Danfoss APP Series User Manual
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Danfoss APP Series User Manual

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MAKING MODERN LIVING POSSIBLE
User manual
Installation, Operation and
Maintenance Manual
APP pumps (APP 1.5-3.5)
APP 1.5-3.5
ro-solutions.com

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Summary of Contents for Danfoss APP Series

  • Page 1 MAKING MODERN LIVING POSSIBLE User manual Installation, Operation and Maintenance Manual APP pumps (APP 1.5-3.5) APP 1.5-3.5 ro-solutions.com...

  • Page 2: Table Of Contents

    Pre mounting checklist, based on Danfoss preferred system design . . . . . . . . . . . . . . . .
  • Page 3 User manual Installation, Operation and Maintenance APP Pumps (APP 1.5-3.5) Maintenance and service of the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 7 .

  • Page 4: Table Of Contents Validity

    User manual Installation, Operation and Maintenance APP Pumps (APP 1.5-3.5) Validity This manual is valid for APP pumps with the following code numbers/serial numbers: APP 1.5 Code no . 180B3043 Serial no . APP 1.8 Code no . 180B3044 Serial no . APP 2.2 Code no .

  • Page 5: Eu Declaration Of Conformity

    EU Declaration of Conform- 180R9267 / IOM APP Pumps - v02 / 09.2013...

  • Page 6: Introduction

    The APP pumps and pump units are manufac- • If any changes are made without written tured by Danfoss A/S, and are sold and marketed approval the warranty will automatically by a net of authorized distributors world wide . become void .

  • Page 7: Manufacturer And Customer Service Address

    When working near the pump system, safety Danfoss recommends to build systems with a shoes, safety glasses, hearing protection and high degree of safety . Danfoss preferred system safety helmet must always be worn . design and P&ID are found in appendix 1, Data sheet, and appendix 2, Instruction .

  • Page 8: Commissioning And Servicing The Unit

    . 2.4 Adhere to the following important points 2.5 In case of doubt Please contact Danfoss A/S in case of doubt . • Before using the pump/pump unit it is very Contact information is listed in section 1 .3, important to read and understand this user Manufacturer and customer service address .

  • Page 9: Filtration

    2, Instruction . pump . Danfoss recommends not to build a filter bypass All air must be bleeded from both the low- function or to use filters with an integrated pressure and high-pressure side before the RO bypass .

  • Page 10: Return To Supplier

    User manual Installation, Operation and Maintenance APP Pumps (APP 1.5-3.5) Wrong lifting: Pumps which have a weight above 20 kilos (see appendix 1, Data sheet) must be handled by using lifting eyes and slings . When lifting the pump unit, one sling must be attached to the electric motor and one sling around the pump .

  • Page 11: Installation And Commissioning

    User manual Installation, Operation and Maintenance APP Pumps (APP 1.5-3.5) Installation and commissioning 5.1 Important dimensions 5.4 Electrical data Physical dimensions and connections of the Check voltage, current frequency and rated pump unit are described in appendix 1, Data power on the electric motor and VFD settings on sheet .

  • Page 12: Pre Mounting Checklist, Based On Danfoss Preferred System Design

    User manual Installation, Operation and Maintenance APP Pumps (APP 1.5-3.5) 5.6 Pre mounting checklist, based on Danfoss preferred system design Table 1: Check points when assembling and commissioning system Check points Comment OK ? Ensure that the environmental conditions are safe .

  • Page 13: Ensure Free Flow

    . for 1 second and observe the direction of rotation either looking at the fan of the motor or Danfoss offers commissioning and service at the coupling through the inspection hole in the system manufacturer’s location . Rate quotes are bell housings (not available on all bell housings) .

  • Page 14: Operation Of Pump Unit

    Instruction for recommended service intervals . are either damaged or running very close to their design pressure, stop the unit Danfoss offers service of the pump at the system immediately . Contact the maintenance manufacturer’s location as well as we offer department .

