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Danfoss APP Series Installation, Operation And Maintenance Manual

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Operation guide
APP pumps with FDA approved seals
APP 53 / APP 65 / APP 78 / APP 86 / APP 92
Installation, Operation and
Maintenance Manual
hpp.danfoss.com
© Danfoss | 2023.03
180R9346 | AQ240486503020en-001702 | 1

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  • Page 1 Operation guide APP pumps with FDA approved seals APP 53 / APP 65 / APP 78 / APP 86 / APP 92 Installation, Operation and Maintenance Manual hpp.danfoss.com © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 1...
  • Page 2 Local regulations...............10 Pre mounting checklist, based on Danfoss preferred system design ..... 11 Lifting and positioning .

  • Page 3: Table Of Contents

    Right and wrong (180R9042) ............113 © Danfoss | 2023.03...
  • Page 4 The digits shown (08) indicate the PUMP version number of the pump. Type APP 78 MADE IN DENMARK Code no. 180BXXXX Serial no. XXXXXX08-XXX Danfoss A/S, 6430 Nordborg, Denmark 4 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 5 Introduction The APP pumps and pump units are manufac- requires a written approval from Danfoss tured by Danfoss A/S, and are sold and marketed High Pressure Pumps. by a net of authorized distributors world wide. This manual contains the necessary instructions •...
  • Page 6 Operation guide Installation, Operation and Maintenance APP 53-92 pumps 1.3 Manufacturer and customer service Your local Danfoss pump distributor can be address found on our homepage. Danfoss A/S Data sheets and instructions on all accessories Danfoss High Pressure Pumps are available on hpp.danfoss.com RO Solutions 1.4 Country specific information...
  • Page 7 Danfoss High Pressure Pumps. 3.4 VFD and Direct on line Danfoss APP pumps can be used with VFD and direct on line. Torque limits can be found in the table below: 3.1 Approved applications and operational...
  • Page 8 2, Instruction. system is pressurised. Special consideration should be given in order to minimize air bubbles Danfoss recommends not to build a filter bypass in the feed flow. Air bubbles can cause cavitation. function or to use filters with an integrated bypass.
  • Page 9 Each pump is tested before shipment, and will therefore contain water. For storage temperature and frost protection see appendix 2, Instruction. The pumps are NOT delivered frost protected from the factory. © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 9...
  • Page 10 Before start-up, the fluid and pump housing temperature must be within the specified temperature range listed see appendix 1, Data sheet. Schematic 1: Recommended system design Media filter Feed Permeate Fresh water permeat flush Brine 10 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 11 Operation guide Installation, Operation and Maintenance APP 53-92 pumps 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 12 1 second and observe the direction of valve(s) as specified. rotation either looking at the fan of the motor or Danfoss check valve VCM 92 comes with a flange the coupling through the inspection hole in the connection that is easily mounted directly on the bell housings (not available on all bell housings).

  • Page 13: Operation Of Pump Unit

    Contact the maintenance department. Danfoss offers service of the pump at the system manufacturer’s location as well as we offer High frequency tones – safety/relief valves training in how to service the pump. Quotes are are either damaged or running very close offered upon request.

  • Page 14: Disassembling And Assembling The Pump Unit

    5, 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 15: Troubleshooting And Scrapping Criteria

    Please use appendix 6, Trouble shooting guide as guideline or send the pump to Danfoss headquarter in Denmark for evaluation. 8.3 Mechanical failure...
  • Page 16 Operation guide Installation, Operation and Maintenance APP 53-92 pumps 16 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 17 Operation guide Installation, Operation and Maintenance APP 53-92 pumps hpp.danfoss.com © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 17...
  • Page 18 Right and wrong (180R9042) ............113 18 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 19 Data sheet APP Pumps APP 53 / APP 65 / APP 78 / APP 86 hpp.danfoss.com © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 1...
  • Page 20 Service and warranty..............41 20 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 21: Benefits

    (see section 10 for Super Duplex) and APP S 674 (API). example). Please see relevant data sheets. Application examples Danfoss APP pumps are built into a broad range • Mobile systems for humanitarian and of RO desalination plants around the world: military organizations •...

