.8 Mount the diﬀerent equipment ........................................................11

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

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

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

5.12 Ensure free ﬂow .......................................................................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 (not applicable for PAHT G 256-308) .................................12

5.17 Check the ﬁlter 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

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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 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

Table of Contents .................................................................................18

1. Data sheet PAHT G 2-308 / ATEX PAHT G pumps (AI106586503089en-000801) ...........19

2. Pump instruction PAHT G 256-308 (AN210086502984en-000602)........................31

3. Electric motor manual (180R9230) ......................................................39

4. Parts list PAHT G (AX319828953697en-000601)..........................................45

5. Trouble shooting guide for PAH, PAHT, PAHT G pumps..................................53

6. Right and wrong - Trouble shooting guide for water hydraulic systems (180R9042).......65

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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps

Validity

This manual is valid for PAHT G pumps both non ATEX and ATEX certiﬁed versions. An ATEX

In case the pump delivered is ATEX certiﬁed, the

additional ATEX instruction must also be read. certiﬁed pump is indicated by Ex in the designation - example PAHT G 256 Ex.

No n ATEX ATE X certiﬁed

PAHT G 256 Code no. 180B6090 PAHT G 256 Ex 180B6190

Serial no. XXXXXX03-XXX XXXXXX03-XXX

PAHT G 308 Code no. 180B6091 PAHT G 308 Ex 180B6191

Serial no. XXXXXX03-XXX XXXXXX03-XXX

PUMP

Type PAHT G 256 Code no. 180BXXXX

Serial no. XXXXXX03-XXX

MADE IN DENMARK

Danfoss A/S, 6430 Nordborg, Denmark

The serial number is referring to the Serial no. on

the product label. The digits shown (03) indicate

the version number of the pump.

This documentation is compatible with previous

pump versions.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps

1. Introduction

1.1 General

The PAHT G pumps and pump units are manufactured by Danfoss A/S, and are sold and marketed by a net of authorized distributors world wide.

This manual contains the necessary instructions for the installation, operation and service of the pumps used for technical water.

In case the pump delivered is ATEX certiﬁed, the additional ATEX instruction must also be read.

The PAHT G pumps must not be used for other purposes than those recommended and speciﬁed without ﬁrst consulting your local pump distributor.

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:

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

It is important that these instructions are always available to the personnel concerned.

1.2 Symbols

Indicates something to be noted by the

reader

Indicates a situation which will or could

result in damage to the pump and its function

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

• Transportation of the pump unit

• Lifting the unit

• Installing the pump unit

• Connecting the pump unit to the water system

• Connecting the electric motor and instrumentation

• Commissioning the unit

• Servicing the motor pump unit, mechanical and electrical parts

• Decommissioning the motor pump unit

The pump must always be installed and used in accordance with existing national/local sanitary, safety regulations and laws.

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

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.

Hearing protection required

Safety shoes required

Safety helmet required

Protective garments must be wor n

Protective garments

must be worn

Danger HOT.

Do not touch

Electrical

hazard

Electrical hazard

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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 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 1 NB 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 G 256-308 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.

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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.

Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps

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

3.7 Filtration

(10µm absolute [β10 ≥ 5000]) Requirements are speciﬁed in appendix 1, Data sheet and appendix 2, Instruction.

Danfoss recommends not to build a ﬁlter bypass function or use ﬁlters with an integrated bypass. If the above recommendation is not followed the warranty for the pump will automatically become void.

It should be possible to monitor the condition of the ﬁlter via the diﬀerential/delta pressure across the ﬁlter.

Using insuﬃcient ﬁltration or a ﬁlter bypass can cause a failure or decreased service life of the pump.

3.8 Properties of water

It is recommended NOT to use the pump for other media than speciﬁed in the Data sheet.

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.

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.

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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 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.

Once the lifting is done the lifting eye must be removed from the pump.

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 G 256-308 pumps

System

5 5

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.

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. 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!

5.5 Local regulations

Commissioning must always be done in

accordance with valid regulations and local

standards.

Open system design

1 4 5 5 6

Closed system design (not applicable for PAHT/PAHT G 256-308)

SYSTEM

Reservoir

6 6 7

System

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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 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 G 256-308 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 (not applicable for

PAHT G 256-308)

• Check if the reservoir is clean.

• Check if ﬁlter element is present and

mounted correctly.

• Fill water at the reservoir using the ﬁlling

valve. Inspect immediately for leakage.

• Bleed high-pressure pump until only water

leaves the high-pressure pump. Remember to close all bleeding and draining plugs.

• Adjust pressure relief valve to minimum

setting.

• Check rotation of the high-pressure pump

by description in 5.15.

• Start high-pressure pump for 2 minutes, to

make sure all air is out of the system.

• Check reservoir low level switch/controls.

The high-pressure pump must stop if low level switch is activated.

• Adjust pressure relief valve to working

pressure.

• Check the temperature switch/controls.

The high-pressure pump must stop if temperature is above speciﬁed set point.

• Check the ﬁlter pressure switch/controls. A

warning must be given if pressure is above speciﬁed set point.

• If the system is running within the system

design limits, the system is released for operation.

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

5.17 Check the ﬁlter condition

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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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 G 256-308 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.

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 ﬁltration of the water.

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

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

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.

E) Open bleeding and drain plugs. Wait until

the pump and system are emptied for water.

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Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 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 www. danfoss.high-pressurepumps.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.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 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.

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.