  • Page 15: Disassembling And Assembling The Pump Unit

    3, Parts list . If the pump is going to be returned to Danfoss for repair or a warranty claim, it is important to contact Danfoss in order to receive a return number and a form to fill out with product information .

  • Page 16: Troubleshooting And Scrapping Criteria

    . Please use appendix 6, Trouble shooting If the pump is running dry, the temperature will guide as guideline or send the pump to Danfoss quickly increase which can cause burns . headquarter in Denmark for evaluation .
  • Page 17 User manual Installation, Operation and Maintenance APP Pumps (APP 1.5-3.5) 180R9267 / IOM APP Pumps - v02 / 09.2013...

  • Page 18: Subject Index

    Denmark 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 subsequential changes being necessary in specifications already agreed.

  • Page 19: Appendices For Installation, Operation And Maintenance Manual

    MAKING MODERN LIVING POSSIBLE 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 ro-solutions.com...
  • Page 20 User manual Appendices for IOM APP Pumps (APP 1.5-3.5) Table of Contents Data sheet for APP 1.5-3.5 pumps (521B0850) ..........3 APP pump instruction APP 0.6-3.5 (180R9065) .

  • Page 21: Data Sheet For App 1.5-3.5 Pumps (521B0850)

    MAKING MODERN LIVING POSSIBLE Data sheet for APP 1.5-3.5 pumps (521B0850) Data sheet APP pumps APP 1.5-3.5 ro-solutions.com...
  • Page 22 Data sheet APP pumps - APP 1.5-3.5 Data sheet for General information APP 1.5-3.5 pumps (521B0850) Benefits Table of Contents Technical data Flushing valve Flow at different rpm Power requirements Temperature and corrosion Operation Storage Noise level Filtration Dimensions 10.1 Pump 10.2 Complete unit...
  • Page 23 4) Intermittent pressure is acceptable for less than 2) For lower pressure, please contact 10 seconds per minute. Danfoss RO Sales Organization. 5) For speeds above 3000 rpm the pump must be 3) For higher pressure, please contact boosted at a pressure of 2-5 bar (29.0 - 72.5 psi).
  • Page 24 1) Typical average fl ow at 80 bar (1160 psi). Intermittent pressure is acceptable for less than 2) For lower pressure, please contact Danfoss RO Sales Organization. 10 seconds per minute. 3) For higher pressure, please contact Danfoss RO Sales Organzation.
  • Page 25 Data sheet APP pumps - APP 1.5-3.5 Power requirements Pump Flow Pressure Calc. model factor 60 bar 70 bar 80 bar l/min 870 psi 1015 psi 1160 psi APP 1.5 25.11 1.51 6.63 3.21 kW 3.75 kW 4.29 kW 2890 468.6 APP 1.5 30.17...
  • Page 26 7.2 Storage Frost protection is required at temperatures Storage temperature: below 2°C. Danfoss recommends to use DOW- -40°C to +70°C (+40°F to 158°F) provided that FROST from DOW Chemical Company or Chilsafe the pump is drained of fluid and stored mono propylene glycol from Arco Chemical ”plugged”.
  • Page 27 Data sheet APP pumps - APP 1.5-3.5 10. Dimensions 10.1 Pump Description APP 1.5 - APP 3.5 Port position 21.0 0.83 Port position 21.0 0.83 Ø 105 Parallel key, DIN 6885 5 × 5 × 20 0.20 × 0.20 × 0.78 Bleeding M6, Hexagon AF = 5 mm Inlet connection...
  • Page 28 Motor shaft If alternative mounting is required, please The pump should be connected to the rest of the contact Danfoss Sales Organization for further plant with flexible hoses. information. Min. 5 mm 180R9267 / IOM APP 1.5-3.5 Appendices - v04 / 11.2013...
  • Page 29 A safety valve (8) can be installed in order Place a monitoring pressure switch (3) set to avoid system damage as the Danfoss at min. inlet pressure between filter and APP pump creates pressure and flow pump inlet.
  • Page 30 Denmark 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 subsequential changes being necessary in specifications already agreed.

