Danfoss D1P130 Bedienungsanleitung

User Manual

ATEX certified

Axial piston pump, variable displacement

D1P130/D1P145/193/260

www.danfoss.com

Revision history Table of revisions

Date Changed Rev

August 2021 First edition 0101

User Manual

ATEX certified D1P 130/145/193/260

2 | ©Danfoss | August 2021 BC376161003883en-000101

Introduction General information........................................................................................................................................................................ 4

Intended use...................................................................................................................................................................................... 4

Marking of Danfoss D1 pumps...............................................................................................................................................4

Production place and date of pump....................................................................................................................................6

Example ATEX label - D1P........................................................................................................................................................6

Technical information ATEX technical specifications.......................................................................................................................................................7

T-codes and maximum surface temperature.........................................................................................................................7

Oil types / Operating fluids...........................................................................................................................................................7

Viscosity and temperature for D1P pump..........................................................................................................................8

Ambient temperature................................................................................................................................................................8

Oil temperature........................................................................................................................................................................... 8

Viscosity..........................................................................................................................................................................................8

Filtering................................................................................................................................................................................................9

Installation, operation and maintenance

Assembly of D1 pump to the system......................................................................................................................................10

Operation..........................................................................................................................................................................................11

Pre-start up controls for D1P pump...................................................................................................................................11

Start up.........................................................................................................................................................................................12

Operational checks.............................................................................................................................................................12

Maintenance....................................................................................................................................................................................12

Service and repair of D1P pump......................................................................................................................................... 14

Safety precautions....................................................................................................................................................................14

User Manual

ATEX certified D1P 130/145/193/260

Contents

©Danfoss | August 2021 BC376161003883en-000101 | 3

General information

Purpose of this document

This User Manual has been prepared by the manufacturer in order to provide important information

regarding the safe installation, operation and maintenance of ATEX certified pumps.

This User Manual is a supplement to existing product instruction as ATEX components are subjected to

some limitations compared to standard components. The limitations are described in this ATEX

instruction.

It is intended for machine/system manufacturers, fitters and service technicians. Please read this User

Manual carefully before you work with and start-up the pump.

This User Manual must lie close to the pump.

Manufacturer responsibility

The manufacturer declines any responsibility in case of:

•Use of the product not according to safety regulations and legislation valid in the user’s country.

•Use of the product in operating conditions not allowed according to the product technical

documentation.

•Improper installation: the instructions given in this User Manual are not followed or not properly

followed.

•Hydraulic system problems.

•Modification of the product.

•Operations executed by personnel not properly trained or not assigned to such a kind of operations.

Product safety

The safety of the product depends upon the strict observation of the indications given in this User

Manual: in particular, it is necessary to:

•Always operate within allowed product working operating conditions (please refer to the Technical

Information of the pump in usage).

•Always perform an accurate ordinary maintenance activity.

•Assign the inspection activity as well as maintenance activity to duly trained personnel.

•Only use original spares.

•Always use the product according to the indications you find in this manual.

Intended use

Hydraulic pump converts hydraulic energy (pressure, oil flow) into mechanical energy (torque and

speed). They are designed for mobile and stationary applications.

The pumps fulfill the explosion requirements with the Directive 2014/34/EU for the category shown on

the name plate.

The D1P pumps have an identifying name plate. The name plate provides essential information and

specification for correct and safe use.

This identifying plate has to be maintained so that the data can be clearly read; consequently, a periodic

cleaning of the plate is required.

Marking of Danfoss D1 pumps

The Danfoss hydraulic pumps are marked as equipment for Group II, category 2 for gas and dust

environment and with ignition protection constructional safety and liquid immersion.

User Manual

ATEX certified D1P 130/145/193/260

Introduction

4 | ©Danfoss | August 2021 BC376161003883en-000101

Temperature class/Maximum surface temperature depends on the operating conditions (ambient and

fluid temperature).

ATEX marking

Marking For model code option

CE Ex II 3G Ex h IIA T3 Gc AN3 (temperature class T3)

CE Ex II 3G Ex h IIA T4 Gc AN4 (temperature class T4)

CE Ex II 3G Ex h IIA T5 Gc AN5 (temperature class T5)

See Viscosity and temperature for D1P pump on page 8 for more information about temperature classes.

