Danfoss APP 16/1200 User Manual Download

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APP 16-22

User manual

Installation, Operation and
Maintenance Manual

APP pumps (APP 16-22)

MAKING MODERN LIVING POSSIBLE

Lenntech

LQIR#OHQQWHFKFRP

Tel. +31-152-610-900

ZZZOHQQWHFKFRP

Fax. +31-152-616-289

LQIR#OHQQWHFK

FRP

Tel. +31-152-610-900

ZZZOHQQWHFKFRP

Fax. +31-152-616-289

Lenntech

Summary of Contents for APP 16/1200

Page 1: ...ion and Maintenance Manual APP pumps APP 16 22 MAKING MODERN LIVING POSSIBLE Lenntech LQIR OHQQWHFK FRP Tel 31 152 610 900 ZZZ OHQQWHFK FRP Fax 31 152 616 289 LQIR OHQQWHFK FRP Tel 31 152 610 900 ZZZ...

Page 2: ...nspection transportation handling lifting and storage 9 4 1 Arrival inspection 9 4 2 Warning 9 4 3 General safety information 9 4 4 Transport and handling 9 4 5 Return to supplier 10 4 6 Storage 10 5...

Page 3: ...4 Disassembling and assembling the pump unit 15 7 5 Assembling the pump unit 16 7 6 Procedure for mounting pump back onto electric motor 16 7 7 Getting the pump unit back into operation 16 7 8 Storag...

Page 4: ...0 Code no 180B3254 Serial no 01 APP 16 1500 Code no 180B3250 Serial no 01 APP 17 1200 Code no 180B3255 Serial no 01 APP 17 1500 Code no 180B3251 Serial no 01 APP 19 1200 Code no 180B3256 Serial no 01...

Page 5: ...5 180R9265 IOM APP Pumps v01 01 2013 EU Declaration of Conform ity...

Page 6: ...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...

Page 7: ...must be verified and free flow from safety valves must be ensured All pipe and hose connections must be stress free mounted securely fastened to the pumps and well supported Improper installation wil...

Page 8: ...replacement of the complete motor pump unit it is recommended having sufficient space around the unit For easy access to the unit at least 1 meter 40 inches available space should be kept free around...

Page 9: ...ed 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 w...

Page 10: ...t the unit load is balanced before attempting to lift as the centre of the mass is different from pump to pump and pump unit to pump unit How to mount the pump and the electric motor correctly togethe...

Page 11: ...be corroded If dirt or rust is not removed the pump and the valves can be damaged and in the worst case damaged beyond repair 5 3 Fluid temperature Before start up the fluid and pump housing temperatu...

Page 12: ...n outlet CP13 Check piping for possible air gaps 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 i...

Page 13: ...e hole in the bell housing not available on all bell houses If the motor is turning the wrong direction switch two phases in the connection box of the motor or reprogram the direction in VFD 5 17 Comm...

Page 14: ...Very high temperatures can indicate one or more damaged parts inside the pump The pump then needs to be stopped immediately and inspected before running again Contact the maintenance depart ment G Dro...

Page 15: ...or 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 hous...

Page 16: ...the coupling manufacturer Mount the flexible coupling and bell housing according to the Data sheet appendix 1 and APP pump instruction appendix 2 7 7 Getting the pump unit back into operation Find ins...

Page 17: ...the high pressure can lead to eye or skin damage Leaking can result in flooding which again can cause a risk of slipping tripping or falling If water is dripping into the electric motor it can lead t...

Page 18: ...tor 6 8 Dimensions 8 11 Disassembling 15 16 E Electric motor 6 7 8 9 10 11 12 13 16 17 Electrical failure 17 Electrical hazard 6 Electrics 12 EU Declaration of Conformity 5 F Failure 8 17 Filter condi...

Page 19: ...Front page for Appendices APP 16 22 User manual Appendices for Installation Operation and Maintenance Manual APP pumps APP 16 22 MAKING MODERN LIVING POSSIBLE...

Page 20: ...2013 Table of Contents 1 Data sheet for APP 16 22 pumps 521B1183 3 2 APP pump instruction APP 11 13 and APP 16 22 180R9223 15 3 IOM Electric motors 180R9230 27 4 Recommended service intervals for APP...