Electrical

hazard

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.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Operation guide

Appendices

PAHT G 256-308 Installation, Operation and Maintenance Manual

hpp.danfoss.com

Operation guide | Installation, Operation and Maintenance Manual for PAHT G 256-308 pumps

Table of Contents

1. Data sheet PAHT G 2-308 / ATEX PAHT G pumps (AI106586503089en-000801) ...........19

2. Pump instruction PAHT G 256-308 (AN210086502984en-000602)........................31

3. Electric motor manual (180R9230) ......................................................39

4. Parts list PAHT G (AX319828953697en-000601)..........................................45

5. Trouble shooting guide for PAH, PAHT, PAHT G pumps..................................53

6. Right and wrong - Trouble shooting guide for water hydraulic systems (180R9042).......65

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Data sheet

PAHT G pumps

PAHT 2-308 pumps /

PAHT G 2.0 - PAHT G 308 ATEX PAHT G 2.0 - PAHT G 308

PAHT G 2-308 pumps / ATEX PAHT G pump

danfoss.high-pressurepumps.com

hpp.danfoss.com

Data sheet | PAHT G 2-308 and ATEX PAHT G pumps

Table of Contents

Contents

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

2. Beneﬁts................................................................................21

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

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

4.4 PAHT G 256-308........................................................................22

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

5.5 PAHT G 256-308 typical ﬂow curves at max pressure ....................................23

6. Motor requirements....................................................................24

7. Installation.............................................................................25

7.1 Filtration ..............................................................................25

7.2 Noise ..................................................................................25

7.3 Open-system design ...................................................................26

7.4 Closed-system design (not applicable for PAHT G 256-308)..............................27

8. Dimensions and connections...........................................................28

8.5 PAHT G 256-308........................................................................28

9. Service.................................................................................29

1. Introduction

The Danfoss range of PAHT G high-pressure pumps is speciﬁcally designed for use with technical water such as:

• Ultra-pure water that has undergone multiple reverse osmosis processes

• De-ionized water

• Demineralized water

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

The range of PAHT G pumps is based on the standard PAHT pump series. The PAHT G pumps are made with extra coatings that reduce the wear of the pump. This coating is particularly important for pumps used in gas turbine applications or other similar applications where the wear of the pumps is higher due to the ultra pure water quality.

The next pages will cover both PAHT G and PAHT G ATEX pumps. ATEX certiﬁed pumps are indicated by Ex in the type designation - example PAHT G 12.5 Ex.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Data sheet | PAHT G 2-308 and ATEX PAHT G pumps

Below sectional drawing is an example of a PAHT G pump.

1: Mounting ﬂange 2: Shaft seal 3: Connecting ﬂange 4: Port plate 5: Valve plate 6: Retainer plate 7: Swash plate 8: End cap

9: Spring 10: 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

ATEX available

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.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Data sheet | PAHT G 2-308 and ATEX PAHT G pumps

4. Technical data

4.4 PAHT G 256-308

Pump size 256 308

Code number PAHT G 180B6090 180B6091

Code number ATEX PAHT G 180B6190 180 B6191

Housing material AISI 316

or higher

Geometric displacement

cm³/rev 256 308

in³/rev 15.6 18.8

Pressure

Min. outlet pressure

Max. outlet pressure

Inlet pressure, continuous

Max inlet pressure, peak

barg 30 30

psig 435 435

barg 120 120

psig 1740 1740

barg 2-6 2-6

psig 29-87 29-87

barg 10 10

psig 145 145

Speed

Min. speed rpm 450 450

Min. speed, continuous

rpm 700 700

Max. speed rpm 1250 1250

Typical ﬂow - Flow curves available in section 5

450 rpm at max. pressure

1250 rpm at max. pressure

450 rpm at max. pressure

1250 rpm at max. pressure

l/min 89.6 10 7.8

l/min 294.4 354.2

gpm 23.3 28.0

gpm 76.5 92.1

Typical motor size

1000 rpm at max. pressurekW50 Hz

1200 rpm at max. pressurehp60 Hz

Torque at max. outlet pressure

Media temperature

Ambient temperature

Sound pressure level

Nm 549.6 661.3

lbf-ft 405.6 448.0

°C 2-50 2-50

°F 37-12 2 37-122

°C 0-50 0-50

°F 32-12 2 32-122

dB(A) 82 87

Weight kg 105 105

lbs 231 231

AISI 316

or higher

55 75

100 125

1% per minute peak, 10% per minute during start up.

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

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Data sheet | PAHT G 2-308 and ATEX PAHT G pumps

400

350

300

250

200

150

100

l/min

550

650

750

850

1050

1150

1250

950

450

rpm

PAHT 256

PAHT 308

5. Flow

The ﬂow (Q eﬀ) at various pressure (p calculated with the following equation:

Q eﬀ = Q

(th)

– [(Q

– Q (p

(th)

)) x (p / p

max

The theoretical ﬂow can be calculated with the following equation:

V x n Q

(th)

1000

) can be

max

)]

max

At zero pressure the true ﬂow equals the theoretical ﬂow Q

: Theoretical ﬂow (l/min / gpm)

(th)

Q (p

max

: Max pressure (barg / psig)

max

p: Pressure (barg / psig) V: Displacement (cm3 / rev.) n: Motor speed (rpm)

5.5 PAHT G 256-308 typical ﬂow curves at max pressure

l/min

400

350

300

250

200

(th)

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

gpm), see 4.1-4.4

PAHT G 308

PAHT 308

PAHT G 256

PAHT 256

150

100

1250

rpm

PAHT G 308

PAHT 308

PAHT G 256

PAHT 256

450

gpm

100

550

650

750

850

950

1050

1150

450

550

650

750

850

950

1050

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

1150

rpm

1250

Data sheet | PAHT G 2-308 and ATEX PAHT G pumps

6. Motor requirements

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

n x V x p P =

600.000 x η

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

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

The required torque is calculated as follows:

V x p M =

62.8 x η

To determine the correct motor size, both the power and torque requirement must be veriﬁed.

