Danfoss APP W HC Series Operation Manual Download

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Operation guide | Installation, Operation and Maintenance APP W HC 15 - 30 pumps

180R9410 | AQ282628894589en-000801 | IOM APP W HC 15-30 Pumps | 01.2022

Table of Contents

1 .

Data sheet for APP W HC pumps 15-30 (AI283147317727en-000601) . . . . . . . . . . . . . . . . . . . . .19

2 .

Instruction for APP W HC pumps 15-30 (AN283148361728en-000402) . . . . . . . . . . . . . . . . . . . .33

3 .

IOM Electric motors (180R9230) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4 .

Recommended service intervals (AX283334052821en-000301) . . . . . . . . . . . . . . . . . . . . . . . . . .49

5 .

Parts lists APP W HC pumps 15-30 (AX283149261730en-000301) . . . . . . . . . . . . . . . . . . . . . . . . .53

6 .

Trouble shooting guide (521B1447) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

7 .

Right and wrong (180R9042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Contents

Summary of Contents for APP W HC Series

Page 1: ...om APP W HC 21 43 User manual Installation Operation and Maintenance Manual APP W HC pumps APP W HC 21 43 Operation guide APP W HC pumps APP W HC 15 30 Installation Operation and Maintenance Manual hp...

Page 2: ...8 3 9 Air bubbles 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 handl...

Page 3: ...p unit back into operation 14 7 8 Storage of the pump 14 8 Troubleshooting and scrAPP W HCing criteria 15 8 1 General safety information 15 8 2 Operational conditions which can cause pump failures 15...

Page 4: ...C 21 1000 Code no 180B5001 Serial no XXXXXX02 XXX APP W HC 24 1200 Code no 180B5002 Serial no XXXXXX02 XXX APP W HC 30 1200 Code no 180B5003 Serial no XXXXXX06 XXX The serial number is referring to th...

Page 5: ...the 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 reg...

Page 6: ...oling 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 the electric motor if the motor...

Page 7: ...ng 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 wor...

Page 8: ...micals on the pump materials see Part List for full overview of materials Danfoss product warranty doesn t cover cases where chemicals are the root cause of the failure or claim Additionally use of ce...

Page 9: ...lt in personal 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 cha...

Page 10: ...rroded If dirt 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 temper...

Page 11: ...ab movement of the spider 3 5 mm CP12 Check correct connections on the pump in outlet CP13 Check piping for possible air gaps 5 7 Lifting and positioning Lift the pump unit onto base Remember vibratio...

Page 12: ...in the bell 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 mot...

Page 13: ...not stopped for 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 In...

Page 14: ...ding to the Disassembling and Assembling Instruction available at www hpp danfoss com Clean all parts and surfaces with a fluid compatible with the materials found in the pump Wipe the parts clean and...

Page 15: ...esult in flooding 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 verticall...

Page 16: ...Operation guide Installation Operation and Maintenance APP W HC 15 30 pumps 16 180R9410 AQ282628894589en 000801 IOM APP W HC 15 30 Pumps 01 2022...

Page 17: ...Operation guide APP W HC pumps APP W HC 15 30 Appendices for Installation Operation and Maintenance Manual hpp danfoss com...

Page 18: ...1 Data sheet for APP W HC pumps 15 30 AI283147317727en 000601 19 2 Instruction for APP W HC pumps 15 30 AN283148361728en 000402 33 3 IOM Electric motors 180R9230 43 4 Recommended service intervals AX...

Page 19: ...ro solutions com 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 43 Data sheet APP W HC Pumps APP W HC 15 30 hpp danfoss com...

Page 20: ...P W HC 30 flow curves measured at 110 barg 1595 psig 24 6 Flushing valve curves 25 6 1 APP W HC 15 30 integrated flushing valve 25 7 Motor requirements 25 7 1 Calculation factor for APP W HC 15 30 110...

Page 21: ...esistant materials e g Duplex EN1 4462 UNS S31803 and Super Duplex EN1 4410 UNS S32750 stainless steel and carbon reinforced PEEK Certified quality Positive Material Identification PMI report availabl...

Page 22: ...5 20 1000 rpm at max pressure m h 21 21 27 1200 rpm at max pressure m h 25 31 Technical specifications Media 2 temperature C 2 50 2 50 2 50 2 50 F 36 122 36 122 36 122 36 122 Ambient temperature C 0 5...