  • Page 31: App Pump Instruction App 0 .6-3 .5 (180R9065)

    MAKING MODERN LIVING POSSIBLE APP pump instruction APP 0.6-3.5 (180R9065) Instruction APP pump instruction APP 0.6-1.0, APP 1.5-2.5 and APP 3.0-3.5 ro-solutions.com...
  • Page 32 Instruction APP pump instruction APP 0.6-1.0, APP 1.5-2.5 and APP 3.0-3.5 APP pump instruction Identification APP 0.6-3.5 (180R9065) System design Table of Contents Open-ended systems with water supply from a tank Open-ended systems with direct water supply Problems with reversing pumps General guidelines for calculation of pressure losses General comments on Building up the pump unit...
  • Page 33 Instruction APP pump instruction APP 0.6-1.0, APP 1.5-2.5 and APP 3.0-3.5 Identification System design The design of the system must ensure that self 2.2 Open-ended systems with direct water emptying of the pump during standstill is supply avoided. The pump is supplied with water direct from a booster pump.
  • Page 34 Instruction APP pump instruction APP 0.6-1.0, APP 1.5-2.5 and APP 3.0-3.5 2.4 General guidelines for calculation of The inlet line connection must be properly pressure losses tightened, as possible entrance of air will cause In order to avoid the risk of cavitation, the inlet cavitation.
  • Page 35 3.1 Mounting unit (Please also see hints in “Right and Wrong”) If alternative mounting is desired, please contact the Danfoss Sales Organization. Choose proper tolerances to ensure an easy mounting of the elastic coupling without use of tools. Elastic coupling...
  • Page 36 Instruction APP pump instruction APP 0.6-1.0, APP 1.5-2.5 and APP 3.0-3.5 3.3 Orientation The valve should be placed as close to the pump The pump can be mounted/oriented in any as possible. The opening characteristics of the horizontal direction. Vertically only with the shaft valve must not result in peak pressures higher pointing upwards.
  • Page 37 For further information on anti-freeze media, 5.2 Pressure please contact the Danfoss Sales Organization. The inlet pressure must be min. 0.9 bar (13 psi) and max. 5 bar (72.5 psi) abs. At lower pressures...
  • Page 38 Denmark 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 subsequential changes being necessary in specifications already agreed.

  • Page 39: Iom Electric Motors (180R9230)

    IOM Electric motors (180R9230) Electric Motors Motor Manual hoyermotors.com Manual 180R9262 / IOM APP 0.6-1.0 Appendices - v01 / 09.2012...
  • Page 40 Motor Manual 1. General Correct alignment is essential to avoid bearing, vibration and shaft failure. This manual concerns the following types of standard Use appropriate methods for alignment. induction motors from Hoyer: Re-check the alignment after the final tightening of the HMA2, HMC2, HMD, HMT, MS, Y2E1, Y2E2, YDT bolts or studs.
  • Page 41 Motor Manual Bearing size and type are specified on the rating plate. The table values are based on an ambient temperature of Motor types HMA2 and HMC2 is as standard with lifetime 25°C. The values must be halved for every 15K increase in greased bearing with motor size ≤225.
  • Page 42 Motor Manual Motor Manual IOM electromotor - Hoyermotors 1. General 1. General Correct alignment is essential to avoid bearing, vibration Correct alignment is essential to avoid bearing, vibration and shaft failure. and shaft failure. This manual concerns the following types of standard This manual concerns the following types of standard Use appropriate methods for alignment.
  • Page 43 180R9267 / IOM APP 1.5-3.5 Appendices - v04 / 11.2013...
  • Page 44 SVEND HØYER A/S Chains · Gears · Motors Tlf. (+45) 86 98 21 11 Main office: Svend Høyer A/S Over Hadstenvej 42 · DK 8370 Hadsten Tel. (+45) 86 98 21 11 · Fax (+45) 86 98 17 79 E-mail: svendhoyer@svendhoyer.dk · http://www.svendhoyer.dk Sverige: Svend Høyer AB Malmövägen 18 ·...

