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Operation guide
APP pumps
APP 53 / APP 65 / APP 78 / APP 86 / APP 92
Installation, Operation and
Maintenance Manual
hpp.danfoss.com
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
Table of Contents Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.2 Symbols
1.3
1.4
1.4.1
Manufacturer and customer service address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Country specific information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
United Kingdom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1
2.2
2.3
2.4
2.5
General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Preferred system design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Commissioning and servicing the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Adhere to the following important points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
In case of doubt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Approved applications and operational limits for the pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Application range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Electric motor data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
VFD and Direct on line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Noise and vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Space requirement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.8 Filtration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.9
3.10
Properties of water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Air bubbles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.11 Chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.
4.1
Arrival inspection, transportation, handling, lifting and storage . . . . . . . . . . . . . . . . . . . . . . . . . .8
Arrival inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.2 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.3
4.4
4.5
General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Transport and handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Return to supplier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.6 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5.
5.1
5.2 Cleanliness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
5.3
5.4
5.5
5.6
5.7
5.8
Installation and commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Important dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Fluid temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Electrical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Local regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Pre mounting checklist, based on Danfoss preferred system design . . . . . . . . . . . . . . . . . . . . .11
Lifting and positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Mount the different equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.9 Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.10 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.11 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.12
5.13
5.14
5.15
5.16 Verify direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.17 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.18
5.19
Ensure free flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Verify setting of safety/relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Flush the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Bleed and remove air from the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Check the filter condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Instruct operator and maintenance personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
6.
6.1
6.2
7.
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
Operation of pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
What to listen and look for . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Maintenance and service of the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Service and inspection interval for the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Shut down of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Disassembling and assembling the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Assembling the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Procedure for mounting the pump onto the electric motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Getting the pump unit back into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Storage of the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
8.
8.1
8.2
8.3
8.4
8.5
8.6
Troubleshooting and scrapping criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Operational conditions which can cause pump failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Mechanical failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Electrical failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Responsibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Scrapping criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.
6.
7.
8.
Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.
Data sheet for APP pumps 53-92 AI167386503010en-001 3 01) . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.
Instruction for APP pumps 53-92 (180R9368) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3.
4.
Electric motors (180R9230) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Bowex coupling manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Recommended service intervals (AX281930801330en-000401) . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Parts list (AX191786502906en-001101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Trouble shooting (521B1447) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Right and wrong (180R9042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 3
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
Validity This manual is valid for APP pumps with the following type an serial number or higher:
Type
APP 53
APP 65
APP 78
APP 86
APP 92
Serial no.
XXXXXX 08 -XXX
XXXXXX 08 -XXX
XXXXXX 08 -XXX
XXXXXX 08 -XXX
XXXXXX 08 -XXX
PUMP
Type APP 78
Code no. 180BXXXX
Serial no. XXXXXX08-XXX
MADE IN DENMARK
The serial number is referring to the Serial no. on the product label. The digits shown (08) indicate the version number of the pump.
Danfoss A/S, 6430 Nordborg, Denmark
4 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
1.
Introduction 1.1 General
The APP pumps and pump units are manufactured by Danfoss A/S, and are sold and marketed by a net of authorized distributors world wide.
This manual contains the necessary instructions for the installation, operation and service of the pumps used in a Sea Water Reverse Osmosis
(SWRO) system or Brackish Water Reverse
Osmosis (BWRO) system.
In case the pump delivered is ATEX certified, the additional ATEX instruction must also be read.
The APP pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor.
• If any changes are made without written approval the warranty will automatically become void.
It is important that these instructions are always available to the personnel concerned.
1.2 Symbols
Indicates something to be noted by the reader
Indicates a situation which will or could result in damage to the pump and its function
Use of the pump in other applications that are not suitable for the pump unit can cause damages to the pump unit, with risk of personal injury.
Indicates a situation which will or could result in personal injury and/or damage to the pump
Electrical hazard - Indicates a high- voltage warning
All personnel being responsible for operation and maintenance of the pump unit must read and fully understand these instructions, especially the section “Safety”, before:
• Transportation of the pump unit
• Lifting the unit
• Installing the pump unit
• Connecting the pump unit to the water system
• Connecting the electric motor and instrumentation
• Commissioning the unit
• Servicing the pump unit, mechanical and electrical parts
• Decommissioning the pump unit
The pump must always be installed and used in accordance with existing national/local sanitary, safety regulations and laws.
It is the responsibility of the safety officer or the chief operator to assure compliance with all local regulations that are not taken into account in this manual.
Safety glasses required
Hearing protection required
Safety shoes required
Safety helmet required
!
Protective garments must be worn
Protective garments must be worn
Danger HOT.
Do not touch
© Danfoss | DCS (im) | 2021.12
Changing the pumps’ or pump units’ operational limits and hardware:
• Changes to the delivered pump or motor pump unit may only be done with a written approval from Danfoss High Pressure Pumps.
• Operation outside the Danfoss specifications requires a written approval from Danfoss
High Pressure Pumps.
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 5
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
1.3 Manufacturer and customer service address
Danfoss A/S
Danfoss High Pressure Pumps
RO Solutions
Nordborgvej 81,
DK-6430 Nordborg
Denmark
Telephone: +45 7488 4024
Fax: +45 7445 3831
Email: [email protected]
Homepage: hpp.danfoss.com
Your local Danfoss pump distributor can be found on our homepage.
Data sheets and instructions on all accessories are available on hpp.danfoss.com
1.4 Country specific information
1.4.1 United Kingdom
UK importer:
Danfoss Ltd.
22 Wycombe End
HP9 1NB Beaconsfield
United Kingdom
2. Safety
2.1 General information
Dangers that can arise from not following the instructions:
When the pump or pump unit is managed by untrained personnel, there is a danger of:
• Death or fatal injuries
• Costly damages and claims
When using an electric motor, the motor must always be supplied with adequate cooling ventilation.
When using an electric motor together with a
VFD, the motor must be designed for operation with a VFD.
VFD operation may increase the temperature inside the electric motor if the motor is not designed for VFD operation. This can damage the motor and cause unintended breakdown.
6 | © Danfoss | DCS (im) | 2021.12
All electrical installation work must only be carried out by authorized personnel in
accordance with EN60204-1 and/or local regulations.
It is recommended to install a lockable circuit breaker to avoid inadvertent starting and/or electrical hazard. The lockable circuit breaker must be used during installation, operation and maintenance.
It is recommended to place a local safety switch nearby the pump, enabling service personnel to cut power for the electric motor.
Protect the motor and other electrical equipment from overloads with suitable equipment.
In case the pump delivered is ATEX certified, the additional ATEX instruction must also be read.
!
Protective garments must be worn
Danger
Installation and maintenance must always take place during complete shutdown in an unpressurised condition.
The drive unit must be secured against inadvertent switching-on (with signs, switching off electricity power supply) in order to avoid serious injuries due to rotating parts. Do not reach inside the working area during the operation of the coupling.
For protection against accidental contact appropriate security must be installed.
Before start-up, the settings for all protective devices, such as sensors/switches and safety valves must be verified and free flow from safety valves must be ensured.
Always wear suitable safety clothing when handling the pump.
When working near the pump system, safety shoes, safety glasses, hearing protection and safety helmet must always be worn.
All pipe and hose connections must be stressfree mounted, securely fastened to the pump and well supported. Improper installation will or can result in personal injury and/or damage to the pump.
Use of this manual does not relieve operation and maintenance personnel of the responsibility of applying good judgment when operating and maintaining the pump and its components.
Under certain operational conditions the surface of the pump can be above 60°C / 140°F. Under these conditions the pump must be labelled with a “Danger Hot” sign.
2.2 Preferred system design
Danfoss recommends to build systems with a high degree of safety. Danfoss preferred system design and P&ID are found in appendix 1, Data sheet, and appendix 2, Instruction.
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
3.
Technical data
© Danfoss | DCS (im) | 2021.12
It is always the system builder´s responsibility that the system design does not cause any kind of hazard and is adapted to local regulations and standards.
Proper installation, proper start up and shutdown devices as well as high-pressure protection equipment is essential.
2.3 Commissioning and servicing the unit
It is recommended that commissioning and servicing are carried out by a minimum of two people, where one is acting as a supervisor.
•
•
•
•
•
•
Do not try to lift the pump unit manually; most of the pumps weigh more than
20 kilos, see specific weight for the pump in the appendix 1, Data sheet.
Always bleed the pump prior to initial start-up.
Do not mount the pump without the bell housing and a flexible coupling.
Do not try to start the unit before the system components are mounted, bleeded and adjusted.
Flush the system throughly before connecting the pump or pump unit.
Check rotation direction of the motor before mounting the pump.
•
2.4 Adhere to the following important points
Before using the pump/pump unit it is very important to read and understand this user manual.
2.5 In case of doubt
Please contact Danfoss A/S in case of doubt.
Contact information is listed in section 1.3,
Manufacturer and customer service address.
3.2 Application range
The Danfoss range of APP high-pressure pumps is designed according to EN 809 for use in RO applications with low viscosity and corrosive fluids such as sea water.
3.3 Electric motor data
See recommended motor in appendix 1, Data sheet or appendix 3, IOM for motors. The motors mentioned are the most common used motors by Danfoss High Pressure Pumps.
