Danfoss H1B060 User manual

User Manual
ATEX Certified
Bent Axis Variable Displacement Motors
H1B060/080/110/160/210/250
www.danfoss.com

Revision history Table of revisions
Date Changed Rev
August 2021 Fixed typo and removed old Declaration of Conformity 0102
June 2021 First edition 0101
User Manual
ATEX H1 Bent Axis Variable Displacement Motors
2 | ©Danfoss | August 2021 BC382476021584en-000102

Introduction General information........................................................................................................................................................................ 4
Intended use...................................................................................................................................................................................... 4
Marking of Danfoss Bent Axis motors..................................................................................................................................4
Production place and date of motors..................................................................................................................................6
Example ATEX label - H1B........................................................................................................................................................6
Technical information ATEX technical specifications.......................................................................................................................................................7
T-codes and maximum surface temperature.........................................................................................................................7
Oil types / Operating fluids...........................................................................................................................................................8
Viscosity and temperature for H1B motors....................................................................................................................... 8
Ambient temperature................................................................................................................................................................9
Oil temperature........................................................................................................................................................................... 9
Viscosity..........................................................................................................................................................................................9
Filtering................................................................................................................................................................................................9
Installation, operation and maintenance
Assembly of H1B motor to the system...................................................................................................................................10
Operation..........................................................................................................................................................................................11
Pre-start up controls for H1B motors.................................................................................................................................11
Start up.........................................................................................................................................................................................12
Operational checks.............................................................................................................................................................12
Maintenance....................................................................................................................................................................................12
Service and repair of H1B motors.......................................................................................................................................14
Safety precautions....................................................................................................................................................................14
User Manual
ATEX H1 Bent Axis Variable Displacement Motors
Contents
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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 motorss.
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 motors.
This User Manual must lie close to the motors.
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 motors 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 motors converts hydraulic energy (pressure, oil flow) into mechanical energy (torque and
speed). They are designed for mobile and stationary applications.
The motorss fulfill the explosion requirements with the Directive 2014/34/EU for the category shown on
the name plate.
The H1B motorss 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 Bent Axis motors
The Danfoss hydraulic motors 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 H1 Bent Axis Variable Displacement Motors
Introduction
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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 NNA (temperature class T3)
CE Ex II 3G Ex h IIA T4 Gc NNB (temperature class T4)
CE Ex II 3G Ex h IIA T5 Gc NNC (temperature class T5)
For detailed information on selecting the appropriate T-codes, please see T-codes and maximum surface
temperature on page 7
User Manual
ATEX H1 Bent Axis Variable Displacement Motors
Introduction
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Production place and date of motors
The production location and date of the motors 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 - H1B
Example of ATEX label: H1B motor produced in Germany
Made in Germany
Serial No. N001623456
Model Code
Model No./Ident No.
H1B060-AT-E1ATNA
TBCNGN-NA05NN
035Z00NA
12345678
II 3G Ex h IIA T3 Gc
1
2
3
4
5
6
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 H1 Bent Axis Variable Displacement Motors
Introduction
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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 H1B Technical Information document.
Danfoss does not claim responsibility for the use of the motors in operating conditions not allowed
according to the information shown in this document and the standard H1B 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 and 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] T4 T3 T3
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 motors in the shown area on
one of the side surfaces near the maximum displacement limiter at the bottom side of the motors.
User Manual
ATEX H1 Bent Axis Variable Displacement Motors
Technical information
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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.
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 motors components.
W
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 H1B motors on page 8.
Viscosity and temperature for H1B motors
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]3)
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].
3) Must not be exceeded locally either (e.g. in the bearing area) . The temperature in the bearing area is (depending
on pressure and speed ) up to 5 °C [41 °F] higher than the average case drain temperature.
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.
W
Warning
The above operating temperatures (ambient and oil) of the motors must be guaranteed by the end user.
User Manual
ATEX H1 Bent Axis Variable Displacement Motors
Technical information
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W
Warning
It is compulsory to use oils whose inflammable degree is at least 50K above the maximum surface
temperature of the motors. 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.
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 motors is
22/20/16 (ISO 4406-1999).
User Manual
ATEX H1 Bent Axis Variable Displacement Motors
Technical information
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Assembly of H1B motor to the system
When assembling the motor 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 motor 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 motor 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 motor.
•It is compulsory to use oils whose inflammable degree is at least 50K above the maximum surface
temperature of the motor. Maximum surface temperature is 200° C for Group 11G.
•Make sure that all type of accessory installed on the motor are ATEX specified and have been installed
in accordance with ATEX requirements.
•There are no creeping metal elements external to the motor.
•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 motor 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 motor output shaft and the counter part – the
fitment between motor 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 H1 Bent Axis Variable Displacement Motors
Installation, operation and maintenance
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Operation
The purpose of this section is to indicate the necessary procedures to perform the motors start up.
Pre-start up controls for H1B motors
Before performing the first motors start up, the following points have to be checked.
Hydraulic components must be installed in accordance with their individual instruction.
1. To avoid contamination, plastic plugs in connection ports must not be removed until just before
connections are made.
2. Make sure the motors hydraulic connections allow the motors to rotate in the desired direction. For
motorss with standard direction of rotation:
Clockwise rotation (viewed facing the output shaft) with inlet pressure in the front port.
Counter-clockwise rotation (viewed facing the output shaft) with inlet pressure in the rear port.
CCW CW
P006032
B
A
Generic illustration shown.
3. Select the hydraulic fluid as specified in Oil types / Operating fluids.
4. Ensure full contact between motors mounting flange and connecting part.
Avoid pressing the motors into place by tightening the fixing bolts. Avoid unsuitable seal materials,
for example, twine and Teflon, on threaded unions. Use only the seals supplied, such as O-rings, steel
washers.
5. Make sure that all couplings are completely tightened to prevent leakage.
Do not use more torque than the maximum values given in the instructions.
6. Check to make sure the purity of the oil is greater than 22/20/16 (ISO 4406-1999) and always use a
filter when replenishing the system.
W
Warning
The motors must be filled with fluid prior to any load applications.
User Manual
ATEX H1 Bent Axis Variable Displacement Motors
Installation, operation and maintenance
©Danfoss | August 2021 BC382476021584en-000102 | 11