The mechanical eﬃciency of the pump, at max pressure, is as follows:

PAHT G 256, 308 0.95

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Data sheet | PAHT G 2-308 and ATEX PAHT G pumps

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

A CB

A: Pump B: Bell housing C: Coupling D: Motor

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

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

7.1 Filtration

Proper ﬁltration is crucial for the performance, maintenance and warranty of your pump.

Protect your pump, and the application in which it is installed, by always ensuring that ﬁltration speciﬁcations are met, and by always changing ﬁlter cartridges according to schedule.

Since water has very low viscosity, Danfoss PAHT G pumps have been designed with very narrow clearances in order to control internal leakage rates and improve component performance. To minimize wear on the pump, it is

therefore essential to ﬁlter inlet water properly.

The main ﬁlter must have a ﬁltration eﬃciency of 99.98% at 10 μm. We strongly recommend that you always use precision depth ﬁlter cartridges rated 10 μm abs. β10 ≥ 5,000.

Please note that we do not recommend bag ﬁlters or string-wound ﬁlter cartridges, which

typically have only 50% ﬁltration eﬃciency. This means that out of 100,000 particles that enter such ﬁlters, 50,000 particles pass right through them; compare this to precision depth ﬁlters that are 99.98% eﬃcient, and only allow 20 of the same 100,000 particles to pass through.

For more information on the importance of proper ﬁltration, including explanation of ﬁltration principles, deﬁnitions, and guidance on how to select the right ﬁlter for your pump, please consult our Filtration information and speciﬁcations (Danfoss document number 521B1009).

7.2 Noise

Since the pump unit is mounted on a frame, the overall noise level can only be determined for a complete system. To minimize vibrations and noise throughout the system, it is therefore very important to mount the pump unit correctly on a frame with dampers and to use ﬂexible hoses rather than metal pipes where possible.

The noise level is inﬂuenced by:

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

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

• Pump mounting: Rigid mounting makes more noise than ﬂexible mounting because of the structureborne vibrations. Be sure to use dampers when mounting.

• Connections to pump: Pipes connected directly to the pump make more noise than ﬂexible hoses because of structure-borne vibrations.

• Variable frequency drives (VFDs): Motors regulated by VFDs can produce more noise if the VFD does not have the right settings.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Data sheet | PAHT G 2-308 and ATEX PAHT G pumps

7.3 Open-system design

A Inlet line:

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

B Inlet ﬁlter:

Install the inlet ﬁlter (1) in front of the PAHT G pump (2). Please consult the Danfoss ﬁlter data sheet for guidance on how to select the right ﬁlter. C Monitoring pressure switch:

Install the monitoring pressure switch (3)

between the ﬁlter and the pump inlet. Set

the minimum inlet pressure according to

speciﬁcations described in item 4, technical

data. The monitoring pressure switch stops

the pump if inlet pressure is lower than the

set minimum pressure. D Monitoring temperature switch:

Install the monitoring temperature switch

(4) between the ﬁlter and the pump, on

either side of the monitoring pressure

switch. Set the temperature value accord-

ing to technical data, item 4. The monitor-

ing temperature switch stops the pump if

inlet temperature is higher than the set

value.

E Hoses:

Always use ﬂexible 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 speciﬁcations described in item 4, technical data.

G Non-return valve (6):

Should be installed after the outlet to prevent pump backspin, which may ruin the pump.

H Pressure relief valve:

As the Danfoss PAHT G pump begins to create pressure and ﬂow immediately after start-up regardless of any counter pressure, a pressure relief valve (7) should be installed to prevent system damage.

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

1 4 5 5 6

SYSTEM

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Data sheet | PAHT G 2-308 and ATEX PAHT G pumps

System

5 5

7.4 Closed-system design (not applicable for PAHT G 256-308)

A Inlet line:

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

B Inlet ﬁlter:

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

C Monitoring pressure switch:

Install the monitoring pressure switch (3) in front of the ﬁlter (1). Set the maximum inlet pressure to 2 barg (29.0 psig). The monitoring pressure switch will stop the pump (5) if inlet pressure is higher than 2 barg (29.0 psig), indicating that the ﬁlter element must be changed.

D Monitoring temperature switch:

Install the monitoring temperature switch (4) in the tank. Set the temperature value according to technical data, item 4. The monitoring temperature stops the pump if inlet temperature is higher than the set value.

E Hoses:

Always use ﬂexible hoses (6) to minimize vibrations and noise.

F Inlet pressure:

In order to eliminate the risk of cavitation and other pump damage, pump inlet pressure must be maintained according to speciﬁcations described in item 4, technical data.

G Non-return valve (7):

Should be installed after the outlet to prevent pump backspin, which may ruin the pump.

H Pressure relief valve:

As the Danfoss PAHT G pump begins to create pressure and ﬂow immediately after start-up regardless of any counter pressure, a pressure relief valve (8) should be installed to prevent system damage.

I System water ﬁlling:

To ensure proper ﬁltration of new water (10) supplied to the system, always use the ﬁlling valve (9).

