Danfoss APP 5.1 User Manual
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Danfoss APP 5.1 User Manual

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MAKING MODERN LIVING POSSIBLE
User manual
Installation, Operation and
Maintenance Manual
APP pumps (APP 5.1-10.2)
L enntech
L enntech
info@lenntech.com Tel. +31-152-610-900
info@lenntech.com Tel. +31-152-610-900
www.lenntech.com Fax. +31-152-616-289
www.lenntech.com Fax. +31-152-616-289
APP 5.1-10.2

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  • Page 1 L enntech MAKING MODERN LIVING POSSIBLE L enntech info@lenntech.com Tel. +31-152-610-900 info@lenntech.com Tel. +31-152-610-900 www.lenntech.com Fax. +31-152-616-289 www.lenntech.com Fax. +31-152-616-289 User manual Installation, Operation and Maintenance Manual APP pumps (APP 5.1-10.2) APP 5.1-10.2...

  • 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 5.1-10.2) Maintenance and service of the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 7 .

  • Page 4: Table Of Contents Validity

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) Validity This manual is valid for APP pumps with the following code numbers/serial numbers: APP 5.1 Code no . 180B3005 Serial no . APP 6.5 Code no . 180B3006 Serial no .

  • Page 5: Ec Declaration Of Conformity

    EU Declaration of Conform- 180R9263 / IOM APP Pumps - v01 / 01.2013...

  • Page 6: Introduction

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) Introduction General Ensure that these instructions are always The APP pumps and pump units are manufac- readily available to all personnel concerned. tured by Danfoss A/S, and are sold and marketed by a net of authorized distributors world wide .

  • Page 7: Safety

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) Safety 2.1 General information All pipe and hose connections must be stress- Dangers that can arise from not following the free mounted, securely fastened to the pumps instructions: and well supported . Improper installation will or...

  • Page 8: Technical Data

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) Technical data 3.6 Space requirement For service and 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 the pump .

  • Page 9: Arrival Inspection, Transportation, Handling, Lifting And Storage

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) Arrival inspection, 4.1 Arrival inspection Pumps which have a weight above 20 kilos (see transportation, The pump is packed in a cardboard or wood box Data sheet, appendix 1) must be handled by...

  • Page 10: Return To Supplier

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) See below examples of where to/not to attach the lifting slings on the pump unit: Incorrect lifting can result in personally injury Correct lifting with 2 separate slings: and/or damage to the pump unit.

  • Page 11: Installation And Commissioning

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) Installation and commissioning 5.1 Important dimensions Physical dimensions and connections for the pump unit are described in Data sheet, appendix 1 . 5.2 Cleanliness It is very important that the tubes and pipes are completely clean: no dirt, chips or burrs are allowed .

  • Page 12: Lifting And Positioning

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) Table 1: Check points when assembling and commissioning system Check points Comment OK ? Ensure that the environmental conditions are safe . See Arrival inspection, transportation, handling, lifting and storage, chapter 4 .

  • Page 13: Ensure Free Flow

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) 5.12 Ensure free flow • Adjust the pressures to the specified inlet Ensure that the flow from safety/relief valves 8 and outlet pressure for the system and let and 9 is completely unhindered . A blocked...

  • Page 14: Operation Of Motor Pump Unit

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) Operation of motor pump unit 6.1 General safety information Danfoss recommends at the same time also to Before inspecting the pump unit, read the Safety check the filter and membrane condition and chapter 2 in this user manual .

  • Page 15: Maintenance And Service Of The Pump Unit

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) Maintenance and service of the pump unit General safety information motor and afterwards unscrew the bolts/ Before servicing the pump unit, it is necessary to nuts holding the pump and bell housing read and understand this user manual, especially together .

  • Page 16: Assembling The Pump Unit

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) 7.5 Assembling the pump unit Assemble the pump according to the Dis- assembling and Assembling Instruction (available at www .ro-solutions . d anfoss . c om) . Procedure for mounting pump back...

  • Page 17: Troubleshooting And Scrapping Criteria

    User manual Installation, Operation and Maintenance APP Pumps (APP 5.1-10.2) Troubleshooting and scrapping criteria 8.1 General safety information If a VFD is used and wrongly programmed, it can Before inspecting the pump unit, it is necessary damage the pump and lead to high tempera- to read and understand this user manual, tures or other dangers .

  • 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 MAKING MODERN LIVING POSSIBLE Front page for Appendices User manual Appendices for Installation, Operation and Maintenance Manual APP pumps (APP 5.1-10.2) APP 5.1-10.2...
  • Page 20 APP pump instruction APP 5.1-10.2 (180R9072) ........