  • Page 22: Technical Data

    1500 rpm at max. pressure m³/h 1700 rpm at max. pressure m³/h 1780 rpm at max. pressure Efficiency 1000 rpm 1200 rpm 1500 rpm 1700 rpm 1780 rpm 22 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 23 Max. allowable working pressure at continuous operation. The pump is designed according to EN809, i.e. to withstand hydrostatic test pressure (HTP) of 1.3 x MAWP. For lower and higher pressure, please contact Danfoss. Dependent on the NaCI concentration. Typical efficiency at max. pressure after a system has been commissioned and run in.

  • Page 24: Performance Curves

    70,00 65,00 60,00 55,00 50,00 45,00 40,00 35,00 30,00 25,00 20,00 Speed [RPM] 400,00 380,00 360,00 340,00 320,00 300,00 280,00 260,00 240,00 220,00 200,00 180,00 160,00 140,00 120,00 100,00 Speed [RPM] 24 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 25: App 65 Flow At Different Rpm

    70,00 65,00 60,00 55,00 50,00 45,00 40,00 35,00 30,00 25,00 20,00 Speed [RPM] 400,00 380,00 360,00 340,00 320,00 300,00 280,00 260,00 240,00 220,00 200,00 180,00 160,00 140,00 120,00 100,00 Speed [RPM] © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 25...

  • Page 26: App 78 Flow At Different Rpm

    70,00 65,00 60,00 55,00 50,00 45,00 40,00 35,00 30,00 25,00 20,00 Speed [RPM] 400,00 380,00 360,00 340,00 320,00 300,00 280,00 260,00 240,00 220,00 200,00 180,00 160,00 140,00 120,00 100,00 Speed [RPM] 26 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 27: App 86 Flow At Different Rpm

    70,00 65,00 60,00 55,00 50,00 45,00 40,00 35,00 30,00 25,00 20,00 Speed [RPM] 400,00 380,00 360,00 340,00 320,00 300,00 280,00 260,00 240,00 220,00 200,00 180,00 160,00 140,00 120,00 100,00 Speed [RPM] © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 27...

  • Page 28: App 92 Flow At Different Rpm

    65,00 60,00 55,00 50,00 45,00 40,00 35,00 30,00 25,00 20,00 Speed [RPM] 420,00 400,00 380,00 360,00 340,00 320,00 300,00 280,00 260,00 240,00 220,00 200,00 180,00 160,00 140,00 120,00 100,00 Speed [RPM] 28 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 29: Flushing Valve Curves

    0.23 m Calculation factor at 60 barg / 870 psig for APP 53-92 Calculation Name factor APP 53 1500 APP 65 1500 APP 78 1500 APP 86 1700 APP 92 1780 © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 29...

  • Page 30: Temperature And Corrosion

    See example below on how to mount the pump If alternative mounting is required. please and connect it to an electric motor or combus- contact your Danfoss sales representative for tion engine (special coupling). further information. For further instruction on installation of coupling see APP Pump Instruction 180R9368.

  • Page 31: Filtration

    9.2 RO system with direct supply: Inlet line: Since water has very low vicosity, Danfoss APP Dimension the inlet line to obtain mini pumps have been designed with very narrow mum pressure loss (large flow, minimum...
  • Page 32 Operation guide Installation, Operation and Maintenance APP 53-92 pumps High pressure safety or relief valve: As the Danfoss APP pump begins to create pressure and flow immediately after start-up and regardless of any counter pressure, a safety or pressure relief valve (8)

  • Page 33: Dimensions And Connections

    Operation guide Installation, Operation and Maintenance APP 53-92 pumps 10. Dimensions and 10.1 APP 53 connections © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 33...

  • Page 34: App 65 - 92

    Operation guide Installation, Operation and Maintenance APP 53-92 pumps 10.2 APP 65 - 92 APP 65 - 92 34 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 35 Please see typical installations with check valve VCM 92 mounted in the outlet port in the drawing below. Non-standard configurations are available on request. For adjustment on site, please see Installation, Operation and Maintenance Manual or contact Danfoss. Standard configuration Non-standard configuration, turned 45 degrees left.