Start up
During and immediately after the motors start up, any hydraulic system must be closely and frequently
checked.
1. To assure best motors performance, run the motors for approximately one hour at 30% of rated
pressure and speed before running at full load.
When running make sure the motors and oil temperature and noise level are sufficiently low. High
temperature or noise level might be symptoms of unforeseen operation conditions that have to be
analyzed and cleared.
2. Check for system leakage and make sure the system is operating satisfactorily.
3. To ensure that the contamination in the hydraulic system does not damage the motors; the following
procedure is recommended after a brief period in operation:
a) After a brief period in operation, have a hydraulic fluid specimen analyzed for the required
cleanliness level.
b) Replace oil filter or change the hydraulic fluid if the required cleanliness level is not reached.
Operational checks
The product is a component which requires no settings or changes during operation.
The machine/system manufacturer is responsible for the proper project planning of the hydraulic system
and its control.
Danfoss recommends ongoing tests for optimal motors performance.
1. Regularly verify that the temperature of the ambient and the operating oil are those initially
determined.
2. Do not subject the motors to pressure, pressure drop or speeds exceeding the maximum values
stated in the appropriate catalogs.
3. Filter the oil to maintain the grade of contamination at 22/20/16 (ISO 4406-1999) or better.
Maintenance
W
Warning
If maintenance has to be performed in an explosive and hazardous atmosphere, an anti-sparking safety
tool must be used.
User Manual
ATEX H1 Bent Axis Variable Displacement Motors
Installation, operation and maintenance
12 | ©Danfoss | August 2021 BC382476021584en-000102