J Minimum level switch:

Install the minimum level switch (11) above

the outlet of the reservoir. The level switch must stop the pump if the water in the reservoir is below the switch, which indicates that the reservoir is empty.

Reservoir

6 6 7

System

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Data sheet | PAHT G 2-308 and ATEX PAHT G pumps

8. Dimensions and connections

8.5 PAHT G 256-308

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Data sheet | PAHT G 2-308 and ATEX PAHT G pumps

9. Service Danfoss PAHT G pumps are designed for long periods of service-free operation to ensure low maintenance and life cycle costs. Provided that the pump is installed and operated according to Danfoss speciﬁcations, Danfoss PAHT G pumps typically run up to 8,000 hours. However, the service schedule for your Danfoss PAHT G pump may vary according to the application and other factors.

The life of a pump may be greatly shortened if Danfoss recommendations concerning system design and operation are not followed.

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

Other factors that aﬀect pump performance and lifetime include:

• running the pump at speeds outside speciﬁcations

• supplying the pump with water at temperatures higher than recommended

• running the pump at inlet pressures outside speciﬁcations

• running the pump at outlet pressures outside the speciﬁcations.

We recommend that you inspect your pump after 8,000 hours of operation even if it is running without any noticeable problems. Replace any worn parts if necessary, including pistons and shaft seals, to keep your pump running eﬃciently and to prevent breakdown. If worn parts are not replaced, then our guidelines recommend more frequent inspection.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Danfoss A/S

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 reserve s the 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 ﬁcations alread y agreed. All trade marks in this mate rial are proper ty of the respec tive companies . Danfoss and the Danf oss logotyp e are trademark s of Danfoss A/S. Al l rights reserv ed.

AI106586503089en-000801| 30

Instruction

Pump instruction

PAHT G pumps PAHT G 256 and PAHT G 308

PAHT 256-308 and PAHT G 256-308

danfoss.high-pressurepumps.com

hpp.danfoss.com

Instruction | Pump instruction PAHT G 256-308

Table of Contents

1. Identiﬁcation ..........................................................................32

2. System design .........................................................................33

2.1 Open-ended systems with direct water supply..........................................33

2.2 Preferred system design and P&ID ......................................................33

2.3 Reversible pumps ......................................................................34

2.4 General comments on..................................................................34

3. Building up the pump unit .............................................................34

3.1 Mounting..............................................................................34

3.2 Direction of rotation ...................................................................35

3.3 Orientation ............................................................................35

3.4 Protection from too high pressures .....................................................36

3.5 Connections ...........................................................................36

3.6 Grounding .............................................................................36

4. Initial start-up..........................................................................36

5. Operation..............................................................................36

5.1 Temperature ...........................................................................36

5.2 Pressure ...............................................................................36

5.3 Dry running............................................................................36

5.4 Disconnection .........................................................................36

5.5 Storage ................................................................................36

6. Service.................................................................................37

7. Recommended service intervals........................................................37

7.1 General information....................................................................37

7.2 Inspection of pump parts ..............................................................37

7.3 How to inspect the pump ..............................................................37

1. Identiﬁcation

This instruction includes PAHT G pumps.

PUMP

Type PAHT G 256 Code no. 180BXXXX

Serial no. XXXXXX03-XXX

Danfoss A/S, 6430 Nordborg, Denmark

MADE IN DENMARK

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Instruction | Pump instruction PAHT G 256-308

2. System design The design of the system must ensure that self-emptying of the pump during standstill is avoided.

The inlet pressure of the pump must never exceed the outlet pressure. This may typically occur in boosted or open-ended systems with direct water supply.

2.1 Open-ended systems with direct water

supply

The pump is supplied with water direct from a feed pump.

The inlet pressure for PAHT G 256/308 must be at least 2 barg (29 psig) and it must not exceed 6 barg (87 psig) continuously.

If it is unknown what the peak inlet pressure can be, then there should be a 10 barg (145 psig)

select the right ﬁlter. Thoroughly clean pipes and ﬂush system prior to start-up.

Monitoring pressure switch: C Place a monitoring pressure switch (3) set

at min. inlet pressure between ﬁlter and pump inlet. The monitoring switch must stop the pump at pressures lower than

minimum pressure. Monitoring temperature switch D Place a monitoring temperature switch (4)

set at 50°C between ﬁlter and pump. The

monitoring switch must stop the pump at

temperatures higher than set value. Hoses E Use ﬂexible hoses (5) to minimize vibra-

tions and noise. Inlet pressure: F In order to eliminate the risk of damage

Optrional

safety valve on the inlet side of the pump.

2.2 Preferred system design and P&ID Inlet line: A Dimension the inlet line to obtain mini-

mum pressure loss (large ﬂow, minimum pipe length, minimum number of bends/ connections, and ﬁttings with small

pressure losses). Inlet ﬁlter: B Place an inlet ﬁlter (1) in front of the PAHT G pump (2). Please consult Danfoss ﬁlter datasheet for guidance on how to

1 4 5 5 6

and cavitation, a positive pressure at the inlet is always to be maintained at min. inlet pressure and max. inlet pressure.

Non-return valve G A non-return valve (6) after the outlet can

be installed in order to avoid backspin of

the pump. Pressure relief valve: H A pressure relief valve (7) can be installed in

order to avoid system damage as the

Danfoss PAHT G pump creates pressure and

ﬂow immediately after start-up, regardless

of any counter pressure.

Note: If a non-return valve is mounted in the inlet line, a low pressure relief valve is also required between non return valve (8) and

pump as protection against high pressure

peaks.