  • Page 36: App 53-92 With Ie3 Motor, Iec 315S - 4

    Operation guide Installation, Operation and Maintenance APP 53-92 pumps 10.3 APP 53-92 with IE3 motor, IEC 315S - 4 10.4 APP 53-92 with IE3 motor, IEC 315M - 4 36 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 37: App 53-92 With Ie3 Motor, Iec 315L 1-4

    Operation guide Installation, Operation and Maintenance APP 53-92 pumps 10.5 APP 53-92 with IE3 motor, IEC 315L 1-4 10.6 APP 53-92 with IE3 motor, IEC 315L 2 - 4 © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 37...

  • Page 38: Pump Connections

    80 barg 180Z1992 3” Vic. OSG connector (3.46 inch) (2.56”) Duplex (1160 psig) ) The installation instuction for Style 77DX is located in the Victaulic document I-100 Field Installation Handbook (htpp://static.victaulic.com) 38 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 39: Vcm 3" Victaulic

    Min. flow continously m3/h Max. flow continously barg Max pressure MAWP psig 1200 Opening pressure barg 0.05- 0.08 psig 0.73-1.16 Pressure loss at max. flow barg < 0.45 psig < 6.5 © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 39...

  • Page 40: Flow Versus Pressure

    Pressure drop curves for check valve VCM 92 Flow versus pressure for VCM 92 0,45 0,35 0,25 0,15 0,05 Flow [ m3/h ] Flow versus pressure for VCM 92 Flow [ GPM] 40 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 41: Accessories

    Base frame incl. vibration dampeners IEC 315 180Z0661 14. Service and warranty Warranty Danfoss APP pumps are designed for long operation, low maintenance and reduced lifecycle costs. Pump shutdown: Provided that the pump has been running The APP pumps are made of Duplex/Super...
  • Page 42 Operation guide Installation, Operation and Maintenance APP 53-92 pumps 42 | 180R9346 | AQ240486503020en-001702 AI167386503010en-001301 © Danfoss | DCS-SGDPT/SI | 2023.03...
  • Page 43 Instruction APP Pump Instruction APP 53 / APP 65 / APP 78 / APP 86 / APP 92 hpp.danfoss.com © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 1...

  • Page 44: Identification

    Service and warranty..............53 Identification PUMP Type APP 78 MADE IN DENMARK Code no. 180BXXXX Serial no. XXXXXX08-XXX Danfoss A/S, 6430 Nordborg, Denmark 44 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 45: System Design

    (6) is integrated in Place an inlet filter (1) in front of the APP the APP pump. pump (2). Please consult Danfoss filter data A non-return valve (7) in outlet can be sheet for guidance on how to select the installed in order to avoid backspin of the right filter.

  • Page 46: Preferred Ro System Design With Erd

    As water has very low viscosity, the APP pumps and ERDs in parallel have been designed with very narrow clearance For systems with Danfoss pumps and ERDs in in order to control internal leakage rates and parallel, please see our publication 180R9354, improve component performance.

  • Page 47: Overall Assembly With Coupling Bowex-Elastic®, Type Hew Compact

    Operation guide Installation, Operation and Maintenance APP 53-92 pumps 3.3 Overall assembly with coupling BoWex-ELASTIC®, type HEW compact Danfoss recommends to use a Bowex Elastic HEW Compact Coupling. See the Coupling Manual from BoWex. 1: Bolts 190 Nm ± 10 Thread size 2: Nuts 100 Nm ±...

  • Page 48: Mounting

    3-7 mm space. If alternative mounting is desired, please contact Danfoss High Pressure Pumps. Please take care to observe the recommended length tolerances of the chosen coupling, as an axial force on the pump will damage the pump.

  • Page 49: Direction Of Rotation

    Measure the longest distance “A” from top (“A” and “B” can be found on the next of bell housing to the button of coupling page). claw. © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 49...

