Danfoss APP 1.0 Installation, Operation And Maintenance Manual
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Danfoss APP 1.0 Installation, Operation And Maintenance Manual

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MAKING MODERN LIVING POSSIBLE
User manual
Installation, Operation and
Maintenance Manual
APP pumps (APP 0.6-1.0)
L enntech
L enntech
Tel. +31-152-610-900
Tel. +31-152-610-900
Fax. +31-152-616-289
Fax. +31-152-616-289
APP 0.6-1.0

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  • Page 1 L enntech L enntech MAKING MODERN LIVING POSSIBLE Tel. +31-152-610-900 Tel. +31-152-610-900 Fax. +31-152-616-289 Fax. +31-152-616-289 User manual Installation, Operation and Maintenance Manual APP pumps (APP 0.6-1.0) APP 0.6-1.0...

  • Page 2: Table Of Contents

    Local regulations............... 11 Pre mounting checklist, based on Danfoss preferred system design ..... 11 Lifting and positioning .
  • Page 3 User manual Installation, Operation and Maintenance APP Pumps (APP 0.6-1.0) Maintenance and service of the pump unit ..........15 General safety information .

  • Page 4: Validity

    This manual is valid for APP pumps with the following code numbers/serial numbers: APP 0.6 Code no. 180B3048 Serial no. APP 0.8 Code no. 180B3037 Serial no. APP 1.0 Code no. 180B3049 Serial no. 180R9262 / IOM APP Pumps - v01 / 12.2012...

  • Page 5: Eu Declaration Of Conformity

    EU Declaration of Conform- 180R9262 / IOM APP Pumps - v01 / 12.2012...

  • Page 6: Introduction

    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. 1.2 Symbols This manual contains the necessary instructions...

  • Page 7: Safety

    VFD operation. 2.5 In case of doubt Please contact Danfoss A/S in case of doubt. Contact information are listed in section 1.3, Manufacturer and customer service address. Before start-up, the settings for all protective...

  • Page 8: Technical Data

    3.1 Approved applications and operational limits for the pumps The pump and the pump units are designed for Danfoss recommends not to build a filter bypass the use in a Sea Water Reverse Osmosis (SWRO) function or use filters with an integrated bypass.

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

    User manual Installation, Operation and Maintenance APP Pumps (APP 0.6-1.0) 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 handling, lifting and with plugs in the port connections to protect the using lifting eyes and slings.

  • Page 10: Return To Supplier

    User manual Installation, Operation and Maintenance APP Pumps (APP 0.6-1.0) 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. 4.5 Return to supplier Please see maintenance chapter 7.

  • Page 11: Installation And Commissioning

    5.5 Local regulations Commissioning must always be done in accordance with valid regulations and local standards. 5.6 Pre mounting checklist, based on Danfoss preferred system design Schematic 1: Recommended system design 180R9262 / IOM APP Pumps - v01 / 12.2012...

  • Page 12: Lifting And Positioning

    See Data sheet or Instruction, pump. appendices 1 and 2. Filtration condition (10µm absolute (ß10 = 5000) See Danfoss requirements in Data sheet and Instruction, appendices 1 and 2 Power supply for electric motor and VFD. See Data sheet for the used motor and VFD, appendix 1.

  • Page 13: Ensure Free Flow

    Start the feed pump and ensure that the flow from the feed pump to the high pressure pump Danfoss offers commissioning and service at is unhindered. system manufacturer’s location. Rate quotes are offered upon request.

  • Page 14: Operation Of Motor Pump Unit

    Data sheet, appendix 1; APP pump instruction or Instruction for recommended service intervals in appendix 2 and 4. Danfoss offers service of the pump at the system manufacturer’s location as well as training in servicing the pump. Quotes are offered upon request.