SYSTEM

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Instruction | Pump instruction PAHT G 256-308

2.3 Reversible pumps

If exposed to high pressure in the outlet while the electric motor is not energized, the pumps will start spinning backwards. This will not harm the pumps as long as the pressure in the inlet does not exceed the max. pressure peak of 10 barg (145 psig).

If a non-return valve is mounted in the inlet line, a low-pressure relief valve is also required as protection against high-pressure pulses and high pressure in general.

Alternatively a high-pressure check valve can be mounted in the pump discharge line to prevent the pump from reversing.

The dotted setup ensures that the inlet pressure does not exceed 10 barg (145 psig), when a non-return valve is mounted in the inlet.

In order to avoid the risk of cavitation, the inlet pressure at the pump must be min. 2 barg (29 psig).

The inlet line connection must be properly tightened, as possible entrance of air will cause cavitation.

2.4 General comments on

Filtration

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

As water has very low viscosity, the PAHT G pumps have been designed with very narrow clearance in order to control internal leakage rates and improve component performance. Therefore it is important that the inlet water is ﬁltered properly to minimize the wear of the pump.

The main ﬁlter must have a ﬁltration eﬃciency of

99.98% at 10 µm. We recommend to use precision depth ﬁlter cartridges rated 10 µm abs. β10 ≥ 5000 (equivalent to a ﬁltration eﬃciency of

99.98%). Bag ﬁlters and string wound ﬁlter cartridges typically have only 50% ﬁltration eﬃciency. This means that for each 100,000 particles reaching the ﬁlter, 50,000 particles pass through it compared to only 20 particles in a ﬁlter with an eﬃciency of 99.98%.

For more information on the importance of proper ﬁltration, please consult our publication “Filtration” (code number 521B1009), which also will provide you with an explanation of ﬁltration deﬁnitions and a guidance on how to select the right ﬁlter.

Monitoring

It is recommended to continuously monitor the following conditions:

• ﬁlter clogging

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

3. Building up the pump unit

3.1 Mounting

A: Elastic coupling B: Bell housing C: Motor shaft D: Pump ﬂange

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Instruction | Pump instruction PAHT G 256-308

1. Mount the coupling ﬂush or maximum 1mm oﬀset from the pump shaft end. Ensure an air gap between coupling and pump ﬂange of min. 4 mm (0.16 in).

2. Mount the bell housing on pump. Secure nuts with the right torque.

3. Measure the longest distance “A” from top of bell housing to the button of coupling claw.

4. Mount the coupling on motor shaft. Ensure the coupling and motor ﬂange are not in contact with each other.

5. Measure from motor ﬂange to the top of the coupling. That measurement “B” shall be 3-5 mm (0.12 - 0.2 inch) shorter than the measurement “A”.

6. Adjust respectively, verify the measurement, and secure both couplings with the right torques on the locking screws (see coupling operation & mounting instruction).

7. Mount the elastic gear ring and mount the bell housing/pump on the motor. After mounting it must be possible to move the elastic gear ring 3-5mm (0.12 - 0.2 in) axial “C”. The check can be done through the inspection hole of bell housing. Secure ﬂange bolts with the right torque.

3.2 Direction of rotation

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

PUMP

Type PAHT G 256 Code no. 180BXXXX

Serial no. XXXXXX03-XXX

MADE IN DENMARK

Danfoss A/S, 6430 Nordborg, Denmark

3.3 Orientation

The pump can be mounted/orientated in any horizontal direction with the inlet and the outlet pointing upwards, downwards or to either side.

If alternative mounting is desired, please contact the Danfoss Sales Organization.

Choose proper tolerances to ensure an easy mounting of the elastic coupling without use of tools.

Please take care to observe the recommended length tolerances of the chosen coupling, as an axial force on the pump will damage the pump.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Instruction | Pump instruction PAHT G 256-308

4. Initial start-up

3.4 Protection from too high pressures

The pump should be protected against too high pressure by means of a safety valve or a pressure relief valve.

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

The opening characteristics of the valve must not result in peak pressures higher than 100 barg (1450 psig).

Both the inlet and outlet lines must be ﬂexible soft hoses.

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

3.5 Connections

I: Inlet O: Outlet C: Bleeding

1. Flush inlet line before connecting the pump, to remove possible impurities from pipes, hoses etc.

2. Loosen top bleeding plug “C” (see item 3.5) using an allen key (only plugs with internal hexagan sockets). Retighten the plug, when water appears from the bleeding plug.

3. Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump (see label on pump).

D: Parallel key

3.6 Grounding

To prevent stray current corrosion we recommend grounding of the pump and all other parts in the system. All parts in the system must be electrical potential equalized to a single reference point (grounding point). It is recommended that the electrical resistance in the grounding cable is equal to or below 0.25 Ohm towards the grounding point.

4. Now the pump is ready for start-up.

WARNING: Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump (see label on pump). Otherwise the pump will be damaged if a check valve is placed between pump and feed pump.

5. Operation 5.1 Tempe ratur e

Fluid temperature: Min. +2°C to max. +50°C (Min. +35.6°F to max. +122°F)

Ambient temperature: Min. +2°C to max. +50°C (Min. +35.6°F to max. +122°F)

Storage temperature: Min. -40°C to max. +70°C (Min. -40°F to max. +158°F)

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

5.2 Pressure

The inlet pressure for PAHT G 256/308 must be min. 2 barg (29 psig) and max. 6 barg (87 psig). At lower pressures the pump will cavitate, resulting in damage of the pump.

