Danfoss APP 13 User Manual Download

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180R9264 | AQ115586503043en-000903 | 1

Operation guide.

APP pumps

APP 11 / APP 13

Installation, Operation and

Maintenance Manual

hpp.danfoss.com

Summary of Contents for APP 13

Page 1: ...Danfoss 2023 03 180R9264 AQ115586503043en 000903 1 Operation guide APP pumps APP 11 APP 13 Installation Operation and Maintenance Manual hpp danfoss com...

Page 2: ...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 t...

Page 3: ...o 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 failu...

Page 4: ...x 1500 180B3221 Serial no XXXXXX04 XXX XXXXXX04 XXX APP 13 1200 Code no 180B3214 APP 13 Ex 1200 180B3224 Serial no XXXXXX04 XXX XXXXXX04 XXX APP 13 1500 Code no 180B3213 APP 13 Ex 1500 180B3223 Serial...

Page 5: ...mechanical and electrical parts Decommissioning the pump unit The pump must always be installed and used in accordance with existing national local sanitary safety regulations and laws It is the resp...

Page 6: ...ys be supplied with adequate cooling ventilation When using an electric motor together with a VFD the motor must be designed for operation with a VFD VFD operation may increase the temperature inside...

Page 7: ...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 worki...

Page 8: ...ubbles can cause cavitation 3 10 Chemicals The pump should not be exposed to any chemicals as it can result in damage to piping equipment and internal parts in the pump 4 1 Arrival inspection The pump...

Page 9: ...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 Sto...

Page 10: ...or rust is not removed the pump and the valves can be damaged In worst case the pump can be damaged beyond repair 5 3 Fluid temperature Before start up the fluid and pump housing temperature must be...

Page 11: ...tlet CP13 Check piping for possible air gaps 5 7 Lifting and positioning Lift the pump unit onto base Remember vibration dampeners if needed Fasten the motor to the base See also chapter 4 Arrival ins...

Page 12: ...housings 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 When the motor is turning...

Page 13: ...or inspection as recommended it can lead to damage of the pump or break down See also service and warranty section in the appendix 1 Data sheet in appendix 2 Instruction or appendix 4 Instruction for...

Page 14: ...ng and Assembling Instruction available at www ro solutions danfoss com Clean all parts and surfaces with a fluid compatible with the materials found in the pump Wipe the parts clean and dry with a li...

Page 15: ...ding which can cause slipping tripping or falling If water is leaking into the electric motor it can cause electric shock fire short circuit or even death When mounting the pump vertically always moun...

Page 16: ...16 180R9264 AQ115586503043en 000903 Danfoss 2023 03 Operating guide Installation Operation and Maintenance APP 11 13...

Page 17: ...503043en 000903 17 Danfoss 2023 03 Operating guide Installation Operation and Maintenance APP 11 13 Operation guide APP pumps APP 11 APP 13 Appendices for Installation Operation and Maintenance Manual...

Page 18: ...or APP pumps APP 11 13 AI274333290009en 000701 19 2 Pump instruction APP 11 13 180R9223 33 3 IOM Electric Motors 180R9230 45 4 Recommended service intervals for APP pumps AX290244627150en 000201 51 5...

Page 19: ...Danfoss 2023 03 180R9264 AQ115586503043en 000903 1 Data sheet APP Pumps APP 0 6 1 0 APP 1 5 3 5 APP W 5 1 10 2 APP 11 13 APP 16 22 APP 21 46 hpp danfoss com...

Page 20: ...at 60 barg 870 psig 23 6 Flushing valve curves 24 6 4 APP 11 13 integrated flushing valve 24 7 Motor requirements 25 7 4 Calculation factor for APP 11 13 25 8 Temperature and corrosion 26 8 1 Tempera...

Page 21: ...tions please see data sheets for APP S all super duplex and APP S 674 API Positive Material Identification PMI report available on request IATF 16949 ISO 9001 ISO 14001 3 Application examples Danfoss...

Page 22: ...00 rpm at max pressure m h 11 25 13 84 1200 rpm at max pressure gpm 48 71 39 61 58 51 48 75 Technical specifications Media 2 temperature C 2 50 2 50 2 50 2 50 F 35 6 122 35 6 122 35 6 122 35 6 122 Amb...

Page 23: ...0 0 45 0 50 0 55 0 60 0 65 0 1 2 0 0 1 3 0 0 1 4 0 0 1 5 0 0 1 1 0 0 1 0 0 0 9 0 0 8 0 0 7 0 0 1 2 0 0 1 3 0 0 1 4 0 0 1 5 0 0 1 1 0 0 1 0 0 0 9 0 0 8 0 0 7 0 0 APP 11 1500 APP 11 1500 APP 13 1500 APP...

Page 24: ...urves All pumps except APP W 5 1 10 2 are supplied with an integrated flushing valve that allows the fluid to flow from inlet to the outlet when the pump is not running 6 4 APP 11 13 integrated flushi...

