Danfoss APP series User Manual Download

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ro-solutions.com

APP 1.5-3.5

User manual

Installation, Operation and

Maintenance Manual

APP pumps (APP 1.5-3.5)

MAKING MODERN LIVING POSSIBLE

Summary of Contents for APP series

Page 1: ...ro solutions com APP 1 5 3 5 User manual Installation Operation and Maintenance Manual APP pumps APP 1 5 3 5 MAKING MODERN LIVING POSSIBLE...

Page 2: ...l inspection 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...

Page 3: ...it back into operation 15 7 8 Storage of the pump 15 8 Troubleshooting and scrapping criteria 16 8 1 General safety information 16 8 2 Operational conditions which can cause pump failures 16 8 3 Mecha...

Page 4: ...manual is valid for APP pumps with the following code numbers serial numbers Validity APP 1 5 Code no 180B3043 Serial no 02 APP 1 8 Code no 180B3044 Serial no 02 APP 2 2 Code no 180B3045 Serial no 02...

Page 5: ...5 180R9267 IOM APP Pumps v02 09 2013 EU Declaration of Conform ity...

Page 6: ...e unit Servicing the pump unit mechanical and electrical parts Decommissioning the pump unit The pump must always be installed and used in accordance with existing national local sanitary safety regul...

Page 7: ...using an electric motor the motor must always 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 ope...

Page 8: ...he 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 working...

Page 9: ...es 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 is...

Page 10: ...y and or damage to the pump unit see appendix 2 Instruction 4 5 Return to supplier Please see maintenance chapter 7 4 6 Storage Each pump is tested before shipment and will therefore contain water For...

Page 11: ...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 12: ...ck 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 inspection trans...

Page 13: ...ings 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 in...

Page 14: ...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 rec...

Page 15: ...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 lint...

Page 16: ...n 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 mount the motor a...

Page 17: ...User manual Installation Operation and Maintenance APP Pumps APP 1 5 3 5 17 180R9267 IOM APP Pumps v02 09 2013...

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

Page 19: ...ro solutions com Front page for Appendices User manual Appendices for Installation Operation and Maintenance Manual APP pumps APP 1 5 3 5 APP 1 5 3 5 MAKING MODERN LIVING POSSIBLE...

Page 20: ...1 2013 Table of Contents 1 Data sheet for APP 1 5 3 5 pumps 521B0850 3 2 APP pump instruction APP 0 6 3 5 180R9065 13 3 IOM Electric motors 180R9230 21 4 Recommended service intervals for APP pumps 18...

Page 21: ...1 Data sheet for APP 1 5 3 5 pumps 521B0850 ro solutions com Data sheet APP pumps APP 1 5 3 5 MAKING MODERN LIVING POSSIBLE...

Page 22: ...hoe 5 Valve plate 6 Swash plate 7 Cylinder barrel 8 Spring 9 Port plate 10 Connecting flange 11 Housing with bearing 12 Flushing valve DATA SHEET Water Pumps APP1 5 3 5 1 General information APP1 5 AP...

Page 23: ...psi 290 290 290 290 290 290 Outlet max pressure continuous 3 bar 80 80 80 80 80 80 psi 1160 1160 1160 1160 1160 1160 Outlet max pressure intermittent 4 bar 100 100 100 100 100 100 psi 1450 1450 1450...

Page 24: ...kW 4 29 kW 2890 468 6 APP1 5 30 17 1 81 7 97 3 86 kW 4 51 kW 5 15 kW 3470 468 6 APP1 8 26 78 1 61 7 07 3 43 kW 4 00 kW 4 57 kW 2890 463 2 APP1 8 32 18 1 93 8 50 4 12 kW 4 81 kW 5 49 kW 3470 463 2 APP2...

Page 25: ...2 kW 8 2 kW 2930 470 0 APP 3 5 56 0 3 4 14 8 7 2 kW 8 4 kW 9 6 kW 2930 470 0 The power requirements can be determined using one of the following guiding equations l min bar 16 7 m3 h bar 0 26 gpm psi...