Max. inlet pressure peak (e.g. in case the pump stops momentarily) up to 10 barg (145 psig) are acceptable. Max. pressure on the pump’s outlet line should be limited at 120 barg (1740 psig) continuously.

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

5.3 Dry running

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

5.4 Disconnection

If the inlet line is disconnected from the water supply, the pump will be emptied of water through the disconnected inlet line. When starting up again, follow the bleeding procedure described under section 4, Initial start up.

5.5 Storage

When preparing the pump for long-term storage or for temperatures below the freezing point, ﬂush the pump with an anti-freeze medium type monopropylene glycol to prevent internal corrosion or frost in the pump.

For further information on anti-freeze media, please contact the Danfoss Sales Organization.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Instruction | Pump instruction PAHT G 256-308

Recommended procedure:

1. Disconnect the water supply to the pump.

2. Through the lower bleeding plug, empty the pump housing of water and close it again.

3. Connect the pump to a tank containing anti-freeze additive. Connect a hose to the inlet port of the pump and via another hose return the ﬂow from the outlet port port to the tank with anti-freeze additives.

4. Quickly start and stop the pump. Make sure that the pump does not run dry. The pump is now protected against internal corrosion and frost.

6. Service The Danfoss PAHT G pumps are designed for long periods of service-free operation to provide customers with low maintenance and life cycle costs. Provided that the pumps are installed and operated according to Danfoss speciﬁcations, the Danfoss PAHT G pumps typically run 8,000 hours between service routines. However, the service schedule for your PAHT G pump may vary according to the application and other factors.

The life of a pump may be greatly shortened if Danfoss recommendations concerning system design and operation are not followed.

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

7. Recommended service

intervals

7.1 General information

This guideline provides information on the recommended service intervals for the PAHT G pumps. The recommendation is based upon good engineering practice and on experience gained from operation even under extreme conditions.

The recommendation is for guidance only.

7.2 Inspection of pump parts

Danfoss recommends to inspect the pumps after 8,000 hours. Typical signs of wear are seen on the contact/sliding 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

Other factors that aﬀect pump performance and lifetime include:

• running the pump at speeds outside speciﬁcations

• supplying the pump with water at temperatures higher than recommended

• running the pump at inlet pressures outside speciﬁcations

• running the pump at outlet pressures outside the speciﬁcations.

If service inspection due to the application is complicated, the plant operator can decide to extend the service interval by evaluating the following deviations:

• Sound - does the pump have any unusual sounds?

• Electric motor power consumption and speed compared with measurement made in the past.

• Pressure/ﬂow according to measurements made in the past?

We advise that the above mentioned parameter during the extended service interval is inspected for every 500-2,000 hours beyond the 8,000 hours. The pump must in any case be inspected after maximum 16,000 hours or 2 years.

7.3 How to inspect the pump

Service manuals are available on the internet hpp.danfoss.com

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

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Danf already on order pro

Danfoss A/S

High Pressure Pumps DK-6430 Nordborg Denmark

oss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products

vided that such alterations can be made without subsequential changes being necessary eady agreed.

180R9385 | AN210086502984en-000602 | 38

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,

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Connection diagram Anschlußdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexión Collegamento Schemat polacsen

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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

PAHT 2-308 pumps

PAHT G pumps

PAHT G 2-308 pumps

PAHT G 2/3.2/6.3 - PAHT G10/12.5 PAHT G 20/25/32 - PAHT G 50/63/70/80/90 PAHT G 256/308

danfoss.high-pressurepumps.com

hpp.danfoss.com

Parts list | PAHT G pumps

Table of Contents

Contents

1. General ..............................................................................47

14. Spare parts list for PAHT G 256-308 Serial number 03 or higher ..........................48

15. Exploded view for PAHT G 256-308 Serial number 03 or higher ..........................49

16. Exploded view PAHT G 256-308 Serial number up to and including 02 ...................50

17. Tool set for PAHT G 256-308 ............................................................51

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Parts list | PAHT G pumps

1. General

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

Non Atex ATEX

PAHT G 256 PAHT G 256 Ex PAHT G 308 PAHT G 308 Ex

In the following the pumps will be called PAHT G.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Parts list | PAHT G pumps

14. Spare parts list for PAHT G 256-308

Serial number 03 or higher

Pos. Qt y. Designation Material

180B4370 - Screw & seal set (PAHT G 256-308)

180B4369 - Cylinder barrel set

(PAHT G 256-308)

180B4367 - Valve plate set (PAHT G 256-308)

180B4366 - Retainer set (PAHT G 256-308)

180B4368 - Piston set (PAHT G 256-308)

180B4331 - Swash plate set (PAHT G 256)