  • Page 50: Connections

    Adjust respectively, verify the measure- If alternative mounting is desired, please contact ment, and secure both couplings with the Danfoss High Pressure Pumps. right torques on the locking screws (see coupling operation & mounting instruction). Choose proper tolerances to ensure an easy...

  • Page 51: Initial Start-Up

    Internal Otherwise the pump will be damaged if a flushing check valve is placed between pump and feed valve pump. © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 51...

  • Page 52: Operation

    If the water pump is operated above the Super Duplex line, always flush water pump with fresh In case of lower operating temperatures, please water at operation stop in order to minimize the contact Danfoss High Pressure Pumps. risk of crevice corrosion. NaCl vs. temperature 80 º...

  • Page 53: Storage

    Service and warranty Warranty Pump shutdown: Danfoss APP pumps are designed for long The APP pumps are made of Duplex/Super operation, low maintenance and reduced Duplex materials with excellent corrosion lifecycle costs.
  • Page 54 Operation guide Installation, Operation and Maintenance APP 53-92 pumps 54 | 180R9346 | AQ240486503020en-001702 180R9368 | AN220686503013en-000901 © Danfoss | DCS-SGDPT/SI | 2023.03...

  • Page 55: Electric Motors (180R9230)

    Electric Motors Motor Manual hoyermotors.com M a n u a l...
  • Page 56 Inspect the motor at regular intervals, keep it clean and doubled supply frequency. ensure free ventilation air flow, check the condition of shaft Only mount or remove drive components (pulley, coupling, seals and replace if necessary. Both electrical and mechanical 56 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 57 Maintenance, repairs and replacement on this type must At 60Hz the time will be reduced by app. 20%. Data for vertically mounted motors are half of the above only be carried out by qualified specialists. values. © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 57...
  • Page 58 Operation guide Installation, Operation and Maintenance APP 53-92 pumps Connection diagram Anschlußdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexión Collegamento Schemat polacsen 58 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 59 Operation guide Installation, Operation and Maintenance APP 53-92 pumps © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 59...
  • Page 60 Hoyer Motors, Motor Manual, April 2019 Head Offices Branch Offices Denmark Germany Benelux Over Hadstenvej 42 · DK-8370 Hadsten Landsberger Straße 155 · 80687 München Vasteland 78 · 3011 BN, Rotterdam T +45 86 98 21 11 · F +45 86 98 17 79 T +49 89 700 88 235 ·...
  • Page 61 Type HEW Compact Type HEW-ZS Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 61...
  • Page 62 Standard values of wear marking of coupling for potentially explosive atmospheres EU Certificate of conformity Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: 62 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 63 2.7206 0.5303 G 150 113.4 2.7809 0.5861 6.6418 1.1406 G 200 6.6099 1.3419 Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 63...
  • Page 64 235 192 205 365 120 140 150 90 68 328 240 12 M16 75.0 0.36 0.26 Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: 64 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 65 [mm] z x M 295.27 G 80 333.4 438.15 438.15 G 125 Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 65...
  • Page 66 The operating/assembly instructions are part of your product. Please store them carefully and close to the cou- pling. The copyright for these operating/assembly instructions remains with KTR. Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: 66 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 67 HEW, HEW Compact and HEW-ZS described in here corresponds to the technical status at the time of printing of these operating/assembly instructions. Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 67...
  • Page 68 With size 150 nuts as per DIN EN ISO 4014 are required additionally. ® ® Illustration 7: BoWex-ELASTIC type HEW1 Illustration 8: BoWex-ELASTIC type HEW2 Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: 68 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 69 Size G 80 G 125 Quantity z (component 4.3) Quantity z (component 6) Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 69...