Page 26: ...e noise than low rpm Rigid mounting of the pump generates more noise than flexible mounting Pipe mounting direct to the pump increases the noise level compared to a flexible hose 9 Filtration As water...

Page 27: ...nsions 10 1 Pump Description APP 1 5 APP 3 5 A Port position mm 21 0 in 0 83 B Port position mm 21 0 in 0 83 C mm 105 in 4 1 D mm 166 in 6 5 E Parallel key DIN 6885 mm 5 5 20 in 0 20 0 20 0 78 F Bleed...

Page 28: ...2 160 254 210 505 188 166 11 kW IEC 160M1 2 APP 3 5 350 422 160 254 210 505 188 166 11 kW IEC 160M1 2 11 Installation 11 1 Mounting The figure below illustrates how to mount the pump and connect it to...

Page 29: ...front of the APP pump 2 Please consult section 9 Filtration for guidance on how to select the right filter Thoroughly clean pipes and flush system prior to start up 3 Place a monitoring pressure swit...

Page 30: ...unning according to the Danfoss specifications Danfoss guarantees 8 000 hours service free operation however max 18 months from date of produc tion If Danfoss recommendations concerning system design...

Page 31: ...2 APP pump instruction APP 0 6 3 5 180R9065 ro solutions com Instruction APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 MAKING MODERN LIVING POSSIBLE...

Page 32: ...s 2 4 General guidelines for calculation of pressure losses 2 5 General comments on 3 Building up the pump unit 3 1 Mounting 3 2 Direction of rotation 3 3 Orientation 3 4 Protection from too high pres...

Page 33: ...ld always be above the pump 2 Place the inlet filter before the tank 3 Dimension the inlet line to obtain mini mum pressure loss large flow area minimum pipe length minimum number of bends connections...

Page 34: ...can be optimized according to below guidelines 2 5 General comments on Filtration A good ltration is vital to ensure a long and trouble free life of the pump When selecting a filter or strainer pleas...

Page 35: ...recommend a separation wall to separate the inlet from the outlet end of the tank Monitoring It is recommended to continuously monitor the following conditions Water level in the tank Filter contamin...

Page 36: ...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 200 bar 2900 psi The valve outlet must not be connected d...

Page 37: ...unit should include a pressure gauge on the high pressure side 5 3 Dry running When running the pump must always be connected to the water supply in order to avoid damage if it should run dry In syst...

Page 38: ...Pressure Pumps DK 6430 Nordborg Denmark 6 1 Periodic maintenance The APP pump is designed so that lubrication follows from the water itself and there is thus no oil in the pump The pump requires no pe...

Page 39: ...21 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 3 IOM Electric motors 180R9230 Electric Motors Motor Manual hoyermotors com Manual...

Page 40: ...l frequency and the doubled 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 th...

Page 41: ...Combustible dust areas 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 fo...

Page 42: ...ary Both electrical and mechanical connections must be checked and tightened if necessary Thread M5 M6 M8 M10 M12 M16 M20 T Nm 2 5 3 5 7 12 18 35 55 Motor Manual Hoyer Motors Motor Manual October 2011...

Page 43: ...25 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013...

Page 44: ...dk http www svendhoyer dk Sverige Svend H yer AB Malm v gen 18 S 331 42 V rnamo Tel 46 37 04 77 13 Fax 46 37 01 00 46 E mail svendhoyer svendhoyer se http www svendhoyer se Norge Svend H yer AS Torve...

Page 45: ...4 Recommended service intervals for APP pumps 180R9199 ro solutions com Instruction Recommended service intervals for APP pumps MAKING MODERN LIVING POSSIBLE...

Page 46: ...e interval 1 1 Housing main bearing Duplex PEEK No need for service 11 125 211 1 Mounting flange end flange Wetted part Duplex Dry part AISI 316L No wear part 121 181 1 Port flange Duplex No wear part...