1 1 Housing Duplex / PEEK

2 2 Pin ø6 x 10 AISI 316 x

3 4 Bleeding plug G 1/4" Super duplex x

4 4 O-ring ø11 x 2 NBR x

5 28 Screw M8 x 30 AISI 316 x

9 1 O-ring ø228 x 4 NBR x x x x

10 2 O-ring ø9,19 x 2,62 NBR x x x

11 1 End cover CW Duplex

13 3 Screw M8 x 16 AISI 316 x

31 1 Swash plate Super Duplex x x

34 2 Pin ø10,5 x 20 Duplex x x x

61 1 Cylinder barrel Super duplex / PEEK x

62 4 Spring Duplex x

63 1 Spring guide Polypropylen x

64 1 Retainer Ball Super duplex x

65 1 Retainer plate Super duplex x

66 9 Piston Super duplex / PEEK x

67 1 Key 12 x 8 x 70 AISI 316 x

71 1 Retainer Guide Super duplex / PEEK x

91 1 Port plate Super duplex / PEEK x

92 1 Valve plate Super duplex x

93 9 Back up ring PTFE x

94 9 O-ring ø30,2 x 3 NBR x

121 1 Port ﬂange Duplex

122 1 O-ring ø68 x 2 NBR x

123 1 O-ring Ø228 x 4 NBR x

124 1 Shaft sealing Hasteloy C276 x

125 1 Cover Super duplex

126 2 Pin ø10,5 x 20 Super duplex x x

127 4 Screw M6 x 16 AISI 316 x

128 18 Screw M8 x 90 AISI 316 x

132 2 Bleeding plug G 1/4" Super duplex x

133 2 O-ring ø11 x 2 NBR x

142 1 Washer for shaft seal Polypropylen x

147 3 Screw M8 x 30 AISI 316 x

1 Service instruction x x x x x x x

180B4332 - Swash plate set (PAHT G 308)

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Parts list | PAHT G pumps

15. Exploded view for PAHT G 256-308 Serial number 03 or higher

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Parts list | PAHT G pumps

16. Exploded view PAHT G 256-308

Serial number up to and including 02

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Parts list | PAHT G pumps

17. Tool set for PAHT G 256-308

Designation

Allen key, 6 mm x

Adjustable pin wrench x

Combination wrench, 10 mm x

Combination wrench, 13 mm x

Nut, M8 x 6.5 x 13 x

Guide bolt, M8 x 140 x

Shaft seal extractor, Ø45 x

Press bush, Ø45 x

Eye bolt, M8 x

Press bush for valve plate x

Stop for retainer plate x

Screw, M8 x 20 x

Screw, M8 x 70 x

180B4259 Tool set

(PAHT 256-308)

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Danfoss A/S

High Pressure Pumps DK-6430 Nordborg Denmark

AX319828953697en-000601

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 ﬁsh bone chart .......................................................55

1. No ﬂow/no pressure....................................................................56

2. Reduced ﬂow/reduced pressure ........................................................57

3. High torque on electric motor ..........................................................58

4. Noise from pump ......................................................................59

5. Noise from installation .................................................................60

6. Typical signs of wear ...................................................................61

6.1 Valve plate.............................................................................61

6.2 Port plate ..............................................................................62

6.3 Swash plate............................................................................62

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

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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

Trouble shooting ﬁsh 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 M in/max nominal

electric motor

5.4 Hoses/pipes mounted

5.5 V ibration damper 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 To o high outlet pressure

3.2 Pump starts against pressure

3.3 Constant torque

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

3. High torque on el. motor

3.4 Water pump damage

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

1. No ﬂow/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 oﬃce for guidelines

in how to troubleshoot internal pump parts.

1.5.1 Ensure that the air gap between the two

coupling parts is min 5 mm. It should always be possible to move the plastic part on the coupling at least 3 mm.

If motor-type relay or the electrical fuse is blown, check that electric motor is sized correctly.

To ensure easy mounting of the ﬂexible coupling without using tools, the tolerances must be dimensioned accordingly.

WARNING: Any axial and/or radial loads on the shaft must be avoided. Any axial or radial load will cause breakdown.

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

1.6 Pump damage

(the internal parts may be damaged)

1.6.1 Contact Danfoss sales oﬃce for guidelines

in how to troubleshoot internal pump parts.

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

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

A B C

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

2. Reduced ﬂow/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 ﬁt. If there is any space (clearance) between liner and piston, liner or piston is worn.

2.1.5 Pre-treatment: Analyse ﬂuid for content of particles.

- Check that ﬁlters are OK and working correctly.

2.1.6 Main ﬁltration: Check that the correct ﬁlter type is used (particles in ﬂuid must not exceed 10 μm). Danfoss High Pressure Pumps supplies ﬁlters, please contact the sales oﬃce.

Typical signs of wear:

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

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

The ﬁlters can be bypassed, even if they are correctly mounted. Some ﬁlters can create channelling where particles can pass through the ﬁlter in tunnels. String wounded ﬁlters are typically channelling ﬁlters. A string wound ﬁlter may have a ﬁltration eﬃciency of only 50%, which will cause internal wear and must always be followed by a main ﬁlter.

2.1.7 Fluid type: The PAH/PAH F (tapwater) and PAHT/PAHT G (ultra pure water) pumps are designed for water operation; for any other ﬂuid, please contact Danfoss High Pressure Pumps sales oﬃce for further help.

2.1.8 High ﬂuid temperature: If ﬂuid 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/ﬂow.

2.2.2 Check if ﬁlters 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.

Insuﬃcient ﬁltration means that too many or too large hard particles can pass the main ﬁlter because it is damaged, bypassed or simply too poor. Filtration eﬃciency must be 99.98% (Beta = 5000) at 10 μm to prevent abnormal wear of the pump.

Temperature > 50° C will cause wear on internal pump parts. Mount a temperature switch and check its set point / function. The temperature switch will ensure that the pump stops at ﬂuid temperatures > 50° C.

If the pressure drop across the ﬁlters is too high, the booster pump does not deliver suﬃcient ﬂow/pressure. No pressure or low pressure results in cavitation and insuﬃcient internal lubrication causing wear on internal pump parts.

Mount a low-pressure switch in front of the pump and check its set point/ function. The low- pressure switch ensures that the pump does not start until the inlet pressure has reached 1 bar.

