Danfoss D1P130 User manual

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

Operation
The purpose of this section is to indicate the necessary procedures to perform the pump start up.
Pre-start up controls for D1P pump
Before performing the first pump 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 pump hydraulic connections allow the pump to rotate in the desired direction. For
pumps 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.
Generic illustration shown.
3. Select the hydraulic fluid as specified in Oil types / Operating fluids.
4. Ensure full contact between pump mounting flange and connecting part.
Avoid pressing the pump 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 pump must be filled with fluid prior to any load applications.
User Manual
ATEX certified D1P 130/145/193/260
Installation, operation and maintenance
©Danfoss | August 2021 BC376161003883en-000101 | 11

Start up
During and immediately after the pump start up, any hydraulic system must be closely and frequently
checked.
1. To assure best pump performance, run the pump for approximately one hour at 30% of rated
pressure and speed before running at full load.
When running make sure the pump 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 pump; 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 pump performance.
1. Regularly verify that the temperature of the ambient and the operating oil are those initially
determined.
2. Do not subject the pump 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.
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ATEX certified D1P 130/145/193/260
Installation, operation and maintenance
12 | ©Danfoss | August 2021 BC376161003883en-000101

•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 D1P pump 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 pump.
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 certified D1P 130/145/193/260
Installation, operation and maintenance
©Danfoss | August 2021 BC376161003883en-000101 | 13

Service and repair of D1P pump
In case a service or repair intervention on the pump 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 pump is done properly.
Only Authorized Service Centers may perform repairs specified in the Repair Instructions.
•D1 High Power Open Circuit Pumps Repair Instructions: Literature number AX195286485156.
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 certified D1P 130/145/193/260
Installation, operation and maintenance
14 | ©Danfoss | August 2021 BC376161003883en-000101

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 BC376161003883en-000101
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