  • Page 21: Data Sheet For App 5.1-10.2 Pumps (521B0851)

    MAKING MODERN LIVING POSSIBLE Data sheet for APP 5.1-10.2 pumps (521B0851) Data sheet APP pumps APP 5.1-10.2 ro-solutions.com...
  • Page 22 12.2 Repair General information APP 5.1, APP 6.5, APP 7.2, APP 8.2 and APP 10.2 All parts included in the APP pumps are designed pumps are designed to supply low viscosity and to provide long service life, i.e. long service life corrosive fluids under high pressure, e.g.
  • Page 23 Intermittent pressure is acceptable for less than 10 seconds per minute. For speeds above 1500 rpm the APP pump must be boosted at a pressure of 2-5 bar (29-72.5 psi). 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012...
  • Page 24 = 0.75 kW 1 kW = 1.34 hp 1 gpm = 3.79 l/min 1 l/min = 0.26 gpm = 4.40 gpm 1 gpm = 0.23 m 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012...
  • Page 25 Since the APP pump is typically mounted on a bell housing or frame, the noise level can only be determined for the complete unit (system). 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012...
  • Page 26 10,000 particles pass through it compared to only 20 particles in a filter with an efficiency of 99.98%. 10. Dimensions 10.1 APP pump 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012...
  • Page 27 18.5 kW, HUC2 180 M-4 APP 10.2 22 kW, HUC2 180 L-4 APP 10.2 30 kW, HUC2 200 L-4 For inlet and outlet connections data, see “Accessories catalogue” (521B0903). 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012...
  • Page 28 1 bar (14.5 psi) At speeds above 1500 rpm - use 2 bar (29 psi) as set point. 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012...
  • Page 29 Danfoss RO Solutions Sales materials with fine corrosion properties. Organisation. However, it is always recommended to flush the APP pump when the system is shut down. 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 521B0851 / DKCFN.PD.013.FB3.02 / 10.2012...
  • 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 5.1-10.2 (180R9072)

    MAKING MODERN LIVING POSSIBLE APP pump instruction APP 5.1-10.2 (180R9072) Instruction APP pump instruction APP 5.1-10.2 ro-solutions.com...
  • Page 32 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 180R9072 / 521B0747 / DKCFN.PI.010.D4.02 / 10.2012 La pression d’ouverture du clapet anti-retour doit êtr égale à la pression mesurée à l’entrée de la pompe.
  • Page 33 521B0747 DKCFN.PI.010.D3.ML xcéder la pression alimentée par une ec alimentation taller un clapet ostat à l’entrée de la 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 180R9072 / 521B0747 / DKCFN.PI.010.D4.02 / 10.2012 re supérieure ou 521B074...
  • Page 34 521B0747 DKCFN.PI.010.D3.ML the environment. inoxydable ou plastique) et étanche pour éviter l’intrusion d 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 180R9072 / 521B0747 / DKCFN.PI.010.D4.02 / 10.2012 Automatic pressure equalization between tank and surroundings en provenance de l’extérieur.
  • Page 35 2.3 Problems with reversing pumps 2.3 Pompes réversibles d’impuretés 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 180R9072 / 521B0747 / DKCFN.PI.010.D4.02 / 10.2012 The design of the system must ensure that self-emptying of the pump La conception du système doit gar oir et during standstill is avoided.
  • Page 36 18 (LBF-FT) 3.5 (LBF-FT) torque Recommended torque values refer to steel washers containing a rubber sealing element. Victualic® is a registered trademark of Victualic. 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 180R9072 / 521B0747 / DKCFN.PI.010.D4.02 / 10.2012...
  • Page 37 5.4 Disconnection If the inlet line is disconnected from the water supply, the pump will be emptied of water through the disconnected inlet line. 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 180R9072 / 521B0747 / DKCFN.PI.010.D4.02 / 10.2012...
  • 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 180R9230...
  • Page 40 The motor are balancing with half key, ensure that the drive components are also the same. Hoyer Motors, Motor Manual, October 2011 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013...
  • Page 41 Data for vertically mounted motors are half of the above values. Maintenance, repairs and replacement on zone 22 motors must only be carried out by qualified specialists. Hoyer Motors, Motor Manual, October 2011 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013...
  • Page 42 Motor Manual Instruction IOM electromotor - Hoyermotors 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 43: 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...
  • Page 44 Duplex or PEEK 40,000 hours 3, 129* Bleeding screw Duplex No wear part Parallel key AISI 302 40,000 hours depends on pump size 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 180R9199 / 521B1135 / DKCFN.PI.013.C1.02 / 09.2012...
  • Page 45 All pistons must be replaced within the next All pistons must be replaced immediately. 100-200 hours. Abrasive wear of the piston shoes. All pistons must be replaced immediately. 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 180R9199 / 521B1135 / DKCFN.PI.013.C1.02 / 09.2012...
  • Page 46 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 47: App Parts List (521B0941)