  • Page 15: Maintenance And Service Of The Pump Unit

    For spare parts and service tools, please see Parts pump unit list, appendix 5. Remove all connections from the pump. Danfoss offers service of the pump at the system Disassemble the pump according to the manufacturer’s location and training in servicing Disassembling and Assembling Instruction the pump.

  • Page 16: Assembling The Pump Unit

    Installation, Operation and Maintenance APP Pumps (APP 0.6-1.0) Assembling the pump unit Assemble the pump according to the Dis- assembling and Assembling Instruction (available at www.ro-solutions.danfoss.com). Procedure for mounting pump back onto electric motor Do always follow the procedure delivered with...

  • Page 17: Troubleshooting And Scrapping Criteria

    Please use appendix 6, Trouble shooting guide as the operational specification. guideline or send the pump to Danfoss head- quarter in Denmark for evaluation. approved fluid. For other observations or troubles, please see direction.

  • 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 0.6-1.0) APP 0.6-1.0 ro-solutions.com...
  • Page 20 User manual Appendices for IOM APP Pumps (APP 0.6-1.0) Table of Contents Data sheet for APP 0.6-1.0 pumps (521B1136) ..........3 APP pump instruction APP 0.6-3.5 (180R9065) .
  • Page 21 MAKING MODERN LIVING POSSIBLE Data sheet for APP 0.6-1.0 pumps (521B1136) Data sheet Data sheet APP 0.6-1.0 ro-solutions.com...
  • Page 22 Data sheet APP 0.6-1.0 Data sheet for General information APP 0.6-1.0 pumps (521B1136) Benefits Table of Contents Technical data Flow at different rpm Flushing valve Power requirements Temperature and corrosion Operation Storage Noise level Filtration Dimensions 10.1 Pump 10.2 Complete unit Installation 11.1 Mounting...
  • Page 23 6.85 Weight Integrated flushing valve 1) Typical average flow at 80 bar (1160 psi). 2) For lower pressure, please contact Danfoss RO Sales Organization. 3) For higher pressure, please contact Danfoss RO Sales Organzation. 4) Intermittent pressure is acceptable for less than 10 seconds per minute.

  • Page 24: Flow At Different Rpm

    Using the diagram shown below, it is easy to Flow at different rpm select the pump which fits the application best if the flow required and the rotation speed (rpm) of the pump are known. APP 1.0 APP 0.8 APP 0.6 1000 1500...

  • Page 25: Power Requirements

    3.61 1.73 kW 2.02 kW 2.31 kW 2840 APP 0.8 16.3 0.98 4.31 2.07 kW 2.41 kW 2.76 kW 3400 APP 1.0 16.5 0.99 4.37 2.14 kW 2.49 kW 2.85 kW 2840 474.6 APP 1.0 19.8 1.19 5.24 2.57 kW 2.99 kW...

  • Page 26: Storage

    APP 0.6-1.0 7.2 Storage Frost protection is required at temperatures Storage temperature: below 2°C. Danfoss recommends to use -40°C to +70°C (+40°F to 158°F) – provided that DOWFROST from DOW Chemical Company or the pump is drained of fluid and stored Chilsafe mono propylene glycol from Arco ”plugged”...

  • Page 27: Dimensions

    F (mm) G (mm) H (mm) IEC Electric motor APP 0.6 200 1.5 kW, IEC 90S-2 APP 0.8 200 2.2 kW, IEC 90L-2 APP 1.0 250 3.0 kW, IEC 100L-2 180R9262 / IOM APP 0.6-1.0 Appendices - v02 / 12.2012...

  • Page 28: Installation

    Note: Any axial and/or radial loads on the shaft If alternative mounting is required, please must be avoided. contact Danfoss Sales Organization for further information. The pump should be connected to the rest of the plant with flexible hoses.