Page 21: ...1 Data sheet for APP 16 22 pumps 521B1183 ro solutions com Data sheet Data sheet APP 16 22 MAKING MODERN LIVING POSSIBLE...

Page 22: ...alt water to flow from inlet to the outlet when the pump is not running 1 General information 1 Shaft Sealing 2 Bolts for bell housing 3 Flushing valve 4 Port plate 5 Bleeding plug 6 Valve thrust plat...

Page 23: ...ous 3 bar 80 70 80 70 80 70 80 70 psi 1160 1015 1160 1015 1160 1015 1160 1015 Inlet min Pressure bar 2 2 2 2 2 2 2 2 psi 29 29 29 29 29 29 29 29 Inlet max Pressure continuous bar 5 5 5 5 5 5 5 5 psi 7...

Page 24: ...quired and the rotation speed rpm of the pump are known 5 00 8 00 11 00 14 00 17 00 20 00 23 00 700 800 900 1000 1100 1200 m3 h rpm 1200 rpm version APP 22 APP 19 APP 17 APP 16 5 00 8 00 11 00 14 00 1...

Page 25: ...41 kW 1480 511 APP 17 1200 287 17 2 75 8 35 kW 40 kW 46 kW 1180 498 APP 17 1500 281 16 9 74 2 33 kW 38 kW 44 kW 1480 513 APP 19 1200 314 18 8 82 9 38 kW 44 kW 50 kW 1180 499 APP 19 1500 313 18 8 82 7...

Page 26: ...4 dB at 80 bar 1500rpm Generally noise will be reduced if speed is reduced and vice versa Use flexible hoses in order to minimize vibrations and noise Since the pump is typically mounted on a bell hou...

Page 27: ...epth filter cartridges rated 10 m abs 10 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...

Page 28: ...AF 6 mm Inlet port M52 x 1 5 depth 21 mm Outlet port M52 x 1 5 depth 21 mm Pump mounting flange 125 B 4 Accessories Type Code no 2 inlet hose kit 2 m 79 2 Victaulic 180Z0298 2 inlet Vic Super Duplex 2...

Page 29: ...EC motors and couplings Please always check required motor power and dimensions 13 2 Open ended system with direct water supply In order to eliminate the risk of cavitation a positive inlet pressure i...

Page 30: ...d flow backwards in case of the pump stops momentarily 8 A safety valve or a pressure relief valve 8 can be installed in order to avoid system damage as the Danfoss APP pump creates pressure and flow...

Page 31: ...13 180R9265 IOM APP 16 22 Appendices v02 01 2013 Data sheet APP 16 22...

Page 32: ...r its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed A...

Page 33: ...2 APP pump instruction APP 11 13 and APP 16 22 180R9223 www ro solutions com Instruction APP pump instruction APP 11 13 and APP 16 22 MAKING MODERN LIVING POSSIBLE...

Page 34: ...en ended systems with direct water supply 2 2 Preferred RO system design and P ID 2 3 Reversible pumps 2 4 General comments on 3 Building up the pump unit 3 1 Mounting 3 2 Direction of rotation 3 3 Or...

Page 35: ...d 5 bar 72 5 psi continuously 1 Place the filter 1 in the water supply line in front of the pump 2 Place a monitoring pressure switch 3 between filter and pump inlet set at min 2 bar 29 psi inlet pres...

Page 36: ...ed 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 st...

Page 37: ...unt 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...

Page 38: ...ecommended 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 label 3 3 Orientation The...

Page 39: ...ced as close to the pump as possible The opening characteristics of the valve must not result in peak pressures higher than 80 bar 1 160 psi Both the inlet and outlet lines must be flexible soft hoses...

Page 40: ...Super Duplex 1 5 Victaulic OD 48 3 mm 180H0053 For more details on the accessories please contact the Danfoss RO Solutions Sales Organisation 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: ...torage 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 f...

Page 43: ...t will strongly influence the life of the APP pumps 6 2 Maintenance After 8 000 hours of operation it is strongly recommended to inspect the pump and change any worn parts e g pistons and shaft seal T...

Page 44: ...the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specification...

Page 45: ...27 180R9265 IOM APP 16 22 Appendices v02 01 2013 3 IOM Electric motors 180R9230 Electric Motors Motor Manual hoyermotors com Manual 180R9230...