  • Page 45: Recommended Service Intervals For App Pumps (180R9199)

    MAKING MODERN LIVING POSSIBLE Recommended service intervals for APP pumps (180R9199) Instruction Recommended service intervals for APP pumps ro-solutions.com...
  • Page 46 Design/features Danfoss APP pumps are designed for long If the Danfoss recommendations concerning operation and low maintenance and life cycle system-design (see our data sheet) are not costs.
  • Page 47 Instruction Recommended service intervals for APP pumps Appendix 1 Pistons: In case of doubt - the pistons must be replaced. The pistons are the heart of the pump regarding service. The pictures below is ment as a guideline for evaluating the wear of the sliding surface. If the pistons break down, the pump will suffer a breakdown.
  • Page 48 Denmark 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 subsequential changes being necessary in specifications already agreed.

  • Page 49: App Parts List (521B0941)

    MAKING MODERN LIVING POSSIBLE APP parts list (521B0941) Parts list APP Pumps APP 1.5-3.5 APP 0.6-43 / APM 0.8-2.9 / APM 1.8-2.9 APP W 5.1- 10.2 APP 1.5-3.5 ro-solutions.com...
  • Page 50 Parts list APP 0.6-43 / APM 0.8-2.9 / APP W 5.1-10.2 Table of Contents General Parts list APP 21-43 Parts list APP 0.6 - 1.0 Compact (521B0941) Exploded view APP 0.6 - 1.0 Compact Parts list APP 0.6 - 1.0 and APM 0.8 - 1.2 Exploded view APP 0.6 - 1.0 and APM 0.8 - 1.2 Parts list APP 1.5 - 2.5 and APM 1.8 - 2.9 Exploded view APP 1.5 - 2.5 and APM 1.8 - 2.9...
  • Page 51 Parts list PAHT and PAHT G pumps General 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 •...
  • Page 52 Parts list APP 0.6-43 / APM 0.8-2.9 / APP W 5.1-10.2 Parts list Note: APP 1.5 - 2.5 and The parts listed are not sold separately, only in APM 1.8 - 2.9 various kits Parts for APM 1.8-2.9 are equivalent to the parts for APP 1.5-2.5 except for the valve plate sets.
  • Page 53 Parts list APP 0.6-43 / APM 0.8-2.9 / APP W 5.1-10.2 Exploded view APP 1.5 - 2.5 and APM 1.8 - 2.9 180R9267 / IOM APP 1.5-3.5 Appendices - v04 / 11.2013 521B0941 / DKCFN.PC.073.A13.02 / 10.2013...
  • Page 54 Parts list APP 0.6-43 / APM 0.8-2.9 / APP W 5.1-10.2 Parts list Note: APP 3.0 - 3.5 The parts listed are not sold separately, only in various kits. Exploded view, see next page. Pos. Qnt. Designation Material Housing Duplex / PEEK Pin (Ø4x14) AISI 316 Swash plate...
  • Page 55 Parts list APP 0.6-43 / APM 0.8-2.9 / APP W 5.1-10.2 Exploded view APP 3.0 - 3.5 180R9267 / IOM APP 1.5-3.5 Appendices - v04 / 11.2013 521B0941 / DKCFN.PC.073.A13.02 / 10.2013...
  • Page 56 Denmark 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 subsequential changes being necessary in specifications already agreed.