  • Page 70 The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his re- sponsibility. Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: 70 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 71 Table 10: Cap screws DIN EN ISO 4762 Size G 80 G 125 Tightening torque [Nm] Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 71...
  • Page 72 If used in hazardous areas for the explosion group IIC (marking II 2GD c IIB T X), only half of the displacement figures (see tables 13 and 14) are permissible. Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: 72 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 73 = 40 % K K = K + K  100 % total Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 73...
  • Page 74 ±0.4 ±0.25 ±0.5 ±0.4 ±0.5 ±0.5 ±0.5 ±0.4 ±0.25 ±0.25 ±0.25  [°] Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: 74 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 75 200 µm electrostatic load does not have to be expected. Multiple coatings exceeding 200 µm are prohibited for explosion group llC. Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 75...
  • Page 76 4) Insert elastomer part, assemble coupling components 5) Find out the reason for overload Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: 76 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 77 If you operate with a worn elastomer part (see chapter 9.3 and 9.4) a proper operation meeting the explosion protection requirements and the directive 2014/34/EU is not ensured. Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 77...
  • Page 78 2) The maximum surface temperature of + 115 °C applies for the use in locations which are potentially subject to dust explo- sion, too. Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: 78 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 79  Visual inspection of the elastomer part (cracks, holes or anything similar). ® Illustration 15: BoWex-ELASTIC type HEW1 Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 79...
  • Page 80 Please absolutely observe the displacement figures specified (see tables 13 and 14). If the figures are exceeded, the coupling will be damaged. Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: 80 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 81 KTR does not assume any warranty claims resulting from insufficient rema- chining. Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 81...
  • Page 82 2017-04-24 i. V. i. A. Date Reinhard Wibbeling Andreas Huecker Engineering/R&D Product Manager Drawn: 2017-04-24 Shg/Hk Replacing: KTR-N dated 2013-06-10 Please observe protection note ISO 16016. Verified: 2017-04-24 Shg Replaced by: 82 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 83 Operation guide Installation, Operation and Maintenance APP 53-92 pumps © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 83...
  • Page 84 Operation guide Installation, Operation and Maintenance APP 53-92 pumps 84 | 180R9346 | AQ240486503020en-001702 © Danfoss | DCS-SGDPT/SI | 2023.03...
  • Page 85 Instruction APP pumps APP 53 - 92 Recommended service intervals hpp.danfoss.com © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 1...
  • Page 86 The recommendation is for guidance only. Design/features Danfoss APP pumps are designed for long operation and low maintenance and life cycle costs. If the Danfoss recommendations concerning system-design (see our data sheet) are not...
  • Page 87 Cavitation of the piston shoes. 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. © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 87...
  • Page 88 Operation guide Installation, Operation and Maintenance APP 53-92 pumps 88 | 180R9346 | AQ240486503020en-001702 AX281930801330en-000401 © Danfoss | DCS-SGDPT/SI | 2023.03...
  • Page 89 Parts list APP Pumps APP 53 / APP 65 / APP 78 / APP 86 / APP 92 hpp.danfoss.com © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 1...
  • Page 90 Tool sets ................98 90 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 91: Validity