3.1 Approved applications and operational limits for the pumps
The pump and the pump units are designed for the use in a Sea Water Reverse Osmosis (SWRO) or Brackish Water Reverse Osmosis (BWRO) systems.
The APP pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor.
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:
Nm APP
53
MAWT 878
APP
65
1,118
APP
78
APP
86
APP
92
1,257 1,112 1,112
MAST 1,700 1,700 1,700 1,700 1,700
MAWT: Maximum allowable working torque
MAST: Maximum allowable starting torque
Use of the pump in other applications not suitable for the pump unit can cause damages to the pump unit, with risk of personal injury.
For system integration of the pump, please see appendix 1, Data sheet and appendix 2,
Instruction.
3.5 Noise and vibration
Noise level for a pump unit with a ”standard” motor measured according to EN ISO 3744: 2010, see appendix 1, Data sheet. Possibilities to reduce noise and vibration are described in the same Data sheet.
3.6 Dimension drawings
Dimensions of the different pumps can be found in appendix 1, Data sheet.
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4. Arrival inspection, transportation, handling, lifting and storage
3.7 Space requirement
When doing service or replacing the complete pump unit, it is recommended to have sufficient space available around the pump in order to ensure easy access. Sufficient space means at least 1 meter/40 inches around the pump. When working with high pressures, it is important to have the right space available around the pump as stated in the safety requirements.
3.9 Properties of water
It is recommended NOT to use the pumps in feed water concentrations higher than 50,000 ppm
TDS without consulting your local Danfoss pump distributor.
3.8 Filtration
(10µm absolute [ß
10
≥ 5000])
Requirements are specified in appendix 1, Data sheet and in appendix 2, Instruction.
Danfoss recommends not to build a filter bypass function or to use filters with an integrated bypass. If the above recommendation is not followed the warranty for the pump will automatically become void.
It should be possible to monitor the condition of the filter via the differential/delta pressure across the filter.
Using insufficient filtration or a filter bypass can cause a failure or decreased service life of the pump.
3.10 Air bubbles
Large bubbles in a pressurised RO system can result in damage to piping, equipment and the pump.
All air must be bleeded from both the low- pressure and high-pressure side before the RO system is pressurised. Special consideration should be given in order to minimize air bubbles in the feed flow. Air bubbles can cause cavitation.
3.11 Chemicals
The pump should not be exposed to any chemicals as it can result in damage to piping, equipment and internal parts in the pump.
4.1 Arrival inspection
The pump is packed in a cardboard or wood box with plugs in the port connections to protect the pumps from damage during transportation.
When the shipment has arrived it is important to check the pump for any damages. The name plate/type designation must be in accordance with the delivery note and your order.
In case of damage and/or missing parts, a report should be documented and presented to the carrier at once.
4.4 Transport and handling
Small pumps which have a weight below 20 kilos can be handled by hand if they are not mounted together with an electric motor. The weight of a small pump with a motor will be above 20 kilos.
Do not use connections/nozzles for lifting!
Do not use only one sling!
4.2 Warning
Before any lifting operation is performed, environmental conditions must be taken into consideration (Ex-rated areas, wind speed, wet/ dry conditions, lifting height, etc.).
4.3 General safety information
Personnel involved in lifting and transporting the equipment (see Safety, chapter 2) must be trained in handling and in safety procedures for lifting heavy loads. Many of the pumps and pump units weigh more than 20 kilos, which requires lifting slings and suitable lifting devices; e.g. an overhead crane or industrial truck to be used as minimum.
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Pumps which have a weight above 20 kilos must be handled by using lifting eyes and slings.
Wrong lifting:
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When the pump is mounted together with a bell housing, the pump can be rotated and in that case the lifting eye cannot be used in all positions. When lifting a pump with bell housing, a sling can be used to lift the pump by positioning it on the drive end of the pump outlet.
When the pump is mounted together with an electric motor, it must not be lifted in the lifting eye . A pump unit with motor must be handled by using two slings around the pump unit. One sling must be attached to the electric motor and one sling around the pump.
Make sure that the unit/load is balanced before lifting. The centre of the mass varies from pump/ pump unit size to pump(pump unit).
See below examples of where to/not to attach the lifting slings on the pump unit with motor:
Correct lifting with 2 separate slings:
Some motors and pumps have specific lifting eyes.
Do not use connections/nozzles for lifting!
Do not use only one sling!
Make sure that the unit/load is balanced before lifting. The centre of the mass varies from pump/ pump unit size to pump/pump unit.
How to mount the pump and the electric motor correctly, see appendix 1, Data sheet or appendix
2, Instruction.
Incorrect lifting can result in personal injury and/or damage to the pump unit, see appendix
2, Instruction.
Once the lifting is done the lifting eye must be removed from the pump.
4.5 Return to supplier
Please see maintenance chapter 7.
4.6 Storage
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.
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5. Installation and commissioning
5.1 Important dimensions
Physical dimensions and connections of the pump unit are described in appendix 1, Data sheet.
5.4 Electrical data
Check voltage, current frequency and rated power on the electric motor and VFD settings on the name plate placed on both the motor and the VFD.
5.2 Cleanliness
It is very important that the tubes and pipes are completely clean : no dirt, chips or burrs are allowed. Flush all piping before connecting the high-pressure pump to ensure the system is clean. Internal surfaces of the piping must not be corroded. If dirt or rust is not removed, the pump and the valves can be damaged. In worst case the pump can be damaged beyond repair!
5.5 Local regulations
Commissioning must always be done in
accordance with valid regulations and local standards.
5.3 Fluid temperature
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
Feed
PI
Media filter
PI PI PI PT
Fresh water permeat flush
PI
PI
Brine
Permeate
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5.6 Pre mounting checklist, based on Danfoss preferred system design
Table 1: Check points when assembling and commissioning system
CP1
CP2
CP4
Check points
Ensure that the environmental conditions are safe.
Minimum and maximum start-up temperature for fluid and pump.
CP3 Filtration condition (10 µm absolute (ß
10
≥ 5000)
Power supply for electric motor and VFD.
CP5 Safety circuit / breaker must be sized for the motor and environment (corrosion and humidity)
CP6 Bolts and screws must conform to environmental conditions as well as fluid and torque requirements.
CP7 Instrumentation, pressure switch should be designed to conform to the environment (corrosion and humidity).
CP8 Check the factory settings of the safety/relief valves or pressure relief valves (page 11).
CP9 Check the settings of the pressure transmitter/switch (3) set at min. inlet pressure (page 11).
CP10 Check that all pressure indicators (PI) are selected to be able to measure the system pressure range (page 11).
CP11 Check that the coupling is installed according to manufacturers instruction
CP12 Ensure all pipings have been flushed and are correct installed
CP13 Check piping for possible air gaps.
Comment
See Arrival inspection, transportation, handling, lifting and storage, chapter 4.
See Data sheet or Instruction, appendices 1 and 2.
See Danfoss requirements in
Data sheet and Instruction, appendices 1 and 2
See Data sheet for the used motor and VFD.
See Data sheet for the used safety circuit.
See Data sheet for the used equipment.
See Data sheets for the used valves.
See Data sheet or Instruction, appendices 1 and 2.
Scaling should at least be 1 bar or more precise.
OK ?
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5.7 Lifting and positioning
Lift the pump unit onto base (Remember vibration dampeners, if needed). Fasten the motor to the base.
See also chapter 4, Arrival inspection, transportation, handling, lifting and storage.
5.9 Electrics
All electrical installation work must be carried out by authorized personnel in accordance with
EN60204-1 and/or local regulations. (see also
Safety, chapter 2)
Turn off the safety circuit breaker and lock it.
Mount the power cable on the electric motor.
If a VFD is used, adjust the protective motor switch/VFD to the current limits found on the name plate of the electric motor.
5.8 Mount the different equipment
(connections, pipes, tubes, check and safety/relief valves, etc.)
• The hard piping and flexible hoses used, must be of proper design and must be installed in accordance with the manufacturer’s recommendations. (see also Design guides 180R9084 and 180R9367 - both available on hpp.danfoss.com).
• Misalignment of the hard pipes may give unintended stress on the pump port connections and may damage the pump.
• Prevent excessive external pipe load.
• Do not connect piping by applying external force (use of wrenches, crane, etc.) Piping must be aligned without residual stress.
• Do not mount expansion joints so that their force applies internal pressure on the pump connections.
5.10 Instrumentation
The pressure switch/sensor should be mounted as close to the pump as possible. It is recommended to test the pressure/sensor switch via an instrumentation manifold.
Mount the pressure switch/sensors according to the manufacturer’s instructions.
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5.11 Connections
Mount and tighten connections and check valve(s) as specified.
Danfoss check valve VCM 92 comes with a flange connection that is easily mounted directly on the outlet port (outlet connection is not required).
Note: Bolts (ref. 11) must be tightened with torque 95Nm ± 9.5 Nm.
Use only Style 77DX coupling or equivalent for the 3” victaulic OSG outlet on the VCM 92.
Unlock the safety circuit breaker. Start the motor for 1 second and observe the direction of rotation either looking at the fan of the motor or the coupling through the inspection hole in the bell housings (not available on all bell housings).
If the motor is turning the wrong direction, switch two phases in the connection box of the motor or reprogram the direction in VFD.
When the motor is turning in the right direction, the pump can be mounted.
95 Nm ± 9.5 Nm
5.12 Ensure free flow
Ensure free flow from the safety/relief valves 8 and 9 (schematic1, page 10). A blocked safety/ relief valve can cause excessive build-up of pressure and thereby cause dangerous situations and damage to the whole system.
5.13 Verify setting of safety/relief valves
Make sure, the safety/relief valves 8 and 9 are placed correctly.
Check the pressure settings on the name plates of the safety/relief valves. If they are within specifications, you can continue.
•
•
•
•
•
•
•
•
•
•
5.17 Commissioning
Close all the bleeding and draining plugs.
Open the pressure valve at the brine site.
Switch the safety circuit breaker on for both motor(s) and VFD(s).
Start the feed pump.
Start the high-pressure pump.
If a VFD or a soft starter is used, a ramp up time of minimum 10 seconds is required to avoid damage of the pump.
Monitor the inlet and outlet pressure of the high-pressure pump and look for leakages.
Check the function of the pressure indicators by slowly closing the valves. The pump unit should stop when the minimum inlet pressure and maximum outlet pressure has been reached.
Adjust the pressures to the specified inlet and outlet pressure for the system and let the pump unit run until the electric motor and pump temperature is stable.
If the system is running within the system design limits, the system is released for operation.
5.18 Check the filter condition
Evaluate contamination found in filter, replace filter elements, if necessary.
5.14 Flush the pump
Fully open the pressure valve at the brine outlet.
Close all the bleeding and draining plugs on the high-pressure pump.
Start the feed pump and ensure free flow to the high-pressure pump.
5.15 Bleed and remove air from the pump
Open the bleeding plugs. Keep the plugs open until the high-pressure pump is bleeded.
5.19 Instruct operator and maintenance personnel
Before using the pump/pump unit, the personnel must be instructed in using the pump/pump unit, its function, components, documentation and safety.
Danfoss offers commissioning and service at system manufacturer’s location. Rate quotes are offered upon request.
5.16 Verify direction of rotation
The direction of rotation must always follow the arrow. The arrow is placed on the pump or pump unit.
Check the direction of rotation before mounting the pump.
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6.
Operation of pump unit
6.1 General safety information
Before inspecting the pump unit, read the Safety chapter 2 in this user manual.
6.2 What to listen and look for
If one or more of the following examples are observed, please act as indicated:
A) Loose bolts – check all bolts and, if necessary, contact the maintenance department in order to have all bolts tightened to the specified torque(s).
B) Leakage – if a small leakage from the bell housing is observed. Contact the maintenance department.
C) Leakage – if there is a large leak, the unit should be stopped immediately. Contact the maintenance department.
D) High frequency tones – safety/relief valves are either damaged or running very close to their design pressure, stop the unit immediately. Contact the maintenance department.
E) Increased noise or vibration – requires the unit to be stopped immediately. Contact the maintenance department.
F) Very high temperatures – may indicate that one or more parts are damaged inside the pump. The pump must be stopped immediately and inspected before it is restarted. Contact the maintenance department.
G) Drop in flow and/or pressure – may indicate wear on one or more parts inside the pump. The pump must be stopped immediately and inspected before it is restarted. Contact the maintenance department.
H) Other observations or troubles, please see appendix 7, Right and Wrong or appendix
6, the Trouble shooting guide.
Both appendices give good advises regarding design, installation, wiring and troubleshooting.
See also service and warranty section in appendix 1, Data sheet and appendix 2,
Instruction.
If the pump is not stopped for inspection as recommended, it can lead to damage of the pump or break-down. See also service and warranty section in the appendix 1, Data sheet, in appendix 2, Instruction or appendix 4,
Instruction for recommended service intervals.
Danfoss offers service of the pump at the system manufacturer’s location as well as we offer training in how to service the pump. Quotes are offered upon request.
Danfoss recommends simultaneously to check the filter and membrane condition and to evaluate contamination; filter and membrane elements must be replaced if necessary.
7.
Maintenance and service of the pump unit
7.1 General safety information
Before servicing the pump unit, it is necessary to read and understand this user manual, especially the Safety, chapter 2. Remember to wear suitable safety equipment according to Safety, chapter 2.
Danfoss offers service of the pump at the system manufacturer’s location and training in how to service the pump. Quotes are offered upon request.
7.2 Service and inspection interval for the pump
Maintenance and service intervals are depending on the cleanliness level of the water, hydraulic load and temperature of the pump unit. The most important parameter is the filtration of the water.
7.3 Shut down of the system
A) Stop the high-pressure pump.
B) Open the pressure valves at the brine site to release the pressure.
C) Stop the feed pump.
See the section Service and warranty in the appendix 1, Data sheet, in appendix 2, Instruction and appendix 4, Instruction for recommended service intervals.
For spare parts and service tools, please see appendix 5, Parts list.
D) Switch off the safety circuit breaker for both the high-pressure pump, feed pump and VFD and lock them. Only personnel servicing the pump unit should be able to unlock/activate the switch again.
E) Open bleeding and drain plugs. Wait until the pump and system are emptied for water.
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F) Make sure the system is not pressuized!
Slowly unscrew and remove the bolts and gaskets from the inlet/outlet hoses or pipes, be careful about jets of water.
Beware that the system can be pressurized!
G) Attach the lifting equipment to the pump unit. For instructions on lifting the complete pump unit, see chapter 4, Arrival inspection, transportation, handling, lifting and storage.
H) For the small pumps, unscrew the bolts holding the pump to the bell housing. For the bigger pumps, unscrew the bolts/nuts from the pump and bell housing to the motor. Afterwards unscrew the bolts/nuts holding the pump and bell housing.
Returns without a return number will be rejected !!!
7.5 Assembling the pump unit
Assemble the pump according to the Disassembling and Assembling Instruction
(available at hpp.danfoss.com).
I) Carefully pull the pump out of the bell housing by using lifting equipment, if necessary.
7.4 Disassembling and assembling the pump unit
A) Remove all connections from the pump.
7.6 Procedure for mounting the pump onto the electric motor
J) Hold the pump in different positions above a drip tray; this should allow most of the water trapped in the pump to drain. Clean and dry the pump surface and plug the bleeding and draining plugs.
K) Move the pump to a clean and safe location where the pump can be inspected/ serviced.
Mount the flexible coupling and bell housing according to appendix 2, Instruction.
7.7 Getting the pump unit back into operation
Find instructions of how to put the pump unit back into operation in chapter 4, Arrival inspection, transportation, handling, lifting and storage and Installation and commissioning, chapter 5.
B) Disassemble the pump according to the
Disassembling and Assembling Instruction
(available at hpp.danfoss.com)
Clean all parts and surfaces with a fluid compatible with the materials found in the pump. Wipe the parts clean and dry with a lint-free clothing.
C) Inspect all parts including shaft seal and if necessary, replace them; see appendix 5,
Parts list.
D) 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. A copy of the form together with contact information and reason for returning should be sent to the email address on the form. The same documents should be attached to the shipment.
7.8 Storage of the pump
If the pump has to be shut down for a longer period, instructions can be found in appendix 2,
Instruction.
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8. Troubleshooting and scrapping criteria
8.1 General safety information
Before inspecting the pump unit, it is necessary to read and understand this user manual, especially the Safety chapter 2.
Remember to wear suitable safety equipment according to Safety chapter 2.
If water is leaking into the electric motor; it can cause electric shock, fire, short circuit or even death. When mounting the pump vertically always mount the motor above the pump to avoid water leaking into the electric motor.
•
•
•
•
•
•
•
•
•
•
•
•
8.2 Operational conditions which can cause pump failures
The following conditions can cause a pump failure :
The pump is running dry.
The inlet pressure is too high.
The inlet pressure is too low.
The temperature of the fluid is too high.
The ambient temperature is too high.
The pump is running against a blocked port/closed manual valve.
The pump is operating at a pressure out of specification.
The pump is running with a non-specified/ approved fluid.
The pump is running in the wrong direction.
The filtration is insufficient.
The pump is not being serviced according to Danfoss specifications (end of life).
There is excessive mechanical load on the shaft coupling and piping.
8.4 Electrical failure
If the wiring of the electric motor is incorrect or the ground connection is missing, it can cause electric shock, burn damages, fire or even death.
If a VFD is used and wrongly programmed, it can damage the pump and lead to high temperatures or other dangers.
All electrical installation must be carried out by authorized personnel in accordance with
EN60204-1 and/or local regulations.
8.5 Responsibility
Danfoss takes no responsibility for any abnormal injuries, risks or damages that could arise caused by abnormal conditions, vibrations, corrosion, abrasives, foreign objects or excessive temperatures and shall not be liable for any consequential or incidental damages.
8.3 Mechanical failure
If the pump is running dry, the temperature will quickly increase which can cause burns.
If there is any leakage at start-up or during operation, a high-pressure jet can cause eye or skin damage.
Leakage can result in flooding, which can cause slipping, tripping or falling.
8.6 Scrapping criteria
Whether the pump can be repaired or need to be scrapped, depends on in which conditions the internal parts are, or how damaged the whole unit is. Please use appendix 6, Trouble shooting guide as guideline or send the pump to Danfoss headquarter in Denmark for evaluation.
For other observations or troubles, please see appendix 7, Right and Wrong which gives good advises regarding design, installation, wiring and troubleshooting.
In case the pump needs to be scrapped, please follow your local environmental rules.
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Operation guide
APP pumps
APP 53 / APP 65 / APP 78 / APP 86 / APP 92
Appendices for Installation, Operation and Maintenance Manual
hpp.danfoss.com
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
Table of Contents
5.
6.
7.
8.
Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
1.
Data sheet for APP pumps 53-92 AI167386503010en-001 3 01) . . . . . . . . . . . . . . . . . . . . . . . . . . .19
2.
Instruction for APP pumps 53-92 (180R9368) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
3.
4.
Electric motors (180R9230) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Bowex coupling manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Recommended service intervals (AX281930801330en-000401) . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Parts list (AX191786502906en-001101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Trouble shooting (521B1447) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Right and wrong (180R9042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
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Data sheet
Data sheet
APP pumps
APP 53-86
Data sheet | APP 53-92 Pumps
Table of Contents 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
2. Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.
4
4.1
5.
5.1
5.2
5.3
5.3
5.4
Application examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
APP 53-92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Performance curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
APP 53 flow at different rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
APP 65 flow at different rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
APP 78 flow at different rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
APP 86 flow at different rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
APP 92 flow at different rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.
6.1
7.
7.1
10.
10.1
10.2
10.3
10.4
10.5
10.6
Flushing valve curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
APP 53-92 integrated flushing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Motor requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Calculation factor at 60 barg / 870 psig for APP 53-92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
8. Temperature and corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
8.1 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
9. Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
9.1 Filtration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
9.2 RO system with direct supply: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Dimensions and connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
APP 53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
APP 65 - 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
APP 53-92 with IE3 motor, IEC 315S - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
APP 53-92 with IE3 motor, IEC 315M - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
APP 53-92 with IE3 motor, IEC 315L 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
APP 53-92 with IE3 motor, IEC 315L 2 - 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
11.
11.1
12.
12.1
12.2
Pump connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
APP 53 - 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
VCM 3” Victaulic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Flow versus pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
13. Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
14. Service and warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
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180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Data sheet | APP 53-92 Pumps
1. Introduction The Danfoss range of APP high-pressure pumps is designed according to EN 809 for use in RO applications with low viscosity and corrosive fluids such as sea water.
Danfoss APP pumps are positive displacement pumps with axial pistons that move a fixed amount of water in each cycle. Flow is proportional to the number of input shaft revolutions
(rpm).
Unlike centrifugal pumps, they produce the same flow at a given speed no matter what the discharge pressure.
The sectional drawing below illustrates the main components of the APP 53-92 pump range.
1 Housing
2 Shaft
3 Swash plate (non drive end)
4 Retainer plate
5 Piston
6 Cylinder barrel
7 Bleeding / drain plug
8 Valve plate
9 Port plate (non drive end)
10 Center flange
11 Spring cartridge
12 Eye bolt
13 Port plate (drive end)
14 Swash plate (drive end)
15 Shaft seal
16 Motor flange
17 Flushing valve
18 Tail stock screws
2. Benefits
3. Application examples
•
•
•
Zero risk of lubricant contamination:
- Oil lubricants are replaced with the pumped medium, water, so there is no contamination risk from the pump.
Low maintenance costs:
- Efficient design and all-stainless steel construction ensure exceptionally long life. When Danfoss specifications are met, service intervals of 8,000 hours can be expected. Service is easy, and can be carried out on-site due to the simple design and few parts.
Low energy costs:
- The highly efficient axial piston design provides the lowest energy consumption of any comparable pump
• on the market.
Easy installation:
- The most compact and lightest design
available.
- The pump can be installed horizon-
tally in different positions rotating it around the shaft (see section 10 for
example).
Danfoss APP pumps are built into a broad range of RO desalination plants around the world:
• Containerized solutions for hotels, resorts and residences on islands and in coastal regions
•
•
•
No pulsation dampeners necessary due to extremely low pressure pulsation.
- Powered directly by electric motors or combustion engines (with special
coupling).
- All pumps are supplied with an integrated flushing valve that allows the fluid to flow from inlet to the outlet, when the pump is not running.
High reliability:
- All parts are made of high corrosion resistant materials e.g. Duplex
(EN1.4462/ UNS S31803) and
Super Duplex (EN1.4410/UNS S32750) stainless steel and carbon reinforced
•
PEEK.
Certified quality:
- Available with positive material idenfication (PMI) certification on
request.
- ISO 9001, ISO 14001, IAFT 16949
- ATEX certification available for APP S (all
Super Duplex) and APP S 674 (API).
Please see relevant data sheets.
•
•
Mobile systems for humanitarian and military organizations
Onboard systems for ships and yachts
Offshore platforms for the oil and gas industry
Municipal and regional waterworks
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Data sheet | APP 53-92 Pumps
4 Technical data 4.1 APP 53-92
700 rpm at max. pressure
1000 rpm at max. pressure
1200 rpm at max. pressure
1500 rpm at max. pressure
1700 rpm at max. pressure
1780 rpm at max. pressure
Efficiency
1000 rpm 3)
1200 rpm 3)
1500 rpm 3)
1700 rpm 3)
1780 rpm 3)
Pump size
Code number
Geometric displacement
Pressure
Max. outlet 1) pressure
(MAWP)
Min. inlet operating pressure
Max. inlet operating pressure
Max. inlet pressure peak cm³/rev.
in³/rev.
barg psig barg psig barg psig barg psig barg psig
Min. outlet pressure
Speed
Min. speed continuous
Max. speed continuous
Flow
Min. flow rpm rpm m³/h gpm m³/h gpm m³/h gpm m³/h gpm m³/h gpm m³/h gpm m³/h gpm
%
%
%
%
%
APP 53/1500 APP 65/1500 APP78 /1500 APP 86/1700 APP 92/1780
180B7806 180B7807 180B7808 180B7809 180B7810
617
37.7
778
47.3
888
54.2
888
54.2
888
54.2
83
1,200
2
29
5
73
10
145
30
435
83
1,200
2
29
5
73
10
145
30
435
83
1,200
2
29
5
73
10
145
30
435
70
1,015
2.5
36
5
73
10
145
30
435
70
1,015
3.5
50
5
73
10
145
30
435
700
1,500
35
154
42
187
24
106
24
106
53
235
88
89
88
700
1,500
45
198
54
238
32
141
32
141
68
299
88
89
89
700
1,500
52
228
62
275
36
158
36
158
78
345
89
90
89
700
1,700
52
228
62
275
36
158
36
158
78
345
88
387
89
89
88
88
700
1,780
78
345
88
387
92
405
52
228
62
275
36
158
36
158
89
89
88
88
87
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Data sheet | APP 53-92 Pumps
Pump size
Code number
Technical specifications
Media 2) temperature
Ambient temperature
Weight (dry)
Weight
(operation) 6) kg lb kg lb
°C
°F
°C
°F
Sound pressure level db(A)
Footprint with
IE3 motor 4) m²
Foot²
Typical motor size
Max.speed at max. pressure 5) kW
HP
APP 53/1500 APP 65/1500 APP 78/1500
180B7806
2–50
36–122
0–50
32–122
196
432
204
450
84-95
1.49
16.0
132
200
180B7807
2-50
36-122
0-50
32-122
196
432
204
450
84-95
1.49
17.0
160
250
180B7808
2–50
36–122
0–50
32–122
196
432
204
450
84-93
1.50
16.1
160
250
APP 86/1700
180B7809
2-50
36-122
0-50
32-122
196
432
204
450
84-96
1.50
16.1
200
300
APP 92/1780
180B7810
2-50
36-122
0-50
32-122
196
432
204
450
84-96
1.50
16.1
200
300
1) 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.
2)
3)
6)
Dependent on the NaCI concentration.
Typical efficiency at max. pressure after a system has been commissioned and run in.
4) Maximum area covered with recommended IE3 motor configurations (excl. of space to service pump)
5) IE3 and NEMA motors, 4-pole, current insulated ND non drive end bearing
Operating with water
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Data sheet | APP 53-92 Pumps
5. Performance curves If the flow required and the rotation speed (rpm) of the pump is known, it is easy to select the pump, fitting the application best, by using the diagram below.
Furthermore, this diagram shows that the flow can be changed by changing the rotation speed of the pump. The flow/rpm ratio is constant, and the “required” flow can be obtained by changing the rotation speed to a corresponding value. Thus, the required rpm can be determined as:
Required rpm =
Required flow x Rated rpm
Rated flow
5.1 APP 53 flow at different rpm
55,00
50,00
45,00
40,00
35,00
30,00
25,00
20,00
90,00
85,00
80,00
75,00
70,00
65,00
60,00
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]
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Data sheet | APP 53-92 Pumps
5.2 APP 65 flow at different rpm
90,00
85,00
80,00
75,00
70,00
65,00
60,00
55,00
50,00
45,00
40,00
35,00
30,00
25,00
20,00
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]
Speed [RPM]
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Data sheet | APP 53-92 Pumps
5.3 APP 78 flow at different rpm
65,00
60,00
55,00
50,00
45,00
40,00
35,00
30,00
25,00
20,00
90,00
85,00
80,00
75,00
70,00
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]
Speed [RPM]
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Data sheet | APP 53-92 Pumps
5.3 APP 86 flow at different rpm
90,00
85,00
80,00
75,00
70,00
65,00
60,00
55,00
50,00
45,00
40,00
35,00
30,00
25,00
20,00
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]
Speed [RPM]
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Data sheet | APP 53-92 Pumps
5.4 APP 92 flow at different rpm
100,00
95,00
90,00
85,00
80,00
75,00
70,00
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]
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Data sheet | APP 53-92 Pumps
6. Flushing valve curves 6.1 APP 53-92 integrated flushing valve
Pressure [barg]
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
0
10
0
20
0
30
0
40
0
50
0
60
0
Flow [l/min]
7. Motor requirements The power requirements can be determined using one of the following guiding equations:
Required power = l/min x barg
Calc. factor
[kW] or
1 hp = 0.75 kW
1 gpm = 3.79 l/min
1 m 3 /h = 4.40 gpm
1 kW = 1.34 hp
1 l/min = 0.26 gpm
1 gpm = 0.23 m 3 /h
16.7 x m 3 /h x barg
Calc. factor
[kW] or
0.35x gpm x psig
Calc. factor
[Hp]
7.1 Calculation factor at 60 barg / 870 psig for APP 53-92
Name
APP 53
APP 65
APP 78
APP 86
APP 92 rpm
1500
1500
1500
1700
1780
Calculation factor
528
534
534
528
522
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Data sheet | APP 53-92 Pumps
8. Temperature and
corrosion
8.1 Operation
The chart below illustrates the corrosive resistance of different types of stainless steel related to NaCl concentration and temperature.
All wetted parts of the APP pump are made of
Duplex or Super Duplex.
If the water pump is operated at high salinity always flush the water pump with fresh water at operation stop in order to minimize the risk of crevice corrosion.
NaCI vs. temperature
80 º C
70
60
50
40
30
20
100
160
316L
1000
1600
Duplex
Super Duplex
10 000
16000
100 000
160000
9. Installation See example below on how to mount the pump and connect it to an electric motor or combustion engine (special coupling).
For further instruction on installation of coupling see APP Pump Instruction 180R9368.
If alternative mounting is required. please contact your Danfoss sales representative for further information.
Note: Do not add any axial or radial loads to the pump shaft.
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180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Data sheet | APP 53-92 Pumps
9.1 Filtration
Proper filtration is crucial for the performance, maintenance and warranty of your pump.
Protect your pump, and the application in which it is installed, by always ensuring that all filtration specifications are met, and by always changing filter cartridges according to schedule.
Since water has very low vicosity, Danfoss APP pumps have been designed with very narrow clearances in order to control internal leakage rates and improve component performance.
To minimize wear on the pump, it is therefore essential to filter inlet water properly.
•
• more noise than flexible hoses, because of structure-borne vibrations.
Variable frequency drives (VFD):
Motors regulated by VFDs can produce more noise if the VFD does not have the right settings.
9.2 RO system with direct supply:
Inlet line: a) Dimension the inlet line to obtain mini mum pressure loss (large flow, minimum pipe length, minimum number of bends/ connections, and fittings with low or no pressure losses) .
The main filter must have a filtration efficiency of
99.98% at 10 μm. We strongly recommend that you always use precision depth filter cartridges rated 10μm abs. ß
10
≥5000.
Please note that we do not recommend bag filters or string-wound filter cartridges, which typically have only 50% filtration efficiency. This means that out of the 100,000 particles that enter such filters, 50,000 particles pass right through; compare this to precision depth filters that are 99.98% efficient, and only allow 20 of the same 100,000 particles to pass through.
Inlet filter: b) Install an inlet filter (1) in front of the APP pump (2). Please consult section 9.1,
“Filtration” for guidance on how to select the right filter. Thoroughly clean pipes and flush system prior to start-up.
Inlet pressure: c In order to eliminate the risk of cavitation and other pump damage, pump inlet pressure must always be maintained according to specifications described in item 4 about technical data.
For more information on the importance of proper filtration, including explanation of filtration principles, definitions and guidance on how to select the right filter for your pump, please consult our Filtration information and specifications (Danfoss document number
521B1009).
Noise
Since the pump unit is typical mounted on a frame or bell housing the overall noise level can only be determined for a complete system. To minimize vibrations and noise throughout the system, it is therefore very important to mount the pump unit correctly on a frame with anti-vibration-dampeners, and to use flexible hoses rather than metal pipes where possible.
Low pressure relief valve: d) Install a low pressure relief valve (9) in order to avoid system or pump damage in case the pump stops momentarily or is spinning
backwards.
Monitoring pressure switch: e Install a monitoring pressure switch (3) between the filter (1) and the pump inlet.
Set the minimum inlet pressure according to specifications described in item 4 about technical data. If the inlet pressure is lower than the minimum pressure set, the monitoring pressure switch must prevent the pump from starting or from running.
The noise level is influenced by:
• Pump speed:
High rpm generates more fluid/structure borne pulsations/vibrations than low rpm, because of higher frequency.
• Discharge pressure:
High pressure generates more noise than low pressure.
• Pump mounting:
Rigid mounting generates more noise than flexible mounting, because of structureborne vibrations. Be sure to use dampeners when mounting.
• Connections to pump:
Pipes connected directly to the pump make
Hoses: f) Always use flexible hoses (4) to minimize vibrations and noise. Please consult the
Danfoss Hoses and hose fittings data sheet (521B0909) for guidance.
Flushing valve: g) For easy system filling and flushing, the
APP pump has an integrated valve (6).
Non-return valve: h) A non-return valve (7) in outlet can be installed in order to avoid backspin of the pump. The volume of water in the membrane vessel works as an accumulator and will send flow backwards in case the pump stops momentarily.
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Data sheet | APP 53-92 Pumps
High pressure safety or relief valve: i) 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) should be installed after the non-return valve to prevent system damage and to avoid high pressure peaks.
Note: If a non-return valve is mounted in the inlet line, a low-pressure relief valve is also required between the non-return valve and pump as protection against high-pressure peaks.
Feed
PI
Media filter
PI PI PI PT
Fresh water permeat flush
PI
PI
Brine
Permeate
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Data sheet | APP 53-92 Pumps
10. Dimensions and
connections
10.1 APP 53
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Data sheet | APP 53-92 Pumps
10.2 APP 65 - 92
APP 65 - 92
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Data sheet | APP 53-92 Pumps
The APP 53-92 connections (inlet and outlet) can be adjusted in intervals of 45 degrees.
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.
Non-standard configuration, turned 90 degrees left.
Non-standard configuration, turned 180 degrees .
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Data sheet | 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
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Data sheet | 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
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Data sheet | APP 53-92 Pumps
11. Pump connections 11.1 APP 53 - 92
Use only Style 77DX coupling or equivalent.
3” Victaulic OSG LP Inlet
3” Victaulic OSG HP Outlet
38 | © Danfoss | DCS (im) | 2021.12
Connection
3” Inlet connector
3” outlet connector
Diameter
(A)
87.8 mm
(3.46 inch)
87.8 mm
(3.46 inch)
Victaulic 1)
(B)
3” Vic. OSG
3” Vic. OSG
Length
(C)
61.0 mm
(2.40”)
65.0 mm
(2.56”)
Material
Super
Duplex
Super
Duplex
Max. Pressure
10 barg
(145 psig)
80 barg
(1160 psig)
Code number
180Z1991
180Z1992
1 ) The installation instuction for Style 77DX is located in the Victaulic document I-100 Field Installation
Handbook (htpp://static.victaulic.com)
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Data sheet | APP 53-92 Pumps
12. VCM 3” Victaulic
The non-return valve is designed for use in
Seawater Reverse Osmosis (SWRO) membrane systems. In case the high-pressure pump stops momentarily, the volume of water in the membrane vessel may work as an accumulator and will send flow backwards. prevents the water from one pump to run into the parallel-coupled pumps at start-up.
The VCM 92 is prepared for easy installation on the high pressure outlet of APP 53-92, series 08 or higher..
Use only Style 77DX coupling or equivalent.
When using multiple pumps in parallel, the non-return valve
12.1 Technical data
Type Connection 1)
VCM 92
3” outlet check valve )
Diameter mm (inch)
Victaulic
(outlet
3) connection)
Length mm (inch)
87.7
(3.45)
3” Vic. OSG
180.5
(7.10)
Material2 2)
Max. pressure barg (psig)
Code number
Super
Duplex
83 (1.200) 180H0058
1) The check valve is mounted directly in the outlet port with a flange with 8 screws M12 x 25.
2) Wetted parts materials: Super Duplex, PEEK, PP, Hasteloy; FKM, NBR
3) The installation instuction for Style 77DX is located in the Victaulic document I-100 Field Installation
Handbook (htpp://static.victaulic.com)
VCM
Min. flow continously
Max. flow continously
Max pressure MAWP
Opening pressure psig barg psig
Pressure loss at max. flow barg psig m³/h gpm m³/h gpm barg
VCM 92
20
88
92
405
83
1200
0.05- 0.08
0.73-1.16
< 0.45
< 6.5
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Data sheet | APP 53-92 Pumps
1. Valve housing (Super Duplex)
2. Valve guide and valve stop (Super Duplex,
PEEK and PP)
3. Valve Cone (Super Duplex)
5. Spring (Hasteloy)
6. O-ring (NBR)
7. O-ring (FKM 75)
8. O-ring (NBR)
12.2 Flow versus pressure
Pressure drop curves for check valve VCM 92
Flow versus pressure for VCM 92
0,5
0,45
0,4
0,35
0,3
0,25
0,2
0,15
0,1
0,05
0
20 25 30 35 40 45 50 55 60
Flow [ m3/h ]
65 70 75 80 85 90 95 100
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Flow versus pressure for VCM 92
5
4
3
7
6
2
1
80 100 120 140 160 180 200 220 240 260 280
Flow [ GPM]
300 320 340 360 380 400 420 440
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Data sheet | APP 53-92 Pumps
13. Accessories
Accessories
Coupling APP 53 - APP 92 IEC 315
Coupling APP 53 - APP 92 IEC 280
Coupling kit APP 53 - APP 92 incl. bell housing IEC 315
Coupling kit APP 53 - APP 92 incl. bell housing IEC 280
Base frame incl. vibration dampeners
Type
Diameter: motor Ø80 mm, pump Ø50
Diameter: motor Ø75 mm, pump Ø50
Ø80/Ø50. IEC 315 Ø660/310
Ø75/Ø50. IEC280 Ø550/265
IEC 315
Code number
180Z4066
180Z4081
180Z4083
180Z4082
180Z0661
14. Service and warranty Warranty
Danfoss APP pumps are designed for long operation, low maintenance and reduced lifecycle costs.
Provided that the pump has been running according to the Danfoss specifications, Danfoss guarantees 8,000 hours service-free operation, however, max. 18 months from date of production.
If Danfoss recommendations concerning system-design are not followed, it will strongly influence the life of the APP pumps.
Other factors that affect pump performance and lifetime include:
- Insufficient filtration
- Insufficient bleeding and venting
- Running the pump at speed outside
specifications.
- Supplying the pump with water at
temperature higher than recommended.
- Running the pump at inlet pressure outside
specifications.
- Running the pump at outlet pressure
outside the specifications.
- Wrong direction of rotation.
Maintenance
After 8,000 hours of operation it is strongly recommended to inspect the pump and change any worn parts, e.g. pistons and shaft seal. This is done in order to prevent a potential breakdown of the pump. If the parts are not replaced, more frequent inspection is recommended according to our guidelines.
Pump shutdown:
The APP pumps are made of Duplex/Super
Duplex materials with excellent corrosion properties. It is, however, always recommended to flush the pump with freshwater when the system is shut down.
When stopping the pump for more than 1 day flush the pump for 10 sec. Flushing through the flushing valve of the pump without rotating the pump is not enough for cleaning the inside of the pump.
The pump can be flushed with biocide like the membranes. The biocide must be compatible with the materials used in our pump (materials can be found in the parts list in the instruction and operational manual).
Repair
In case of irregular function of the APP pump, please contact Danfoss High Pressure Pumps.
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AI167386503010en-001301 | 42
Instruction
APP Pump Instruction
APP 53 / APP 65 / APP 78 / APP 86 / APP 92 hpp.danfoss.com
Instruction | APP Pump Instruction APP 53-92
Table of Contents Table of Contents
1. Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.
2.1
2.2
2.3
2.4
2.5
System design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Open-ended systems with direct water supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Preferred RO system design without ERD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Preferred RO system design with ERD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Preferred RO system design with pumps and ERDs in parallel . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Reversible pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
3.
3.1
3.2
3.3
Building up the pump unit with BoWex coupling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Assembly of the coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Alignment between the motor and pump shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Overall assembly with coupling BoWex-ELASTIC®, type HEW compact . . . . . . . . . . . . . . . . . . .47
3.3.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
3.4
3.5 Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
3.6
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Protection from too high pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4. Building up the pump unit with jaw coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.1 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
4.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
5. Initial start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
6. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.1 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.2 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.3 Dry running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.4 Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
6.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
7. Service and warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
1. Identification
PUMP
Type APP 78
Code no. 180BXXXX
Serial no. XXXXXX08-XXX
MADE IN DENMARK
Danfoss A/S, 6430 Nordborg, Denmark
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Instruction | APP Pump Instruction APP 53-92
2. System design The design of the system must ensure that self-emptying of the pump during standstill is avoided.
The inlet pressure of the pump must never exceed the outlet pressure. This may typically occur in boosted or open-ended systems with direct water supply.
2.1 Open-ended systems with direct water supply
Axial piston pumps require a certain inlet pressure to perform as intended. Please find min. required feed pressure in the pump data sheet.
Please also note that feed pressure must not exceed 5 barg (72.5 psig).
To protect the pump from being damaged by peaks of high-pressure in case the pump stops momentarily, it is required to mount a low- pressure relief valve on the inlet line.
Note: The inlet connection must be properly tightened, as possible entrance of air will cause cavitation.
2.2 Preferred RO system design without ERD
1. Dimension the inlet line to obtain minimum pressure loss (large flow, minimum pipe length, minimum number of bends/ connections, and fittings with small pressure losses).
2. Place an inlet filter (1) in front of the APP pump (2). Please consult Danfoss filter data sheet for guidance on how to select the right filter. Thoroughly clean pipes and flush system prior to start-up.
3. Place a monitoring pressure switch (3) set at min. inlet pressure between filter and pump inlet. The monitoring switch must stop the pump at pressures lower than minimum pressure.
4. Use flexible hoses (4) to minimize vibrations and noise.
5. In order to eliminate the risk of damage and cavitation, a positive pressure at the inlet (5) is always to be maintained at min. inlet pressure and max. inlet pressure.
It is recommend to install safety valve or a pressure relief valve (9) in order to avoid high-pressure peaks in case the pump stops momentarilly or is spinning backwards.
6. For easy system bleeding and flushing, a bypass non-return valve (6) is integrated in the APP pump.
7. A non-return valve (7) in outlet can be installed in order to avoid backspin of the pump. The volume of water in the membrane vessel works as an accumulator and will send flow backwards in case of the pump stops momentarily.
8. A safety valve or a pressure relief valve (8) can be installed in order to avoid system damage as the Danfoss APP pump creates pressure and flow immediately after start- up, regardless of any counter pressure.
Note: If a non-return valve is mounted in the inlet line, a low-pressure relief valve is also required between non-return valve and pump as protection against high-pressure peaks.
Feed
PI
Media filter
PI PI PI PT
Fresh water permeat flush
PI
PI
Brine
Permeate
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Instruction | APP Pump Instruction APP 53-92
2.3 Preferred RO system design with ERD
For P&ID of a setup with an iSave, please see the iSave® Data sheet 521B1378
2.4 Preferred RO system design with pumps and ERDs in parallel
For systems with Danfoss pumps and ERDs in parallel, please see our publication 180R9354,
Guideline for Parallel-coupled pumps and ERD.
2.5 Reversible pumps
If exposed to high-pressure in the outlet while the electric motor is not energized, the pumps may start spinning backwards. This will not harm the pumps as long as the pressure in the inlet does not exceed the max. pressure peak of
10 barg(145 psig).
If a non-return valve is mounted in the inlet line, a low-pressure relief valve is required as protection against high-pressure pulses and high-pressure in general.
Alternatively a high-pressure check valve can be mounted in the pump discharge line to prevent the pump from reversing.
2.6 General comments
A good filtration is vital to ensure a long and trouble-free life of the pump.
As water has very low viscosity, the APP pumps have been designed with very narrow clearance in order to control internal leakage rates and improve component performance. Therefore it is important that the inlet water is filtered properly to minimize the wear of the pump.
The main filter must have a filtration efficiency of
99.98% at 10 μm. We recommend to use precision depth filter cartridges rated 10 μm abs.
β 10 ≥ 5000 (equivalent to a filtration efficiency of
99.98%). Bag filters and string wounded filter cartridges typically have only 50% filtration efficiency. This means that for each 100,000 particles reaching the filter, 50,000 particles pass through it compared to only 20 particles in a filter with an efficiency of 99.98%.
For more information on the importance of proper filtration, please see our data sheet
521B1009 on “Filtration”, which also will provide you with an explanation of filtration definitions and a guidance on how to select the right filter.
The setup of “open-end system” ensures that the inlet pressure does not exceed 10 barg (145 psig), when a non- return valve is mounted in the inlet.
Monitoring
It is recommended to continuously monitor the following conditions:
•
•
Filter clogging
Pressure (inlet- and outlet side of the pump)
3. Building up the pump unit with BoWex coupling
3.1 Assembly of the coupling
We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy before assembly.
Heating the hubs lightly (approx. 80 °C) allows for an easier mounting on the shaft.
Please pay attention to the ignition risk in potentially explosive atmospheres!
3.2 Alignment between the motor and pump shaft
Touching the heated hubs causes burns.
Please wear safety gloves.
With the assembly please make sure that the spline of the hub is fully covered by the internal spline of elastomer (please observe mounting dimensions L coupling
).
Disregarding this advice may cause damage to the coupling.
3-5 mm
[0.12-0.20 inch]
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Instruction | APP Pump Instruction APP 53-92
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
2: Nuts 100 Nm ± 10
3: Torque see table
Thread size M5
Torque [Nm] 2
M6
4.8
M8
10
M10
17
Component
1
2
4
5
7
Quantity Description
1
1
1
10
2
Elastomer part
Hub
Coupling flange
Cap screws
DIN EN ISO 4762
Setscrews
DIN EN ISO 4029
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Instruction | APP Pump Instruction APP 53-92
3.3.1 Mounting
1. Mount the coupling flange (component 4) in front of the elastomer part (component
1) and screw the components together with a tightening torque of 120 Nm.
Lubricate inside the coupling hubs (not the
shafts).
If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all screw connections must be secured against working loose additionally, e.g. conglutinating with Loctite
(average strength).
2.
Please observe the manufacturer’s instructions regarding the use of adhesives. Do not apply glue on the rubber surfaces.
Mount the bell housing on pump. Secure nuts with the right torque.
3. Push the coupling part all the way down to the shoulder of the pump shaft and secure with right torque on the locking screws.
Measure the distance “a” from the end of the bell housing to the end of the toothing of the coupling.
4. Mount the coupling on motor shaft without using hammer. If needed then polish motor shaft/key and inside coupling hub.
5. On the motor shaft position the coupling so that the length from the end of the coupling to the end of the motor flange is
“b= a+32.5 mm” ± 2 mm.
6. Secure coupling on motor shaft with the right torques on the locking scre+ws.
7. Connect carefully pump/bell housing to motor. Turn motor shaft so coupling tooths can interact.
8. Mount motor flange bolts to bell housing and tighten with the right torque.
9. Check coupling space. The pump coupling should be in a position so there is still
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.
b = a + 32.5 mm ± 2 mm
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Instruction | APP Pump Instruction APP 53-92
3.4 Direction of rotation
Is indicated by an arrow engraved in the flange of the pump.
3.5 Orientation
APP 53-92 can be mounted/orientated in steps of
45 degrees. Please see Data sheet 521B1340.
3.6 Protection from too high pressures
The pump should be protected against too high pressure by means of a safety valve or a pressure relief valve.
The opening characteristics of the valve must not result in peak pressures higher than 100 barg
(1450 psig).
The valve should be placed as close to the pump as possible.
We recommend to install flexible soft hoses both in the inlet and outlet lines.
The valve outlet must not be connected directly to the pump suction line.
It must be connected directly to the drain.
Outlet
Outlet Inlet
Inlet
4. Building up the pump unit with jaw coupling
3-5 mm
[0.12-0.20 inch]
IMPORTANT
When using jaw coupling it is critiacal that the recommended measurements are kept.
D
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A: Elastic coupling
B: Bell housing
C: Motor shaft
D: Pump flange
4.1 Mounting
1. Mount the coupling flush with the pump shaft end or maximum 1 mm offset from the pump shaft end. Ensure an air gap between coupling parts of 3-5 mm (0.12-0.2 inch).
2. Mount the bell housing on pump. Secure nuts with the right torque.
3. Measure the longest distance “A” from top of bell housing to the button of coupling claw.
4. Mount the coupling on motor shaft. Ensure the coupling and motor flange are not in contact with each other.
5. Measure from motor flange to the top of the coupling. That measurement “B” shall be 3-5 mm (0.12-0.2 inch) shorter than the measurement “A”.
(“A” and “B” can be found on the next page).
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Instruction | APP Pump Instruction APP 53-92
6. Adjust respectively, verify the measurement, and secure both couplings with the right torques on the locking screws (see coupling operation & mounting instruction).
7. Mount the elastic gear ring and mount the bell housing/pump on the motor. After mounting it must be possible to move the elastic gear ring 3-5 mm (0.12 - 0.2 inch) axial “C”. The check can be done through the inspection hole of bell housing. Secure flange bolts with the right torque.
If alternative mounting is desired, please contact
Danfoss High Pressure Pumps.
Choose proper tolerances to ensure an easy mounting of the elastic coupling without use of tools.
Please take care to observe the recommended length tolerances of the chosen coupling, as an axial force on the pump will damage the pump.
Bolts and nuts torque 75 Nm ± 5 Nm
2
1
C
3
Thread size
Torque
[Nm]
M5
2
M6
4.8
M8
10
M10
17
4.2 Connections
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To prevent stray current corrosion we recommend grounding of the pump and all other parts in the system.
All parts in the system must be electrical potential equalized to a single reference point
(grounding point).
It is recommended that the electrical resistance in the grounding cable is equal to or below 0.25
Ohm towards the grounding point.
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Instruction | APP Pump Instruction APP 53-92
5. Initial start-up 1. Flush inlet line before connecting the pump, to remove possible impurities from pipes, hoses etc.
2. Connect pump inlet to inlet line and flush the pump for 5 min. by means of the internal flushing valve, to remove possible impurities from pipes, hoses etc.
3. Loosen top bleeding plug (see item 3.5) using an allen key (only plugs with internal hexagon sockets). Retighten the plug, when water appears from the bleeding plug.
4. Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump, show on the pump flange.
5. Now the pump is ready for start-up.
WARNING
Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump.
Otherwise the pump will be damaged if a check valve is placed between pump and feed pump.
O
I
Internal flushing valve
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Instruction | APP Pump Instruction APP 53-92
6. Operation 6.1 Temperature
Fluid temperature:
Min. +2°C to max. +50°C
(Min. +35.6°F to max. +122°F)
Ambient temperature:
Min. +2°C to max. +50°C
(Min. +35.6°F to max. +122°F)
In case of lower operating temperatures, please contact Danfoss High Pressure Pumps.
The chart below illustrates the corrosive resistance of different types of stainless steel related to NaCl concentration and temperature.
The APP water pump is made of Duplex and
Super Duplex.
If the water pump is operated above the Super
Duplex line, always flush water pump with fresh water at operation stop in order to minimize the risk of crevice corrosion.
NaCl vs. temperature
80 º C
70
60
50
40
30
20
100
160
316L
1000
1600
Duplex
Super Duplex
10 000
16000
100 000
160000
6.2 Pressure
The inlet pressure shall be min. 2 barg (30 psig) and max. 5 barg (72.5 psig). At lower pressures the pump will cavitate, resulting in damage of the pump.
Max. inlet pressure peak (e.g. in case the pump stops momentarily) up to 10 barg (145 psig) are acceptable.
Max. pressure on the pump’s outlet line shall be limited at 80 barg (1160 psig) continuously.
For APP 86 min. inlet pressure shall be 2.5 barg
(36 psig) and max. outlet pressure shall be
70 barg (1015 psig).
6.3 Dry running
When running, the pump must always be connected to the water supply in order to avoid damage if it should run dry.
6.4 Disconnection
If the inlet line is disconnected from the water supply, the pump will be emptied of water through the disconnected inlet line.
When starting up again, follow the bleeding procedure described under section 4: Initial start up.
For APP 92 min. inlet pressure shall be 3.5 barg
(50 psig) and max. outlet pressure shall be
70 barg (1015 psig).
Note: The pump unit should include a pressure gauge on the high-pressure side.
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6.5 Storage
Storage temperature:
Min. -40°C to max. +70°C
(Min. -40°F to max. +158°F)
When preparing the pump for long-term storage at temperatures below the freezing point, flush the pump with an anti-freeze medium type monopropylene glycol to prevent internal corrosion or frost in the pump.
For further information on anti-freeze media, please contact Danfoss High Pressure Pumps.
Recommended procedure:
1. Disconnect the water supply to the pump.
2. Through the lower bleeding plug, empty the pump housing of water and close it again.
3. Connect the pump to a tank containing anti-freeze additive. Connect a hose to the inlet port of the pump and via another hose return the flow from the outlet port to the tank with antifreeze additives.
4. Quickly start and stop the pump. Make sure that the pump does not run dry.
The pump is now protected against internal corrosion and frost.
Storage:
Storage of pump that have been in operation:
For shorter periods of storage flush the pump with permeate by rotating the pump for 10 sec. empty permeate and store.
For long term storage (more than 2 months)
Danfoss recommends servicing the product and clean any biological growth of the surfaces. Store the pump without water inside.
7. Service and warranty Warranty
Danfoss APP pumps are designed for long operation, low maintenance and reduced lifecycle costs.
Provided that the pump has been running according to the Danfoss specifications, Danfoss guarantees 8,000 hours service-free operation, however, max. 18 months from date of production.
If Danfoss recommendations concerning system-design are not followed, it will strongly influence the life of the APP pumps.
Other factors that affect pump performance and lifetime include:
- Insufficient filtration
- Insufficient bleeding and venting
- Running the pump at speed outside
specifications.
- Supplying the pump with water at
temperature higher than recommended.
- Running the pump at inlet pressure outside
specifications.
- Running the pump at outlet pressure
outside the specifications.
- Wrong direction of rotation.
Pump shutdown:
The APP pumps are made of Duplex/Super
Duplex materials with excellent corrosion properties. It is, however, always recommended to flush the pump with freshwater when the system is shut down.
When stopping the pump for more than 1 day flush the pump with permeate by rotating the pump for 10 sec. Flushing through the flashing valve of the pump without rotating the pump is not enough for cleaning the inside of the pump.
The pump can be flushed with biocide like the membranes. The biocide must be compatible with the materials used in our pump (materials can be found in the parts list in the Service guide and Operating manual).
Repair
In case of irregular function of the APP pump, please contact Danfoss High Pressure Pumps.
Maintenance
After 8,000 hours of operation it is strongly recommended to inspect the pump and change any worn parts, e.g. pistons and shaft seal. This is done in order to prevent a potential breakdown of the pump. If the parts are not replaced, more frequent inspection is recommended according to our guidelines.
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180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 53
© Danfoss | DCS (im) | 2021.05
AN220686503013en-000901 | 180R9368 | 521B1392 | 54
Electric Motors
Motor Manual
hoyermotors.com
M a n u a l
56
Motor
Manual
General
This manual concerns the following types of standard induction motors from Hoyer:
HMA3, HMC3, HMA2, HMC2, HMD, HMT, MS, Y2E1, Y2E2, YDT
These motors are manufactured in accordance with IEC/EN
60034-4 and IEC/EN 60072.