•With hydraulic systems the main criterion for reliability and operating life is very thorough regularly
maintenance.
•Regularly check the system for presence of leakage and the oil level.
•During system’s function, it is necessary regularly to verify that the temperature of the ambient and
the operating oil are those initially determined.
•Replenish and change the oil, the oil and air filters as stated in the respective instructions.
•Regularly check the condition of the oil – viscosity, oxidation, filtration level etc.
Viscosity Verify that the viscosity level is within the recommended values as indicated in
Viscosity and temperature for H1B motors on page 8.
Oxidation Mineral oil gets oxidized proportional to the usage degree and operating
temperature. The oxidation of oil is evident because of its change of color, bad
smell, acidity increase and because of the generation of sludge inside the tank.
In case symptoms of this kind are detected, the system oil must be immediately
changed.
Water presence The presence of water inside oil can be determined by taking oil samples from
the bed of the oil tank: oil floats on water, if present, water tends to stay on the
tank’s bed. If its presence is determined, water must be regularly purged.
Presence of water in the hydraulic system can severely damage the motors.
Degree of
contamination
A high degree of contamination of the operating oil causes a severe wear of all
hydraulic components: for this reason, the cause of the contamination must be
identified and eliminated. In order to avoid mixing of different oils, when
replacing the operating fluid. It is necessary to empty all the machinery and
pipes, clean them carefully and clean the tank.
User Manual
ATEX H1 Bent Axis Variable Displacement Motors
Installation, operation and maintenance
©Danfoss | August 2021 BC382476021584en-000102 | 13

Service and repair of H1B motors
In case a service or repair intervention on the motors is required, it must be performed according to the
information shown in below mentioned Repair Instructions.
The Repair Instruction includes the spare part list and information about how dismantling and
assembling of the motors is done properly.
Only Authorized Service Centers may perform repairs specified in the Repair Instructions.
•H1 Bent Axis Variable Displacement Motors Repair Instructions: Literature number AX152886484588.
Safety precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others
from injury. Take the following general precautions whenever servicing a hydraulic system.
Tools
W
Warning
It is compulsory to use anti sparking safety tools in case the service/repair activity has to be performed in
explosive hazardous atmosphere.
Unintended machine movement
W
Warning
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.
To protect against unintended movement, secure the machine or disable/disconnect the mechanism
while servicing. Follow the manufacturers instructions for securing the machine.
Personal safety
W
Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
Flammable cleaning solvents
W
Warning
Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area
where a source of ignition may be present.
Fluid under pressure
W
Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious
injury and/or infection. This fluid may also be hot enough to cause burns. Use caution when dealing with
hydraulic fluid under pressure. Relieve pressure in the system before removing hoses, fittings, gauges, or
components. Never use your hand or any other body part to check for leaks in a pressurized line. Seek
medical attention immediately if you are cut by hydraulic fluid.
User Manual
ATEX H1 Bent Axis Variable Displacement Motors
Installation, operation and maintenance
14 | ©Danfoss | August 2021 BC382476021584en-000102

Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and
electric components. We specialize in providing state-of-the-art technology and solutions
that excel in the harsh operating conditions of the mobile off-highway market as well as the
marine sector. Building on our extensive applications expertise, we work closely with you to
ensure exceptional performance for a broad range of applications. We help you and other
customers around the world speed up system development, reduce costs and bring vehicles
and vessels to market faster.
Danfoss Power Solutions – your strongest partner in mobile hydraulics and mobile
electrification.
Go to www.danfoss.com for further product information.
We offer you expert worldwide support for ensuring the best possible solutions for
outstanding performance. And with an extensive network of Global Service Partners, we also
provide you with comprehensive global service for all of our components.
Local address:
Danfoss
Power Solutions GmbH & Co. OHG
Krokamp 35
D-24539 Neumünster, Germany
Phone: [phone]
Danfoss
Power Solutions ApS
Nordborgvej 81
DK-6430 Nordborg, Denmark
Phone: [phone]
Danfoss
Power Solutions (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: [phone]
Danfoss
Power Solutions Trading
(Shanghai) Co., Ltd.
Building #22, No. 1000 Jin Hai Rd
Jin Qiao, Pudong New District
Shanghai, China 201206
Phone: [phone]
Danfoss 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
already on order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
©Danfoss | August 2021 BC382476021584en-000102
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