  • Page 57: Trouble Shooting Guide

    MAKING MODERN LIVING POSSIBLE Trouble shooting guide Guideline Trouble shooting guide for APP and APP S 674 pumps ro-solutions.com...
  • Page 58 Instruction Trouble shooting guide for APP and APP S 674 pumps Table of Contents Trouble shooting fish bone chart Trouble shooting guide for No flow/no pressure APP and APP S 674 pumps Reduced flow/reduced pressure High torque on electric motor Noise from pump Noise from installation Typical signs of wear...
  • Page 59 Instruction Trouble shooting guide for APP and APP S 674 pumps Trouble shooting fish bone chart 180R9267 / IOM APP 1.5-3.5 Appendices - v04 / 11.2013 06.2013...
  • Page 60 1.4.2 Check if coupling is damaged. 1.4.3 Check that electric motor is sized correctly. 1.4.4 Check that the electrical installation is correctly sized. 1.4.5 Contact Danfoss Sales office for guidelines in how to troubleshoot internal pump parts. 1.5 Axial load on pump shaft 1.5.1 Ensure that the air gap between the two...
  • Page 61 The filters can be bypassed, even if they are (particles in fluid must not exceed 10 μm). correctly mounted. Some filters can create Danfoss High Pressure Pumps supplies channelling where particles can pass through filters, please contact the sales office.
  • Page 62 Start motors simultaneously. 3.3 Constant torque 3.3.1 Please contact Danfoss High Pressure If the electric motor is too small for the APP or Pumps sales office. APP S 674 pump, it cannot provide sufficient torque.
  • Page 63 4.6.2 If outlet pressure is lower than mentioned noise. Too low pressure also causes insufficient in the pump data sheet, please contact internal lubrication and wear on internal parts. Danfoss High Pressure Pumps technical Pump may eventually be damaged. support. 4.6.3 If outlet pressure has exceeded its...
  • Page 64 5.3 Hose stiffness 5.3.1 Use a more flexible hose. Danfoss can Too stiff hoses cannot dampen the small provide flexible hoses. Please contact pressure pulsations from the pump, and...
  • Page 65 Instruction Trouble shooting guide for APP and APP S 674 pumps Typical signs of wear 6.1 Valve plate Picture 1 A normally worn valve plate has no marks/scratches but only a slightly polished surface. No scratches or marks should be felt. The surface must be flat and level. Picture 2 A worn valve plate has scratches, and/or a polished surface.
  • Page 66 Denmark 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 subsequential changes being necessary in specifications already agreed.

  • Page 67: Right And Wrong (180R9042)

    MAKING MODERN LIVING POSSIBLE Right and wrong (180R9042) Right and wrong Trouble shooting guide for water hydraulic systems danfoss.high-pressurepumps.com 180R9042...
  • Page 68 Pump location Design Pump always to be placed below water Pump location above water surface surface level level will cause damage Choice of material Suction conditions Iron Rubber Copper Plastic Brass Stainless steel Aluminium Always use system components made Non-corrosion proof materials System to be dimensioned to provide Poor suction conditions will cause of corrosion proof materials...
  • Page 69 Installation Assembly of coupling Impurities Chips or other impurities in the system Prior to installation, burrs and chips and Never use force when assembling the The coupling must be easy and simple may cause damage other impurities must be removed from coupling parts, as this will damage the to assemble (see product instruction) pipes and hoses, eg with a felt plug...
  • Page 70 Wiring Starting procedure Cleaning procedure 1. Fill cold water into the system via the return filter and Level indicator 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.
  • Page 71 Trouble shooting Open ended water systems No water supply Is the water supply ok? Is water supplied to the pump? Lower inlet Is water coming Is the electric motor of Is the water in the tank temperature or the pump unit rotating? very hot? Ie above 50 out of the tap? provide better cooling...
  • Page 72 Trouble shooting Closed water systems The system does not work Is there sufficient water in the tank? Is the electric motor of Is the water in the tank the pump unit rotating? very hot? Ie above 50 At temperatures higher than 50 pump drive cuts out.
  • Page 73 User manual Appendices for IOM APP Pumps (APP 1.5-3.5) 180R9267 / IOM APP 1.5-3.5 Appendices - v04 / 11.2013...
  • Page 74 Denmark 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 subsequential changes being necessary in specifications already agreed.

This manual is also suitable for:

App 1.8App 1.5App 2.5App 3.0App 3.5App 2.2

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