Page 23: ...sy to select the pump fitting the application best by using the diagrams below Furthermore these diagrams shows that the flow can be changed by changing the rotation speed of the pump The flow rpm rat...

Page 24: ...APP W HC 15 30 24 180R9410 AQ282628894589en 000801 IOM APP W HC 15 30 Pumps 01 2022 5 2 APP W HC 30 flow curves measured at 110 barg 1595 psig 0 5 10 15 20 25 30 35 m h rpm 0 20 40 60 80 100 120 140 1...

Page 25: ...1 0 0 2 0 0 3 0 0 4 0 0 5 0 0 6 0 0 Pressure barg Flow l min The power requirements can be determined using one of the following guiding equations 7 Motor requirements l min x barg 16 7 x m3 h x barg...

Page 26: ...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 corrosio...

Page 27: ...ons than low rpm because of higher frequency Discharge pressure High pressure generates more noise than low pressure Pump mounting Rigid mounting generates more noise than flexible mounting because of...

Page 28: ...i As the Danfoss APP pump begins to create pressure and flow immediately after start up and regardless of any counter pressure a safey or pressure relief valve 8 should be installed after the non retu...

Page 29: ...28894589en 000801 IOM APP W HC 15 30 Pumps 01 2022 10 Dimensions and connections 10 1 APP W HC 15 30 Accessories see section 12 Fore more details on the accessories please contact the Danfoss High Pre...

Page 30: ...of pump and motor For ad vice and calculation tool please contact Danfoss Pump A mm inch B mm inch C mm inch D mm inch E mm inch F mm inch IEC Electric motor APP W HC 15 550 21 65 693 27 28 280 11 02...

Page 31: ...part replacement more often than the Recom mended Service Intervals which are based on water If Danfoss recommendations concerning system design are not followed it will strongly influence the life of...

Page 32: ...Danfoss DCS im 10 2019 AI283147317727en 000601 32...

Page 33: ...ro solutions com Instruction APP W HC pump instruction APP W HC 21 43 Instruction APP W HC pumps APP W HC 15 30 hpp danfoss com...

Page 34: ...ible pumps 36 2 4 General comments 36 3 Building up the pump unit 36 3 1 Mounting 36 3 2 Direction of rotation 37 3 3 Orientation 37 3 4 Protection from too high pressures 37 3 5 Connections 38 4 Init...

Page 35: ...sure switch 3 set at min inlet pressure between filter and pump inlet The monitoring switch must stop the pump at pressures lower than minimum pressure 4 Use flexible hoses 4 to minimize vibrations an...

Page 36: ...The dotted setup ensures that the inlet pressure does not exceed 10 barg 145 psig when a non return valve is mounted in the inlet In order to avoid the risk of cavitation the inlet pressure for APP W...

Page 37: ...Torque see table below C 1 2 3 2 1 Thread size M5 M6 M8 M10 Torque Nm 2 4 8 10 17 6 Adjust respectively verify the measure ment and secure both couplings with the right torques on the locking screws...

Page 38: ...kit 2m 79 3 Victaulic 180Z0144 2 outlet high pressure hose 120 bar 2 1 2 Victaulic 1 m Style 77DX1 180Z1009 2 outlet high pressure hose 120 bar 2 1 2 Victaulic 1 78 m Style 77DX1 180Z1008 3 inlet con...

Page 39: ...e electric motor corresponds to the direction of rotation of the pump see label on pump Otherwise the pump will be damaged if a check valve is placed between pump and feed pump 4 Initial start up O I...

Page 40: ...eeze additives 4 Quickly start and stop the pump Make sure that the pump does not run dry The pump is now protected against internal corrosion and frost Storage of pump that have been in operation For...

Page 41: ...aterials with excellent corrosion properties It is however always recommended to flush the pump with fresh water when the system is shut down When stopping the pump for more than 1 day flush the ppump...

Page 42: ...Danfoss DCS im 2019 10 AN283148361728en 000402 42...

Page 43: ...M a n u a l Electric Motors Motor Manual hoyermotors com...

Page 44: ...nsure 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 etc using suitable tools...

Page 45: ...bove 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 frequency converter drive w...

Page 46: ...80R9410 AQ282628894589en 000801 IOM APP W HC 15 30 Pumps 01 2022 Connection diagram Anschlu diagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexi n Collegamento Schemat pola...

Page 47: ...47 180R9410 AQ282628894589en 000801 IOM APP W HC 15 30 Pumps 01 2022...