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

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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 ﬂow 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 oﬃce.

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 oﬀ 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 suﬃcient torque.

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

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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

4. Noise from pump

Cause Remedy Comments

4.1 Air in ﬂuid 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 speciﬁed 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 ﬂow”, item 1.2 Pump reversing”).

WARNING: The pump must not run without water for more than a few seconds. If the pump takes in water from the high-pressure outlet line, it builds up pressure and will eventually be damaged.

4.5 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 speciﬁed 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 ﬂuid without being damaged.

The pump and the inlet line must be completely bled before start-up, otherwise the pump will cavitate and make high noise.

WARNING: The pump can only run few minutes with air in the ﬂuid without being damaged.

Too high inlet pressure causes too high pressure inside the pump damaging the pistons and eventually the pump.

Inlet pressure below min. limit causes cavitation and insuﬃcient internal lubrication resulting in wear on internal pump parts.

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

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

Higher rpm than speciﬁed in the pump data sheet results in wear of the pistons, i.e. pistons may be damaged.

High rpm will also increase pressure pulsations from the pump, and the noise level will increase.

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).

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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 insuﬃcient internal lubrication and wear on internal parts. Pump may eventually be damaged.

Too high outlet pressure may damage the pump.

Noise frequency changes during soft start-up/ stop.

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 ﬂexible 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 stiﬀness 5.3.1 Use a more ﬂexible hose. Too stiﬀ 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-ﬂexible 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 ﬂow/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.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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 ﬂat and level.

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

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 runnin g a ﬁngernail over the surface, the valve plate is worn.

The valve plate on picture 3 is highly damaged.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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

6.2 Port plate

Picture 1

Scratches

Level diﬀerences between

dull and shining PEEK

If the por t plate has scratches, level diﬀe rences or both betwe en the arrows, the port plate must be replaced.

Even small scratches or wear will cause loss of ﬂow.

To check: See item 6.1, picture 3

6.3 Swash plate

Picture 1 If the swash plate is polished 360°, it is an indication of insuﬃcient ﬁltration.

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 oﬃce for further information.

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Danfoss A/S

High Pressure Pump Nordborgvej 81, DK-6430 Nordborg Denmark

521B1475 | DKCFN.PI.012.R2.02 | 64

MAKING MODERN LIVING POSSIBLE

Instruction

Right and wrong

Trouble shooting guide for

Trouble shooting guide for water hydraulic systems

water hydraulics

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 ﬁlter

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 ﬁlter with pressure switch

Locate the return ﬁlter in the return line immediately before the tank

Filter location

> 10 mm

Return ﬁlter with bypass valve and poorer ﬁlterability than 10 m will

damage the system

Placing the return ﬁlter upstream of the ﬁnal 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 ﬁlled via ﬁlter

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

Water supply

Filling system with unﬁltered water causes damage

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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 teﬂon tape or packing yarn in joints may cause damage

Grease

Too much grease may develop bioﬁlm causing operational failures

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Ensure always to have 3 mm distance between coupling ﬂanges

13.

Fill system with water before starting to ensure lubrication and cooling

Insuﬃcient distance and/or misalignment between the coupling ﬂanges will damage the pump

Water supply

Starting without water will cause damage

Wiring

Starting procedure

Cleaning procedure

14.

Level and temperature indicators must be ﬁtted. Follow installation instructions

15.

Level indicator

Missing or incorrectly connected level and temperature indicators cause damage

180R9384 | IOM PAHT G 256-308 pumps - v01 |

03.2016

Rotation direction

1. Fill cold water into the system via the return ﬁlter and bleed the pump (Power Packs PPH 4 - 6.3 - 10 and 12.5 are self-bleeding)

2. Start and bleed the system -without pressure by opening the bypass valve

3. Add the cleaning agent to give 3% agent/water solution

4. Run the system for 60 min. and activate all components as often as possible to ensure eﬀective ﬂushing with the cleaning agent

5. Empty the system of the cleaning agent solution

Flushing procedure

6. Fill cold water through the return ﬁlter and bleed the pump (Power Packs PPH 4 - 6.3 - 10 and 12.5 are self-bleeding)

7. Run the system for 30 min. and activate all components as often as possible

8. Empty the system of the water

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

Insuﬃcient bleeding may cause damage (not applicable to Power Packs)

9. Alternatively the system may be ﬂushed by running the unit without the return hose while continuously ﬁlling up water. The ﬂushing should continue until there is no trace of cleaning agent in the return water

10. Change the return ﬁlter element, ﬁll cold water through the return ﬁlter and bleed the pump during start up

11. The system is now ready for operation

Starting procedure

60 min.

Observing the starting procedure will ensure problem-free operation

If the system is not cleaned before starting, the ﬁlter will clog

days

2-3

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

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 ﬁlter is clogging

Is water coming

through the ﬁlter?

Replace ﬁlter 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?

Yes

Is the ﬁlter clogged?

Is the ﬁlter control

light on?

Yes

Replace ﬁlter 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

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Trouble shooting

Closed water systems

The system

does not work

Is there suﬃcient water

in the tank?

Yes

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?

Is the ﬁlter clogged?

Is the ﬁlter 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 ﬁlter ele-

ment

Trace leakage, if any

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

Stamp

180R9384 | AQ188686502990en-000901 | IOM PAHT G 256-308 | 01.2022

180R9384 | AQ188686502990en-000901 | 72

Danfoss PAHT G 256, PAHT G 308 Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual