Danfoss APP 3.5 Operating Manual
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Danfoss APP 3.5 Operating Manual

Danfoss APP 3.5 Operating Manual

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Operating guide
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APP pumps
Installation, Operation and
APP 1.5 - 3.5
Maintenance Manual
Installation, Operation and
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APP pumps (APP 1.5-3.5)
APP 1.5-3.5
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  • Page 1 Operating guide User manual APP pumps Installation, Operation and APP 1.5 - 3.5 Maintenance Manual Installation, Operation and Maintenance Manual APP pumps (APP 1.5-3.5) APP 1.5-3.5 ro-solutions.com hpp.danfoss.com...

  • Page 2: Table Of Contents

    Local regulations...............10 Pre mounting checklist, based on Danfoss preferred system design ..... 11 Lifting and positioning .
  • Page 3 Operating guide | APP 1.5-3.5 pumps Maintenance and service of the pump unit ..........13 General safety information .

  • Page 4: Validity

    In case the pump delivered is ATEX certified, the Validity ATEX and ATEX certified versions. An additional ATEX instruction must also be read. ATEX certified pumps are indicated by Ex in the designation - example APP 3.5 Ex. Code no. 180B3043 On request APP 1.5 APP 1.5 Ex...

  • Page 5: Introduction

    General The APP pumps and pump units are manufac- approval the warranty will automatically tured by Danfoss A/S, and are sold and marketed become void. by a net of authorized distributors world wide. It is important that these instructions are...

  • Page 6: Manufacturer And Customer Service Address

    Operating guide | APP 1.5-3.5 pumps Your local Danfoss pump distributor can be 1.3 Manufacturer and customer service found on our homepage. address Data sheets and instructions on all accessories Danfoss A/S are available on hpp.danfoss.com Danfoss High Pressure Pumps...

  • Page 7: 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 8: 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 9: Return To Supplier

    Operating guide | APP 1.5-3.5 pumps Pumps which have a weight above 20 kilos (see Wrong lifting: 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 10: Installation And Commissioning

    Operating guide | APP 1.5-3.5 pumps 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 11: Pre Mounting Checklist, Based On Danfoss Preferred System Design

    Operating guide | APP 1.5-3.5 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. See Arrival inspection, transportation, handling, lifting and storage, chapter 4.

  • Page 12: Ensure Free Flow

    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 13: 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 14: 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 15: Troubleshooting And Scrapping Criteria

    Please use appendix 6, Trouble shooting 8.3 Mechanical failure 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 16 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 17: Appendices

    Operating guide Appendices APP 1.5 - 3.5 Installation, Operation and Maintenance Manual hpp.danfoss.com...

  • Page 18: Table Of Contents

    Operating guide | APP 1.5-3.5 pumps Table of Contents Contents Appendices ..................17 Data sheet for APP 1.5-3.5 (AI274333290009en-000701) .

  • Page 19: Data Sheet For App 1.5-3.5 (Ai274333290009En-000701)

    APP pumps APP 0.6-1.0 / APP 1.5-3.5 / APP (W) 5.1-10.2 / APP 11-13 / APP 0.6-1.0 / APP 1.5-3.5 / APP (W) 5.1-10.2 / APP 16-22 / APP 21-46 APP 11-13 / APP 16-22 / APP 21-43 ro-solutions.com hpp.danfoss.com.
  • Page 20 Data sheet | APP 0.6-46 / APP (W) 5.1-10.2 pumps Introduction ................21 Table of Contents Benefits.

  • Page 21: Introduction

    No pulsation dampeners necessary due IATF 16949, ISO 9001, ISO 14001. to extremely low pressure pulsation. Danfoss APP pumps are built into a broad range • Mobile systems for humanitarian and Application examples of RO desalination plants around the world: military organizations •...

  • Page 22: Technical Data

    21.2 A-weighted sound pressure level at 1 m from the pump unit For lower and higher pressure, please contact Danfoss. surfaces (reference box) acc. to EN ISO 20361 section 6.2. The noise For speeds above 3000 rpm the pump must be boosted at a pressure measurements are performed acc.

  • Page 23: Flow At Different Rpm

    Thus, the required rpm can be determined as: Required flow x Rated rpm Required rpm = Rated flow 5.2 APP 1.5-3.5 flow curves at 80 barg (1160 psig) APP 3.5 APP 3.0 APP 2.5 APP 2.2 APP 1.8 APP 1.5 18.0...

  • Page 24: Flushing Valve Curves

    Data sheet | APP 0.6-46 / APP (W) 5.1-10.2 pumps All pumps except APP (W) 5.1 - 10.2 are supplied Flushing valve curves with an integrated flushing valve that allows the fluid to flow from inlet to the outlet, when the pump is not running.

  • Page 25: Motor Requirements

    1 gpm 0.23 m 7.2 Calculation factor for APP 1.5-3.5 Name Calculation factor 3450 APP 1.5 3450 APP 1.8 3450 APP 2.2 3000 APP 2.5 3450 APP 3.0 3000 APP 3.5 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps | 03.2023...

  • Page 26: Temperature And Corrosion

    See example below on how to mount the pump If alternative mounting is required. please Installation and connect it to an electric motor or combus- contact your Danfoss sales representative for tion engine (special coupling). further information. Note: Do not add any axial or radial loads to the pump shaft.

  • Page 27: Filtration

    9.2 RO system with direct supply: changing filter cartridges according to schedule. Inlet line: Dimension the inlet line to obtain Since water has very low vicosity, Danfoss APP minimum pressure loss (large flow, pumps have been designed with very narrow minimum pipe length, minimum number clearances in order to control internal leakage of bends/connections, and fittings with low...
  • Page 28 Data sheet | APP 0.6-46 / APP (W) 5.1-10.2 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 safey or pressure relief valve (8)

  • Page 29: Dimensions And Connections

    Data sheet | APP 0.6-46 / APP (W) 5.1-10.2 pumps 10. Dimensions and 10.2 APP 1.5-3.5 connections 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps | 03.2023...

  • Page 30: Dimensions With Motor Unit

    The examples of assemblies with motor are only for IEC motors and couplings. Please make sure to check required motor power and dimensions when selecting size of pump and motor. For ad- vice and calculation tool, please contact Danfoss. A mm B mm C mm...

  • Page 31: Service

    Data sheet | APP 0.6-46 / APP (W) 5.1-10.2 pumps 13. Service 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 32 AI274333290009en-000701 | 32 © Danfoss | DCS (im) | 2021.11...

  • Page 33: Pump Instruction App 1.5-3.5 (180R9065)

    Instruction Instruction APP pump instruction APP pumps APP 0.6-1.0 / APP 1.5-2.5 / APP 3.0-3.5 APP 0.6-1.0, APP 1.5-2.5 and APP 3.0-3.5 ro-solutions.com hpp.danfoss.com...
  • Page 34 Instruction | APP pump instruction APP 0.6-1.0, APP 1.5-2.5 and APP 3.0-3.5 Contents Table of Contents Identification ................35 System design .

  • Page 35: Identification

    Instruction | APP pump instruction APP 0.6-1.0, APP 1.5-2.5 and APP 3.0-3.5 Identification The design of the system must ensure that self System design 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 36: General Guidelines For Calculation Of Pressure Losses

    Instruction | APP pump instruction APP 0.6-1.0, APP 1.5-2.5 and APP 3.0-3.5 The inlet line connection must be properly 2.4 General guidelines for calculation of tightened, as possible entrance of air will cause pressure losses cavitation. In order to avoid the risk of cavitation, the inlet pressure at the pump must be in accordance The suction conditions can be optimized with the specifications mentioned in Data...

  • Page 37: Building Up The Pump Unit

    (Please also see hints in “Right and Wrong”) unit 3-5 mm [0.12-0.2 inch] If alternative mounting is desired, please contact the Danfoss High Pressure Pumps. Choose proper tolerances to ensure an easy mounting of the elastic coupling without use of tools. Elastic coupling...

  • Page 38: Orientation

    Instruction | APP pump instruction APP 0.6-1.0, APP 1.5-2.5 and APP 3.0-3.5 The valve should be placed as close to the pump 3.3 Orientation 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 39: Initial Start-Up

    For further information on anti-freeze media, Max. pressure on the pump’s outlet line should please contact Danfoss High Pressure Pumps. be limited at 80 barg (1160 psig) continuously. Short-term pressure peaks (e.g. in connection with closing of a valve) of up to 100 barg Recommended procedure: (1450 psig) are acceptable.

  • Page 40: Open-Ended Systems With Direct Water Supply

    Service 6.1 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. properties. It is however, always recommended Provided that the pump has been running to flush the pump with fresh water when the...

  • Page 41: Motor Manual

    Electric Motors Motor Manual hoyermotors.com M a n u a l...
  • Page 42 Motor Manual General etc.) using suitable tools, never hit the drive components with a hammer as this will cause damage to the bearing. This manual concerns the following types of standard The motor are balancing with half key, ensure that the drive induction motors from Hoyer: components are also the same.
  • Page 43 Motor Manual connections must be checked and tightened if necessary. The table values are based on an ambient temperature of Bearing size and type are specified on the rating plate. Motor 25°C. The values must be halved for every 15K increase in types HMA3 and HMC3 is as standard with lifetime greased bearing temperature.
  • Page 44 Connection diagram Anschlußdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexión Collegamento Schemat polacsen 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps | 03.2023...
  • Page 45 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps | 03.2023...
  • Page 46 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 47: Recommended Service Intervals For App Pumps (Ax290239527130En-000201)

    Instruction Instruction Recommended service intervals APP pumps for APP 0.6-1.0 / APP 1.5-3.5 / APP 0.6 - 3.5 Recommended service intervals APP (W) 5.1-10.2 / APP 11-13 / APP 16-22 ro-solutions.com hpp.danfoss.com...

  • Page 48: General Information

    The recommen- dation is based upon good engineering practice and on experience gained from operation even under extreme conditions. Danfoss APP pumps are designed for long Design/features operation and low maintenance and life cycle If the Danfoss recommendations concerning costs.
  • Page 49 Instruction | Recommended service intervals for APP 0.6 - 3.5 pumps In case of doubt - the pistons must be replaced. Appendix 1 Pistons: 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.
  • Page 50 AX290239527130en-000201 | 50 © Danfoss | DCS (im | 2021.09...

  • Page 51: Parts List For App 1.5-3.5 (Ax274346749037En-000501)

    Parts list Parts list APP Pumps APP pumps APP 0.6-46 / APM 0.8-2.9 / APP 0.6-43 / APM 0.8-2.9 / APP W 5. 1 -10.2 APP W 5.1-10.2 ro-solutions.com hpp.danfoss.com...
  • Page 52 Parts list | APP 0.6-46 / APM 0.8-2.9 / APP (W) 5.1-10.2 Table of Contents Table of Contents General ................53 Parts list APP 1.5-2.5 and APM 1.8-2.9.

  • Page 53: General

    Parts list | APP 0.6-46 / APM 0.8-2.9 / APP (W) 5.1-10.2 This parts list provides an overview of the General content of the various service sets as well as explodede views for both non ATEX and ATEX certified pumps. ATEX certified pumps are indicated by Ex in the designation.

  • Page 54: Parts List App 1.5-2.5 And Apm 1.8-2.9

    Parts list | APP 0.6-46 / 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 55: Exploded View App 1.5-2.5 And Apm 1.8-2.9

    Parts list | APP 0.6-46 / 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 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps | 03.2023...

  • Page 56: Parts List App 3.0-3.5

    Parts list | APP 0.6-46 / 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 57: Exploded View App 3.0-3.5

    Parts list | APP 0.6-46 / APM 0.8-2.9 / APP (W) 5.1-10.2 Exploded view APP 3.0-3.5 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps | 03.2023...

  • Page 58: Tool Sets

    Parts list | APP 0.6-46 / APM 0.8-2.9 / APP (W) 5.1-10.2 22. Tool sets Note: The parts listed are not sold separately, only in various kits. Designation Shaft bush Press bush Drift Torx (T30) Shaft bush (Ø18) Press bush (Ø18) Allen key (4 mm) Allen key (5 mm) Allen key (6 mm)
  • Page 59 Parts list | APP 0.6-46 / APM 0.8-2.9 / APP (W) 5.1-10.2 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps | 03.2023...
  • Page 60 Danfoss A/S High Pressure Pumps Nordborgvej 81 DK-6430 Nordborg Denmark AX274346749037en-000401 | 60 © Danfoss | DCS (im) | 2018.11...

  • Page 61: Trouble Shooting Guide For App, App S And App S 674 Pumps

    Guideline Trouble shooting guide APP, APP S and APP S 674 pumps ro-solutions.com...
  • Page 62 Swash plate ................70 62 | © Danfoss | DCS (im) | 2023.03...

  • Page 63: Trouble Shooting Fish Bone Chart

    Instruction | Trouble shooting guide for APP, APP S and APP S 674 pumps Trouble shooting fish bone chart | 63 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps © Danfoss | DCS (im) | 2023.03...
  • Page 64 Instructions on internal elements 1.6 Pump damage (the internal parts may be damaged) in how to troubleshoot internal pump – are available on hpp.danfoss.com. parts. 64 | © Danfoss | DCS (im) | 2023.03 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps...

  • Page 65: Reduced Flow/Reduced Pressure

    Check that the motor rotor winding is not damaged. | 65 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps © Danfoss | DCS (im) | 2023.03...

  • Page 66: High Torque On Electric Motor

    Too heavy damage in the pump will increase 3.4 Water pump damage friction causing a high torque (see item 6, Typical signs of wear). 66 | © Danfoss | DCS (im) | 2023.03 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps...
  • Page 67 Noise frequency changes during soft start-up/ 4.7 Soft start/stop running at operation speed. stop. 4.7.2 If noise is abnormal at operation speed, check internal parts (see above). | 67 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps © Danfoss | DCS (im) | 2023.03...
  • Page 68 5.5 Vibration dampener under the electric motor/pump. electric motor, vibrations from the motor and motor pump may be transferred to the frame and the rest of the system/plant. 68 | © Danfoss | DCS (im) | 2023.03 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps...

  • Page 69: Valve Plate

    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. | 69 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps © Danfoss | DCS (im) | 2023.03...

  • Page 70: 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. 70 | © Danfoss | DCS (im) | 2023.03...
  • Page 71 Instruction | Trouble shooting guide for APP, APP S and APP S 674 pumps | 71 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps © Danfoss | DCS (im) | 2023.03...
  • Page 72 Danfoss A/S High Pressure Pumps DK-6430 Nordborg Denmark © Danfoss | DCS (im) | 2015.12...

  • Page 73: Right And Wrong (180R9042)

    Right and wrong Right and Wrong Trouble shooting guide for water hydraulic systems Trouble shooting guide for water hydraulic systems hpp.danfoss.com...
  • Page 74 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 75: Installation

    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 76: Starting Procedure

    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 77: Troubleshooting

    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 78: Closed Water Systems

    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 80 180R9267 | AQ291128576527en-000902 IOM APP 1.5-3.5 Pumps | 80 © Danfoss | DCS (im) | 2023.03...

This manual is also suitable for:

App 1.5App 1.8App 2.2App 2.5App 3.0App 1.5 ex ... Show all

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