    MAKING MODERN LIVING POSSIBLE APP parts list (521B0941) Parts list APP Pumps APP 5.1-10.2 APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2 APPW 5.1- 10.2 APP 5.1-10.2...
  • Page 48 Super Duplex Super Duplex Screw M8x20 Screw M8x20 AISI 316 AISI 316 Screw Screw AISI 316 AISI 316 Instruction Instruction 521B0941 / DKCFN.PC.073.A11.02 / 12.2012 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 521B0941 / DKCFN.PC.073.A11.02 / 12.2012...
  • Page 49 12. Exploded view 12. Exploded view APP 5.1 - 10.2 APP 5.1 - 10.2 APPW 5.1 - 10.2 APPW 5.1 - 10.2 521B0941 / DKCFN.PC.073.A11.02 / 12.2012 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 521B0941 / DKCFN.PC.073.A11.02 / 12.2012...
  • Page 50 Super Duplex Super Duplex Screw M8x20 Screw M8x20 AISI 316 AISI 316 Screw Screw AISI 316 AISI 316 Instruction Instruction 521B0941 / DKCFN.PC.073.A11.02 / 12.2012 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 521B0941 / DKCFN.PC.073.A11.02 / 12.2012...
  • Page 51 12. Exploded view 12. Exploded view APP 5.1 - 10.2 APP 5.1 - 10.2 APPW 5.1 - 10.2 APPW 5.1 - 10.2 521B0941 / DKCFN.PC.073.A11.02 / 12.2012 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013 521B0941 / DKCFN.PC.073.A11.02 / 12.2012...
  • Page 52 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. 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.

  • Page 53: Trouble Shooting Guide

    MAKING MODERN LIVING POSSIBLE Trouble shooting guide Guideline Trouble shooting guide for APP pumps...
  • Page 54 No flow/no pressure Table of Contents Reduced flow/reduced pressure High torque on electric motor Noise from pump Noise from installation Typical signs of wear Valve plate Port plate Swash plate 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013...
  • Page 55 Instruction Trouble shooting guide for APP pumps Trouble shooting fish bone chart 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013...

  • Page 56: No Flow/No Pressure

    180R9092/180R9085 for APP 0.6-1.0 parts. 180R9091/180R9147/180R9089 for APP 1.5-3.5 180R9093/180R9090 for APP 5.1-10.2 180R9228/180R9227 for APP 11-13 and APP 16-22 180R9121/180R9139 for APP 21-38 – are available on www.ro-solutions.com. 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013...

  • Page 57: Reduced Flow/Reduced Pressure

    2.3.2 Check that rotation speed of the electric internal lubrication causing wear on the motor is as stated on name plate on internal pump parts. electric motor. Check that the motor rotor winding is not damaged. 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013...

  • Page 58: High Torque On Electric Motor

    3.4 Water pump damage 3.4.1 Dismantle pump and check for wear. Too heavy damage in the pump will increase friction causing a high torque (see item 6, Typical signs of wear). 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013...

  • Page 59: Noise From Pump

    4.7.1 Check if noise is normal when the pump is Noise frequency changes during soft start-up/ running at operation speed. stop. 4.7.2 If noise is abnormal at operation speed, check internal parts (see above). 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013...

  • Page 60: Noise From Installation

    5.5 Vibration damper under the electric motor 5.5.1 Mount a vibration damper below the When no damper is installed below the electric motor/pump. motor, vibrations from the motor and pump may be transferred to the frame/r est of the system/plant. 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013...

  • Page 61: Typical Signs Of Wear

    If any scratches or marks can be felt by running a fingernail over the surface, the valve plate is worn. The valve plate on picture 3 is highly damaged. 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013...

  • Page 62: Port Plate

    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 63: Right And Wrong (180R9042)

    MAKING MODERN LIVING POSSIBLE Right and wrong (180R9042) Right and wrong Trouble shooting guide for water hydraulic systems 180R9042...
  • Page 64 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 65 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 66 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 67 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 68 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 69 User manual Appendices for IOM APP Pumps (APP 5.1-10.2) 180R9263 / IOM APP 5.1-10.2 Appendices - v02 / 01.2013...
  • Page 70 Fax. +31-152-616-289 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 6.5App 7.2App 8.2App 10.2

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