Page 25: ...uiding equations 7 Motor requirements l min x barg 16 7 x m3 h x barg 0 35 x gpm x psig Required power kW or kW or Calc factor Calc factor Calc factor 1 hp 0 75 kW 1 gpm 3 79 l min 1 m3 h 4 40 gpm 1 k...

Page 26: ...water pump is made of Duplex and Super Duplex If the water pump is operated above the Duplex line always flush water pump with fresh water at operation stop in order to minimize the risk of crevice c...

Page 27: ...harge pressure High pressure generates more noise than low pressure Pump mounting Rigid mounting generates more noise than flexible mounting because of structure borne vibrations Be sure to use damper...

Page 28: ...ressure a safey or pressure relief valve 8 should be installed after the non return valve to prevent system damage and to avoid high pressure peaks Note If a non return valve is mounted in the inlet l...

Page 29: ...Operating guide Installation Operation and Maintenance APP 11 13 10 Dimensions and connections 10 4 APP 11 13 Accessories see section 12 Fore more details on the accessories please contact the Danfos...

Page 30: ...selecting size of pump and motor For ad vice and calculation tool please contact Danfoss 11 3 APP 11 0 13 0 Pump A mm inch B mm inch C mm inch D mm inch E mm inch F mm inch G mm inch IEC Electric mot...

Page 31: ...enance APP 11 13 12 Accessories 12 2 Accessories for APP 11 13 Accessories Type Code No 2 inlet hose kit 2m 79 2 Victaulic 180Z0298 1 outlet hose 1 16m 45 7 1 Victaulic 180Z0167 2 inlet Vic Super Dupl...

Page 32: ...pecifications Maintenance Periodic inspections are required to ensure worn parts if any are replaced in due time Opera tional conditions such as water quality should be taken into consideration when d...

Page 33: ...Danfoss 2023 03 180R9264 AQ115586503043en 000903 1 Instruction APP pumps APP 11 APP 13 APP 16 APP 17 APP 19 APP 22 hpp danfoss com...

Page 34: ...Building up the pump unit 37 3 1 Mounting 37 3 2 Direction of rotation 38 3 3 Orientation 38 3 4 Protection against too high outlet pressure 39 3 5 Connections 39 4 Initial start up 40 5 Operation 41...

Page 35: ...psig is always to be maintained but it must not exceed 5 barg 72 5 psig continuously 1 Place the filter 1 in the water supply line in front of the pump 2 Place a monitoring pressure switch 3 between...

Page 36: ...red between non return valve and pump as protection against high pressure peaks 2 3 Reversible pumps If exposed to high pressure in the outlet while the electric motor is not energized the pump will s...

Page 37: ...sing 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 T...

Page 38: ...care to observe the recommended length tolerances of the chosen coupling as an axial force on the pump will damage the pump 3 2 Direction of rotation Is indicated by means of an arrow on the pump lab...

Page 39: ...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 80 barg 1160 psig Bo...

Page 40: ...rn valve outlet Super Duplex 1 5 Victaulic OD 48 3 mm 180H0053 For more details on the accessories please contact Danfoss High Pressure Pumps Description APP 16 APP 22 Parallel key DIN 6885 mm 12 8 70...

Page 41: ...etc 3 Loosen top bleeding plug C see item 3 3 using an allen key only plugs with internal hexagan sockets Retighten the plug when water appears from the bleeding plug 4 Make sure that the direction o...

Page 42: ...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...

Page 43: ...and still The APP pumps are made of Duplex Super Duplex materials with excellent corrosion properties It is however always recommended to flush the pump with freshwater when the system is shut down Wh...

Page 44: ...Danfoss DCS SGDPT SI 2023 03 44 180R9264 AQ115586503043en 000903 Operating guide Installation Operation and Maintenance APP 11 13 Instruction 180R9223 521B1184 DKCFN PI 013 T3 02...

Page 45: ...86503043en 000903 45 Danfoss 2023 03 Operating guide Installation Operation and Maintenance APP 11 13 M a n u a l Electric Motors Motor Manual hoyermotors com M a n u a l Electric Motors Motor Manual...

Page 46: ...ces 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 e...

Page 47: ...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 fre...

Page 48: ...000903 Danfoss 2023 03 Operating guide Installation Operation and Maintenance APP 11 13 Connection diagram Anschlu diagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexi n C...

Page 49: ...180R9264 AQ115586503043en 000903 49 Danfoss 2023 03 Operating guide Installation Operation and Maintenance APP 11 13...

Page 50: ...cn Branch Offices Germany Landsberger Stra e 155 80687 M nchen 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 Stockho...

Page 51: ...Danfoss 2023 03 180R9264 AQ115586503043en 000903 1 Instruction APP pumps APP 11 22 Recommended service intervals hpp danfoss com...

Page 52: ...000 hours 32 000 hours 125 1 Cover flange for shaft seal Super Duplex No wear part No wear part 93 5 7 9 Back up ring PTFE 24 000 hours 24 000 hours O ring overall NBR 24 000 hours 24 000 hours Screw...