Page 47: ...ns must be replaced The pictures 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 o...

Page 48: ...aterial 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 subsequential changes being ne...

Page 49: ...ro solutions com Parts list APP Pumps APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 MAKING MODERN LIVING POSSIBLE 5 APP parts list 521B0941 APP 1 5 3 5 APM 1 8 2 9 APP 1 5 3 5...

Page 50: ...oded view APP 1 5 2 5 and APM 1 8 2 9 8 Parts list APP 3 0 3 5 9 Exploded view APP 3 0 3 5 10 Parts list APP 5 1 10 2 11 Exploded view APP 5 1 10 2 12 Parts list APP W 5 1 10 2 13 Exploded view APP W...

Page 51: ...7 DKCFN PY 011 A1 02 10 2013 This parts list provides an overview of the content of the various service sets for the PAHT 2 6 3 PAHT G 2 6 3 PAHT 10 12 5 PAHT G 10 12 5 PAHT 20 32 PAHT G 20 32 PAHT 50...

Page 52: ...ing valve set APP 1 5 3 5 Pos Qnt Designation Material 1 1 Housing Duplex PEEK 2 1 Pin 4x14 AISI 316 x 61 1 Cylinder barrel Super Duplex PEEK x 62 1 Spring Duplex x x 63 1 Spring guide PEEK x x 64 1 R...

Page 53: ...Appendices v04 11 2013 Parts list APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 9 521B0941 DKCFN PC 073 A13 02 10 2013 7 Exploded view APP 1 5 2 5 and APM 1 8 2 9 8 85 lbf ft 2 21 lbf ft 2 95 lbf ft 0 74 lbf...

Page 54: ...er Duplex x x 32 1 Centre bolt Duplex x x 33 1 Pin 6x10 PEEK x x x 61 1 Cylinder barrel Super Duplex PEEK x 62 1 Spring Duplex x 63 1 Spring guide PEEK x 64 1 Retainer ball Super Duplex x 65 1 Retaine...

Page 55: ...1 2013 Parts list APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 11 521B0941 DKCFN PC 073 A13 02 10 2013 9 Exploded view APP 3 0 3 5 8 85 lbf ft 2 21 lbf ft 2 95 lbf ft 0 74 lbf ft 2 95 lbf ft 0 74 lbf ft 8 85...

Page 56: ...A S High Pressure Pumps DK 6430 Nordborg Denmark 24 Tool sets 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 1...

Page 57: ...6 Trouble shooting guide ro solutions com Guideline Trouble shooting guide for APP and APP S 674 pumps MAKING MODERN LIVING POSSIBLE...

Page 58: ...2 06 2013 Table of Contents Trouble shooting guide for APP and APP S 674 pumps Trouble shooting fish bone chart 1 No flow no pressure 2 Reduced flow reduced pressure 3 High torque on electric motor 4...

Page 59: ...ent 2 1 6 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 r...

Page 60: ...or 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 of pump 1 4 1 Ensure that coupling between electr...

Page 61: ...is very worn 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 typica...

Page 62: ...at 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 st...

Page 63: ...is broken or worn See 1 No 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...

Page 64: ...r too 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 a more flexible hose Danfoss can provide flexible hoses Please con...

Page 65: ...ve plate has 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...

Page 66: ...trademarks 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...

Page 67: ...7 Right and wrong 180R9042 MAKING MODERN LIVING POSSIBLE danfoss high pressurepumps com 180R9042 Right and wrong Trouble shooting guide for water hydraulic systems...

Page 68: ...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 69: ...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 70: ...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 71: ...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 72: ...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 fuse or short circuit Check power supply an...

Page 73: ...User manual Appendices for IOM APP Pumps APP 1 5 3 5 55 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013...

Page 74: ...er 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...

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Danfoss APP series, User Manual

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