User Manual

ATEX certified D1P 130/145/193/260

Introduction

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Production place and date of pump

The production location and date of the pump is shown at the first 5 digits of the serial no.

Example: Serial No: N191230941

Five first digits are N1912

Nis the manufacturing location (N=Neumünster)

19 is the year (It stands for the last digit in the possible decade).

12 is the week

The last five digits are a consecutive number.

The ATEX certification of the units are done under the scope of:

"Directive 2014/34/EU of the European Parliament and of the Council of 26 February 2014 on the

harmonization of the laws of the Member States relating to equipment and protective systems intended for

use in potentially explosive atmospheres."

With following parameters:

•Equipment group: II

•Zone: 2 (gas)

•Equipment Category: 3G

•Temperature class: T5...T3

•Explosion protection group: II A

The Conformity Assessment Procedure has to be executed according to Directive 2014/34/EU, annex VIII,

Modul A: Internal Production Control (see article 13, section 1 (c)).

The EU declaration of conformity has to be prepared and issued with regard to annex X of /1/. The

“Essential Health and Safety Requirements” defined by /1/, annex II, have to be considered.

Example ATEX label - D1P

Examples of ATEX pump labels – Pump produced in People's republic of China

1. Manufacturer

2. Location of production

3. ATEX code

4. Material number

5. Model code, including unit and displacement

6. Production code

User Manual

ATEX certified D1P 130/145/193/260

Introduction

6 | ©Danfoss | August 2021 BC376161003883en-000101

ATEX technical specifications

The technical specifications in this chapter are supplemental for ATEX systems only. For comprehensive

technical specifications, including maximum pressure rating, maximum flow, etc. please refer to the

standard D1P Technical Information document.

Danfoss does not claim responsibility for the use of the pump in operating conditions not allowed

according to the information shown in this document and the standard D1P Technical Information

document.

Painting or coating can be an electric insulator if a thickness greater than 200 um is applied. The

thickness of the paining of original DPS paint is less than 200 um.

T-codes and maximum surface temperature

Gaseous environment (G)

Ambient oil temperature

Maximum oil

temperature Maximum ambient temperature

≤ 20 °C [64 °F] ≤ 40 °C [104 °F] ≤ 60 °C [140 °F]

≤ 20 °C [68 °F] T5 T5 T5

≤ 40 °C [104 °F] T5 T5 T4

≤ 60 °C [140 °F] T5 T4 T4

≤ 80 °C [176 °F] T4 T4 T3

≤ 115 °C [239 °F] T3 T3 T3

T-codes maximum surface temperature

Temperature class Maximum surface temperature

°C [°F]

T3 200 392

T4 135 275

T5 100 212

To ensure that the surface temperature will not exceed the allowed value according to the used

temperature class, it is recommended to attach a temperature sensor to the pump in the shown area on

one of the side surfaces near the maximum displacement limiter at the bottom side of the pump.

Location to attach temperature sensor

Oil types / Operating fluids

In a hydraulic system the most important task of the oil is to transfer energy. At the same time the oil

must lubricate moving parts in hydraulic components, protect them from corrosion, and transport dirt

particles and heat out of the system. To ensure that hydraulic components operate without problems

and have long operating life it is therefore vital to select the correct oil type with the necessary additives.

User Manual

ATEX certified D1P 130/145/193/260

Technical information

©Danfoss | August 2021 BC376161003883en-000101 | 7

Ratings and performance data are based on operating with hydraulic fluids containing oxidation, rust

and foam inhibitors. These fluids must possess good thermal and hydrolytic stability to prevent wear,

erosion and corrosion of pump components.

Warning

It is compulsory to use oils whose inflammable degree is at least 50K above the maximum surface

temperature of the pump. Maximum surface temperature for Group IIG and IID can be found under

Viscosity and temperature for D1P pump on page 8.