Page 48: ...ny 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 Stockholm T 46 8 446 877 13 swe...

Page 49: ...lutions com Instruction Recommended service intervals for APP 0 6 1 0 APP 1 5 3 5 APP W 5 1 10 2 APP 11 13 APP 16 22 Instruction APP W HC pumps APP W HC 15 30 Recommended service intervals hpp danfoss...

Page 50: ...ing PTFE 24 000 hours O ring overall NBR 24 000 hours Screw overall AISI 316 24 000 hours Pin overall AISI 316 Duplex or PEEK No wear part 152 1 Valve cone flushing valve Duplex or PEEK 48 000 hours 3...

Page 51: ...e 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 of the pis...

Page 52: ...Danfoss DCS im 2021 09 AX283334052821en 000301 52...

Page 53: ...ro solutions com Parts list APP Pumps APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 Parts list APP W HC pumps APP W HC 15 30 hpp danfoss com...

Page 54: ...4 180R9410 AQ282628894589en 000801 IOM APP W HC 15 30 Pumps 01 2022 Table of Contents 1 General 55 2 Parts list APP W HC 15 30 56 3 Exploded view APP W HC 15 24 57 4 Exploded view APP W HC 30 58 5 Too...

Page 55: ...R9410 AQ282628894589en 000801 IOM APP W HC 15 30 Pumps 01 2022 This parts list provides an overview of the content of the various service sets as well as explodede views Type APP W HC 15 APP W HC 21 A...

Page 56: ...5x20 Super Duplex x x x 61 1 Cylinder barrel Super Duplex PEEK x 62 4 Spring Duplex x x 63 1 Spring guide PP x x 66 9 Piston Super Duplex PEEK x 67 1 Key 12x8x70 AISI 316 x 68 1 Retainer assembly Sup...

Page 57: ...Parts list APP W HC 15 30 57 180R9410 AQ282628894589en 000801 IOM APP W HC 15 30 Pumps 01 2022 3 Exploded view APP W HC 15 24...

Page 58: ...Parts list APP W HC 15 30 58 180R9410 AQ282628894589en 000801 IOM APP W HC 15 30 Pumps 01 2022 4 Exploded view APP W HC 30...

Page 59: ...46 and APP HC 15 30 Allen key 6 mm x Adjustable pin wrench x Combination wrench 10 mm x Combination wrench 13 mm x Nut M8x6 5x13 x Guide bolt M8x140 x Shaft seal extractor 45 x Press bush 45 x Press...

Page 60: ...Danfoss DCS im 2018 11 AX283149261730en 000301 60...

Page 61: ...Service guide Trouble shooting guide APP APP S and APP S 674 pumps ro solutions com...

Page 62: ...IOM APP W HC 15 30 Pumps Table of contents Table of contents 62 Trouble shooting fish bone chart 63 1 No flow no pressure 64 2 Reduced flow reduced pressure 65 3 High torque on electric motor 66 4 No...

Page 63: ...2 1 5 Pre treatment 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 pre...

Page 64: ...is started 1 3 6 Check that 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...

Page 65: ...sing 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 through the filter in tunnels String wounded fi...

Page 66: ...2 1 Check 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 wit...

Page 67: ...s 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 u...

Page 68: ...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 contact Danfo...

Page 69: ...nd 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 it up to t...

Page 70: ...loss of flow To check See 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...

Page 71: ...Service guide Trouble shooting guide for APP APP S and APP S 674 pumps Danfoss DCS im 2022 01 180R9410 AQ282628894589en 000801 IOM APP W HC 15 30 Pumps 71...

Page 72: ...Danfoss DCS im 2017 04 521B1447 DKCFN PZ 003 A1 02 72...

Page 73: ...N LIVING POSSIBLE danfoss high pressurepumps com Right and wrong Trouble shooting guide for water hydraulic systems Service guide Right and wrong Trouble shooting guide for water hydraulic systems hpp...

Page 74: ...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 75: ...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 76: ...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 77: ...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 78: ...control lights on Is the filter clogged Is the filter control light on Replace filter ele ment Contact serviceman Stamp Fill water into the system Trace leakage if any A blown fuse or short circuit Ch...

Page 79: ......

Page 80: ...Danfoss DCS im 2022 01 180R9410 AQ2282628894589 en 000801 IOM APP W HC 15 30 Pumps 80...

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