Page 53: ...ictures below is ment as a guideline for evaluating the wear of the sliding surface Cavitation of the piston shoes New inspection is required in 3 000 4 000 hours Cavitation of the piston shoes All pi...

Page 54: ...Danfoss DCS SGDPT SI 2023 03 54 180R9264 AQ115586503043en 000903 Operating guide Installation Operation and Maintenance APP 11 13 AX290244627150en 000201 Instruction...

Page 55: ...Danfoss 2023 03 180R9264 AQ115586503043en 000903 1 Parts list APP pumps APP 0 6 46 APM 0 8 2 9 APP W 5 1 10 2 hpp danfoss com...

Page 56: ...3en 000903 Danfoss 2023 03 Operating guide Installation Operation and Maintenance APP 11 13 Parts list Table of Contents 1 General 57 12 Parts list APP 11 13 58 13 Exploded view APP 11 13 59 22 Tool s...

Page 57: ...nd Maintenance APP 11 13 Parts list This parts list provides an overview of the content of the various service sets as well as explodede views for both non ATEX and ATEX certified pumps ATEX certified...

Page 58: ...1 Cylinder barrel Super Duplex Duplex PEEK x 62 7 Spring Duplex x 63 1 Spring guide PP x 64 1 Retainer ball Super Duplex DLC x 65 1 Retainer plate Super Duplex x 66 7 Piston Super Duplex PEEK x 67 1 K...

Page 59: ...180R9264 AQ115586503043en 000903 59 Danfoss 2023 03 Operating guide Installation Operation and Maintenance APP 11 13 13 Exploded view APP 11 13 Parts list...

Page 60: ...bush x Press bush x Drift x Torx T30 x Shaft bush 18 x x Press bush 18 x x Allen key 4 mm x Allen key 5 mm x Allen key 6 mm x x x x Shaft bush 35 x Shaft seal extractor 35 x x Press bush 35 x x Adjust...

Page 61: ...180R9264 AQ115586503043en 000903 61 Danfoss 2023 03 Operating guide Installation Operation and Maintenance APP 11 13 Parts list...

Page 62: ...Danfoss DCS SGDPT SI 2023 03 62 180R9264 AQ115586503043en 000903 Operating guide Installation Operation and Maintenance APP 11 13 Parts list AX274346749037en 000501...

Page 63: ...Danfoss 2023 03 180R9264 AQ115586503043en 000903 1 Guideline Trouble shooting guide APP APP S and APP S 674 pumps hpp danfoss com...

Page 64: ...13 Table of contents Table of Contents Trouble shooting fish bone chart 67 1 No flow no pressure 68 2 Reduced flow reduced pressure 69 3 High torque on electric motor 70 4 Noise from pump 71 5 Noise f...

Page 65: ...Main filtration 2 1 Wear in pump internal leakage 2 1 7 Fluid type 2 1 8 High fluid temperature 4 1 Air in fluid 4 2 Bleeding conditions of pump 4 3 Min max nominal inlet pressure 4 4 Pump reversing...

Page 66: ...at 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 If motor type relay or the electrical fuse is blown...

Page 67: ...orn 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 chann...

Page 68: ...otor 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 Pumps run in parallel with cascade start may switc...

Page 69: ...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 event...

Page 70: ...t flow turbulence through the pipes and thus increase the noise level 5 3 Hose stiffness 5 3 1 Use a more flexible hose Danfoss can provide flexible hoses Please contact Danfoss High Pressure Pumps sa...

Page 71: ...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 possi...

Page 72: ...e item 6 1 picture 3 6 2 Port plate 6 3 Swash plate Picture 1 If the swash plate is polished 360 it is an indication of insufficient filtration The surface of the swash plate must be plane and even at...

Page 73: ...180R9264 AQ115586503043en 000903 73 Danfoss 2023 03 Operating guide Installation Operation and Maintenance APP 11 13 Instruction...

Page 74: ...Danfoss DCS SGDPT SI 2023 03 74 180R9264 AQ115586503043en 000903 Operating guide Installation Operation and Maintenance APP 11 13 Instruction...

Page 75: ...Danfoss 2023 03 180R9264 AQ115586503043en 000903 1 Service guide Right and wrong Trouble shooting guide for water hydraulic systems hpp danfoss com...

Page 76: ...urn line immediately before the tank Placing the return filter upstream of the final load may damage the pump Pump location 4 Pump always to be placed below water surface level Pump location above wat...

Page 77: ...s may cause damage Grease 10 Correctly limited quantities of grease prevent seizing Too much grease may develop biofilm causing operational failures Water supply 13 Fill system with water before start...

Page 78: ...er 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 solut...

Page 79: ...in the tank very hot Ie above 50 o Lower inlet temperature or provide better cooling Is the control light for low pump suction pressure on The filter is clogging Is the power supply ok Are control lig...

Page 80: ...ater in the tank very hot Ie above 50 o Is the power supply ok Are control lights on Is the filter clogged Is the filter control light on Replace filter element Contact serviceman Stamp Fill water int...

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