Page 46: ...ubled supply frequency Only mount or remove drive components pulley coupling etc using suitable tools never hit the drive components with a hammer as this will cause damage to the bearing The motor ar...

Page 47: ...will be found in agricultural areas and in industrial environments Only one electrical installation may be installed in one specified area zone Only certificated cable glands for category 2D may be u...

Page 48: ...Motor Manual...

Page 49: ...4 Recommended service intervals for APP pumps 180R9199 Instruction Recommended service intervals for APP pumps MAKING MODERN LIVING POSSIBLE...

Page 50: ...3 5 7 9 Back up ring Teflon 24 000 hours O ring overall NBR 24 000 hours Screw overall AISI 316 No wear part Pin overall AISI 316 Duplex or PEEK No wear part 152 1 Valve cone flushing valve Duplex or...

Page 51: ...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 52: ...the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specification...

Page 53: ...5 APP parts list 521B0941 Parts list APP Pumps APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 MAKING MODERN LIVING POSSIBLE APP 16 22 APP 16 22...

Page 54: ...wash plate Super Duplex PEEK x 31 1 Swash plate Super Duplex PEEK x 31 1 Swash plate Super Duplex PEEK x 31 1 Swash plate Super Duplex PEEK x 31 1 Swash plate Super Duplex PEEK x 34 2 Pin 10 5 x 20 Du...

Page 55: ...37 180R9265 IOM APP 16 22 Appendices v02 01 2013 Parts list APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 16 Exploded view APP 16 19 Exploded view APP 16 19...

Page 56: ...PEEK x 62 7 Spring Duplex x 63 1 Spring guide PP x 64 1 Retainer ball Super Duplex x 65 1 Retainer plate Super Duplex x 66 7 Piston Super Duplex PEEK x 67 1 Key 12 x 8 x 70 AISI 316 81 3 Pin 6 4 x 40...

Page 57: ...39 180R9265 IOM APP 16 22 Appendices v02 01 2013 Parts list APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 18 Exploded view APP 22 Exploded view APP 22...

Page 58: ...DK 6430 Nordborg Denmark Designation 180B4188 Tool set APP 0 6 1 0 Compact 180B4142 Tool set APP 0 6 1 0 180B4148 Tool set APP 1 5 3 5 180B4162 Tool set APP 5 1 10 2 180B4230 Tool set APP 11 13 180B42...

Page 59: ...6 Trouble shooting guide Guideline Trouble shooting guide for APP pumps MAKING MODERN LIVING POSSIBLE...

Page 60: ...umps Trouble shooting guide for APP pumps Table of Contents Trouble shooting fish bone chart 1 No flow no pressure 2 Reduced flow reduced pressure 3 High torque on electric motor 4 Noise from pump 5 N...

Page 61: ...filtration 2 1 Wear in pump internal leakage 2 1 9 Type of fluid 2 1 11 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 4...

Page 62: ...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 check that electric motor is sized correctly 1 4 No rotation o...

Page 63: ...e 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 t...

Page 64: ...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 Pumps run in parallel with cascade...

Page 65: ...w 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 eventuall...

Page 66: ...many bends may create too fast flow turbulence through the pipes and thus increase the noise level 5 3 Hose stiffness 5 3 1 Use amore flexible hose Danfoss A S can provide flexible hoses Please contac...

Page 67: ...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...

Page 68: ...ademarks of Danfoss A S All rights reserved Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Picture 1 If the port plate has scratches level differences or both between the arrows the port pla...

Page 69: ...7 Right and wrong 180R9042 MAKING MODERN LIVING POSSIBLE 180R9042 Right and wrong Trouble shooting guide for water hydraulic systems...

Page 70: ...ter upstream of the final load may damage the pump Pump location 4 Pump always to be placed below water surface level Pump location above water surface level will cause damage Water supply 7 System to...

Page 71: ...f grease prevent seizing Too much grease may develop biofilm causing operational failures Water supply 13 Fill system with water before starting to ensure lubrication and cooling Starting without wate...

Page 72: ...e 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 component...

Page 73: ...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 lights on Is the filter clogged Is the filter control light o...

Page 74: ...s 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 into the system Trace leakage if any A blown...

Page 75: ...User manual Appendices for IOM Manual for APP Pumps APP 16 22 57 180R9265 IOM APP 16 22 Appendices v02 01 2013...

Page 76: ...ovided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss...

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