  • Page 29: System With App Pump

    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 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: Building Up The Pump Unit

    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: Orientation

    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: Initial Start-Up

    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: Open-Ended Systems With Direct Water Supply

    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) Electric Motors Motor Manual hoyermotors.com Manual 180R9262 / IOM APP 0.6-1.0 Appendices - v01 / 09.2012 180R9230...
  • 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 Svend Hoyer A/S · Over Hadstenvej 42 · DK-8370 Hadsten T +45 86 98 21 11 · F +45 86 98 17 79 · svendhoyer@svendhoyer.com · svendhoyer.com...
  • Page 43 MAKING MODERN LIVING POSSIBLE Recommended service intervals for APP pumps (180R9199) Instruction Recommended service intervals for APP pumps...
  • Page 44 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 45 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 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 MAKING MODERN LIVING POSSIBLE APP Parts list (521B0941) Parts list APP Pumps APP 0.6-1.0, APP 0.6-1.0 Compact APP 0.6-38 / APM 0.8-2.9 / APM 0.8-1.2 APPW 5.1- 10.2 APP 0.6-1.0...
  • Page 48 Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2 APP 0.6 - 1.0 Compact APP 0.6 - 1.0 Compact Note: The parts listed are not sold separately. Exploded view, see next page. Pos. Qnt. Designation Material Housing Duplex 5-10 Screw M6x12 AISI 316 Swash plate...
  • Page 49 Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2 Exploded view Exploded view APP 0.6 - 1.0 Compact APP 0.6 - 1.0 Compact 180R9262 / IOM APP 0.6-1.0 Appendices - v02 / 12.2012...
  • Page 50 Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2 APP 0.6 - 1.0 and APP 0.6 - 1.0 and Note: APM 0.8 - 1.2 APM 0.8 - 1.2 The parts listed are not sold separately, only in various kits. Parts for APM 0.8-1.2 are equivalent to the parts for APP 0.6-1.0 except for valve plate sets.
  • Page 51 Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2 Exploded view Exploded view APP 0.6 - 1.0 APP 0.6 - 1.0 APM 0.8 - 1.2 APM 0.8 - 1.2 180R9262 / IOM APP 0.6-1.0 Appendices - v02 / 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. 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 53 MAKING MODERN LIVING POSSIBLE Trouble shooting guide Guideline Trouble shooting guide for APP pumps...
  • Page 54 Instruction Trouble shooting guide for APP pumps Trouble shooting guide Trouble shooting fish bone chart for APP pumps 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...
  • Page 55 Instruction Trouble shooting guide for APP pumps Trouble shooting fish bone chart 180R9262 / IOM APP 0.6-1.0 Appendices - v02 / 12.2012...
  • Page 56 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 57 Insufficient filtration means that too many or operation; for any other fluid, please too large hard particles can pass the main filter contact Danfoss sales office for further because it is damaged, bypassed or simply too help. poor. Filtration efficiency must be 99.98% (Beta = 5000) at 10 μmto prevent abnormal...
  • Page 58 Start motors simultaneously. 3.3 Constant torque 3.3.1 Please contact Danfoss sales office. If the electric motor is too small for the APP pump it cannot provide sufficient torque. 3.4 Water pump damage 3.4.1 Dismantle pump and check for wear.
  • Page 59 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 A/S RO Solutions Technical Pump may eventually be damaged. Support. 4.6.3 If outlet pressure has exceeded its...
  • Page 60 5.3 Hose stiffness 5.3.1 Use amore flexible hose. Danfoss A/S can Too stiff hoses cannot damp the small pressure provide flexible hoses. Please contact pulsations from the pump, and subsequently Danfoss sales office for further informa- vibrations occur in the system/plant.
  • Page 61 Instruction Trouble shooting guide for APP 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 62 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 MAKING MODERN LIVING POSSIBLE Right and wrong (180R9042) Right and wrong Trouble shooting guide for water hydraulic systems danfoss.high-pressurepumps.com 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 0.6-1.0) 180R9262 / IOM APP 0.6-1.0 Appendices - v02 / 12.2012...
  • 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 0.8App 0.6180b3048180b3037180b3049

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