Viscosity and temperature for D1P pump

Features Data

Viscosity

Intermittent1) 5 mm2/sec [42 SUS]

Minimum 7 mm2/sec [49 SUS]

Recommended range 12 - 80 mm2[66 - 371 SUS]

Maximum (cold start)2) 1600 mm2/sec [7416 SUS]

Temperature Minimum (cold start)2) -40°C [-40°F]

Maximum intermittent1) 115°C [239°F]

1) Intermittent = Short term t < 3 min per incident.

2) Cold start = Short term t < 3 min; p ≥ 50 bar; n ≤ 1000 min-1(rpm); please contact Danfoss Power Solutions

especially when the temperature is below -25 °C [-13 °F].

Above maximum surface temperatures are without any deposited dust on the product. The possible

insulation effect of a dust layer on the surface has to be taken into account by the safety margin to the

minimum ignition temperature of the dust concerned. For up to 5 mm [1.97 in] layer thickness the safety

margin is 75°C [167°F]. For further information please see IEC 60079-14.

Warning

The above operating temperatures (ambient and oil) of the pump must be guaranteed by the end user.

Warning

It is compulsory to use oils whose inflammable degree is at least 50K above the maximum surface

temperature of the pump. See also .

Ambient temperature

Maximum ambient temperature depends on the requested ATEX class needed.

In general the ambient temperature should lie between -40° C [-40° F] and +70° C [158 °F] to ensure that

the shaft seal retains its sealing capacity.

Oil temperature

Maximum oil temperature depends on the requested ATEX class needed (in this case T3)..

Under normal operating conditions it is recommended to keep the temperature in the range of 60 °C

[140 °F] to 85 °C [185 °F].

Viscosity

Maintain fluid viscosity within the recommended range for maximum efficiency and bearing life.

Minimum viscosity should only occur during brief occasions of maximum ambient temperature and

severe duty cycle operation. Maximum viscosity should only occur at cold start. Limit speeds until the

system warms up.

User Manual

ATEX certified D1P 130/145/193/260

Technical information

8 | ©Danfoss | August 2021 BC376161003883en-000101

Fluid viscosity limits

Conditions mm2/s (cSt) SUS

Minimum 5 42

Continuous 7 49

Maximum 1600 7416

We recommend the use of an oil type having a viscosity of 12 - 80mm2/s [66 - 371 SUS] at the actual

operating temperature.

Filtering

It is necessary to keep the level of oil contamination at an acceptable level to ensure problem-free

operation. The recommended maximum level of contamination in systems in the hydraulic pump is

22/20/16 (ISO 4406-1999).

User Manual

ATEX certified D1P 130/145/193/260

Technical information

©Danfoss | August 2021 BC376161003883en-000101 | 9

Assembly of D1 pump to the system

When assembling the pump in the machine/system it is the builder’s responsibility that the parts used

conform to the ATEX directive and that the components are assembled and running according to the

operational data/design found in product data sheets and instructions.

Only use the pump as required by the explosion protection shown on the name plate.

Always ensure that the following is maintained:

•The supporting frame, chassis, or structure of equipment containing the pump shall be constructed

of electrically conducting material and shall be so arranged as to provide a leakage path to earth

(ground) for any static electricity which occurs on the pump.

•It is compulsory to use oils whose inflammable degree is at least 50K above the maximum surface

temperature of the pump. Maximum surface temperature is 200° C for Group 11G.

•Make sure that all type of accessory installed on the pump are ATEX specified and have been installed

in accordance with ATEX requirements.

•There are no creeping metal elements external to the pump.

•There are no plastic parts that might accumulate electrostatic; or they are shielded.

•The maximum permissible oil and ambient temperature is monitored and not exceeded for the

category and temperature class of the associated zone.

Manufacture the assembly flange on the machine/system where the pump has to be installed: the

relevant surface has to be perfectly smooth, completely de-greased and non-deforming.

It is necessary to verify the perfect alignment between the pump input shaft and the counter part – the

fitment between pump shaft and application’s driven shaft must be executed so that no radial or axial

pre-load is generated – these extra loads reduce the bearings expected lifetime.

User Manual

ATEX certified D1P 130/145/193/260

Installation, operation and maintenance

10 | ©Danfoss | August 2021 BC376161003883en-000101

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