    07 and higher and • up to 06 The serial no. is referring to the Serial no. on the product label. The digits shown (08) indicate the version number of the pump. © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 91...

  • Page 92: Parts List App 53-92 - Serial No. 07 Or Higher

    Int. Valve plate 1.4410 0092 Int. Valve plate 17 1.4410 0095 Port plate (shaft side) 1.4410/PEEK 0095 Port plate (shaft side) 17 1.4410/PEEK 0093 Back-up ring PTFE/Carbon 0094 O-ring (ø30.2 x 3 mm) 92 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 93 O-ring (ø35 x 3) 0152 Valve cone 1.4410 0153 Compression spring 1.4462 0154 Plug/guide 1.4410 0155 O-ring (ø47.2 x 3.5) Instruction Not mounted in APP 53 Only compatible with pump series 08 or higher © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 93...

  • Page 94: Exploded View App 53-92 Serial No. 07 Or Higher

    Operation guide Installation, Operation and Maintenance APP 53-92 pumps Exploded view APP 53-92 serial no. 07 or higher 94 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 95: Parts List App 53-86 - Serial No. Up To 06

    Int. Valve plate 17 1.4410/PP 0093 18 Back-up ring PTFE/Carbon 0094 18 O-ring (ø30.2 x 3 mm) 0095 1 Port plate (shaft side) 1.4410/PEEK 0095 1 Port plate (shaft side) 17 1.4410/PEEK © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 95...
  • Page 96 0151 1 O-ring (ø35 x 3) 0152 1 Valve cone 1.4410 0153 1 Compression spring 1.4462 0154 1 Plug/guide 1.4410 0155 1 O-ring (ø47.2 x 3.5) Instruction Not mounted in APP 53 96 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 97: Exploded View App 53-86 - Serial No. Up To 06

    Operation guide Installation, Operation and Maintenance APP 53-92 pumps Exploded view APP 53-86 - serial no. up to 06 © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 97...
  • Page 98 Torque wrench 60-340 Nm Fork wrench 13 mm Fork wrench 24 mm Fork wrench 30 mm Distance adapter Screwdriver 5.5 x 1 mm Screw (M8 x 16 mm) Screw (M6 65 mm) Shaft tool 98 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...
  • Page 99 Operation guide Installation, Operation and Maintenance APP 53-92 pumps © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 99...
  • Page 100 Operation guide Installation, Operation and Maintenance APP 53-92 pumps 100 | 180R9346 | AQ240486503020en-001702 © Danfoss | DCS-SGDPT/SI | 2023.03 AX191786502906en-001201...
  • Page 101 Service guide Trouble shooting guide APP, APP S and APP S 674 pumps hpp.danfoss.com © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 1...
  • Page 102 Swash plate ................110 102 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03...

  • Page 103: Trouble Shooting Fish Bone Chart

    Operation guide Installation, Operation and Maintenance APP 53-92 pumps Trouble shooting fish bone chart © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 103...

  • Page 104: No Flow/No Pressure

    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 105: Reduced Flow/Reduced Pressure

    Insufficient filtration means that too many or designed for seawater operation; for any too large hard particles can pass the main filter other fluid, please contact Danfoss High because it is damaged, bypassed or simply too Pressure Pumps sales office for further help.

  • Page 106: High Torque On Electric Motor

    3.2.3 Systems with more than one electric motor installed: 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, APP S Pumps sales office. or APP S 674 pump, it cannot provide sufficient torque.

  • Page 107: Noise From Pump

    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 108: Noise From Installation

    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 109: 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. © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 109...

  • Page 110: Port Plate

    To check this, please see item 6.1, picture 3. If the surface has any marks/scratches, it is worn/damaged and a new one is required. Please contact Danfoss High Pressure Pumps sales office for further infor- mation. 110 | 180R9346 | AQ240486503020en-001702...
  • Page 111 Operation guide Installation, Operation and Maintenance APP 53-92 pumps © Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 111...
  • Page 112 Operation guide Installation, Operation and Maintenance APP 53-92 pumps 112 | 180R9346 | AQ240486503020en-001702 © Danfoss | DCS-SGDPT/SI | 2023.03 521B1447 | DKCFN.PZ.003.A1.02...
  • Page 113 Service guide Right and wrong Trouble shooting guide for water hydraulic systems hpp.danfoss.com...
  • Page 114 Pump location Pump location Design Pump always to be placed below water Pump always to be placed below water Pump location above water surface Pump location above water surface surface level surface level level will cause damage level will cause damage Choice of material Choice of material Suction conditions...
  • Page 115 Installation Assembly of coupling Impurities Prior to installation, burrs and chips and Never use force when assembling the Chips or other impurities in the system The coupling must be easy and simple other impurities must be removed from coupling parts, as this will damage the may cause damage to assemble (see product instruction) pipes and hoses, eg with a felt plug...
  • Page 116 Wiring Starting procedure Level indicator Cleaning procedure 1. Fill cold water into the system via the return filter and 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 117 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 water in the tank Is the electric motor of temperature or out of the tap? very hot? Ie above 50 the pump unit rotating? provide better cooling...
  • Page 118 Fill water into the system Check power supply Replace filter and fuses and contact Is the filter control element electrician light on? Contact serviceman Trace leakage, if any Stamp 118 | 180R9346 | AQ240486503020en-001702 © Danfoss | DCS-SGDPT/SI | 2023.03...

This manual is also suitable for:

App 53App 65App 78App 86App 92

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