Motors are rated for the ambient temperature range -20°C to
+40°C and site altitudes ≤ 1000 m above sea level.
Low-voltage motors are components for installation in machinery. They are CE marked according to the Low Voltage
Directive 2014/35/EU.
Motors not fulfilling the IE3 efficiency level must be equipped with a variable speed drive when used in EU.
etc.) using suitable tools, never hit the drive components with a hammer as this will cause damage to the bearing.
The motor are balancing with half key, ensure that the drive components are also the same.
Correct alignment is essential to avoid bearing, vibration and shaft failure.
Use appropriate methods for alignment.
Re-check the alignment after the final tightening of the bolts or studs.
Check that drain holes and plugs face downwards. We recommend opening the drain hole for motors placed outdoors and not running 24 hours / day, so that the motor can breathe, thus ensuring a dry motor.
Transport and storage
Check the motor for external damage immediately upon receipt and, if found, inform the forwarding agent right away.
Check all rating plate data, and compare it with the requirement of the motor.
Turn the shaft by hand to check free rotation, remove transport locking if used.
Transport locking must be used again for internal transport also. It is also important that transport locking is used when motors are transported mounted on equipment.
All motors should be stored indoors, in dry, vibration- and dust-free conditions.
Electrical connection
Work is only permitted to be carried out by qualified specialists and must to be carried out in accordance with local regulations.
Before work commences, ensure that all power is switched off and cannot be switched on again. This also applies to the auxiliary power circuits, e.g. anti-condense heaters.
Check that supply voltage and frequency are the same as rated data.
Motors can be used with a supply deviation of ± 5% voltage and ± 2% frequency, according to IEC60034-1.
Connection diagrams for main supply and accessory as PTC or heater are located inside the terminal box.
Lifting eyebolts must be tightened before use. Damaged eyebolts must not be used, check before use. Lifting eyes at motor must not be used to lift the motor when it is attached to other equipment.
Connections must be made in such a way as to ensure that a permanently safe electrical connection is maintained, both for the main supply and the earth connection.
We recommend that crimped connections are made in accordance with IEC 60352-2.
Before commissioning, measure the insulation impedance. If values are ≤ 10M Ω at 25°C, the winding must be oven dried.
The insulation resistance reference is halved for each 20°C rise in motor temperature.
It is recommended that shafts are rotated periodically by hand to prevent grease migration.
Tightening torques for terminal board screws:
Thread M5
T.(Nm) 2.5
M6
3.5
M8 M10 M12 M16 M20 M24
7 12 18 35 55 80
Installation
The motor must be fixed on a stable, clear and flat foundation.
It must be sufficiently rigid to withstand possible short circuit forces.
It is important to ensure that the mounting conditions do not cause resonance with the rotational frequency and the doubled supply frequency.
Only mount or remove drive components (pulley, coupling,
Ensure that the terminal box is clean and dry.
Unused glands must be closed with blind caps.
Check the terminal box gasket before it is remounted.
Maintenance
Inspect the motor at regular intervals, keep it clean and ensure free ventilation air flow, check the condition of shaft seals and replace if necessary. Both electrical and mechanical
2
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021
Motor
Manual
connections must be checked and tightened if necessary.
Bearing size and type are specified on the rating plate. Motor types HMA3 and HMC3 is as standard with lifetime greased bearings in motors size ≤ 180 for cast iron and size ≤ 132 for aluminium. Motor types HMA2 and HMC2 is as standard with lifetime greased bearing in motors size ≤ 225.
Motor types MS and Y2E is as standard with lifetime greased bearing in motors size ≤ 160.
The table values are based on an ambient temperature of
25°C. The values must be halved for every 15K increase in bearing temperature.
Higher speed operations, e.g. frequency converter drive will require shorter greasing intervals. Typically, doubling the speed will reduce the values by 50%.
Special note for Atex Zone 22 and nA motors
Designation of motor according to IEC standard:
II 3D Ex tc IIIB T120°C
II 3G Ex nA IIC T3
Typical duty hours for lifetime lubricated bearings.
Frame size
56 - 160
180
200
225
180 - 225
Poles
2 - 8
2
2
2
4 - 8
Typical lifetime
40,000h
35,000h
27,000h
23,000h
40,000h
The hazardous 3-phase asynchronous motors are in accordance with International standard IEC 60079-31 and
IEC 60079-15.
Only one electrical installation may be installed in one specified area (zone).
Motors with a re-greasing system must be lubricated with high quality lithium complex grease, NLGI grade 2 or 3, with a temperature range of between -40°C to +150°C.
Motors are normal fitted with a data plate with greasing information; if it is missing use the following re-greasing intervals.
Only certificated cable glands may be used. Unused glands must be closed.
Connections must be made in such a way as to ensure that a permanently safe electrical connection is maintained, both for the main supply and earth connection.
Installations must be in accordance with actual standards for installation in hazardours area.
Frame size
160
180
200
225
250
280
315
355
400
Grease
(g)
20
20
25
25
35
35
50
60
80
2 pole
(h)
4200
4200
3100
3100
2000
2000
1500
1000
800
4 pole
(h)
7000
7000
6500
6500
6000
6000
5500
4000
3000
6 pole
(h)
8500
8500
8500
8500
7000
7000
6500
5000
4000
8 pole
(h)
8500
8500
8500
8500
7000
7000
6500
6000
6000
It is recommended that the IEC standard is followed according to temperature and dust on the motor surface.
The use of motors with so much surface dust that the motor temperature increases is not permitted.
Regularly cleaning is recommended.
The radial shaft sealing ring is part of the ATEX certification.
It is important that the ring is always intact.
The shaft sealing must be regularly checked, and if dry it must be lubricated. It is recommended that the seal is relubricated regularly.
Always use the original seal ring when replaced.
Replacing bearings also means replacing the seals.
Grease the motor while running, open the grease outlet plug and let the motor run 1-2 hours before the outlet grease plug is closed again.
Grease the motor for the first time during commissioning.
All machines must be inspected regularly for mechanical damage.
The user is responsible for changing parts in accordance with the lifetime of parts, in particular: bearings, grease and lubrication of shaft sealing.
The following applies in general for both lifetime lubricated and re-lubricated bearings:
At 60Hz the time will be reduced by app. 20%.
Data for vertically mounted motors are half of the above values.
Maintenance, repairs and replacement on this type must only be carried out by qualified specialists.
3
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021 | 57
Connection diagram
Anschlußdiagram
Anslutningdiagramm
Forbindelsesdiagram
Aansluitdiagram
Connection
Conexión
Collegamento
Schemat polacsen
58
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021 | 59
60
Head Offices
Denmark
Over Hadstenvej 42 · DK-8370 Hadsten
T +45 86 98 21 11 · F +45 86 98 17 79
CVR no. 17 63 06 95 [email protected]
hoyermotors.com
China
19 Jingwu Middle Road · Beilun District
Ningbo 315821 · Zhejiang
T +86 574 26 28 15 77 · F + 86 574 2628 1573 [email protected]
hoyermotors.cn
Hoyer Motors, Motor Manual, April 2019
Branch Offices
Germany
Landsberger Straße 155 · 80687 München
T +49 89 700 88 235 · F +49 89 543 56 333 [email protected]
hoyermotors.com
Sweden
Liljeholmsstranden 5 · PO box 44017
SE-100 73 Stockholm
T +46 8 446 877 13 [email protected]
hoyermotors.com
Benelux
Vasteland 78 · 3011 BN, Rotterdam
Tel. +31 10 420 35 20 · Fax.+31 10 420 44 51 [email protected]
hoyermotors.com
Korea
302ho · Code square · 3150-1 · Daejeo 2-dong
Gangseo-gu · Busan · Korea
T +82 51 996 0251 · F +82 51 996 0252 [email protected]
hoyermotors.com
Important notice.
Text and data in this catalogue are not binding and we reserve the right to implement changes without further notice.
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
KTR-N
Sheet:
Edition:
BoWex-ELASTIC
® highly flexible flange coupling type
HEW1, HEW2 and their combinations according to directive 2014/34/EU for finish bored, pilot bored and unbored couplings
40114 EN
1 of 22
7
Type HEW1 Type HEW2
BoWex-ELASTIC
® highly flexible flange coupling types
HEW Compact and HEW-ZS and their combinations for finish bored, pilot bored and unbored couplings
Type HEW Compact
Please observe protection note ISO 16016.
Drawn:
Verified:
© Danfoss | DCS (im) | 2021.12
Type HEW-ZS
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 61
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
KTR-N
Sheet:
Edition:
40114 EN
2 of 22
7
BoWex-ELASTIC ® HEW is a highly flexible plug-in shaft coupling. It dampens torsional vibrations, reduces shocks and insulates structure-borne noise.
The BoWex-ELASTIC ® HEW coupling compensates for relatively large shaft displacements, for example caused by inaccuracies in production, thermal expansion etc.
Table of contents
1 Technical data
2 Advice
2.1
Coupling selection
2.2
General advice
2.3
Safety and advice symbols
2.4
General hazard warnings
2.5
Intended use
2.6
Reference to EC Machinery Directive 2006/42/EC
3 Storage, transport and packaging
3.1
Storage
3.2
Transport and packaging
4 Assembly
4.1
Components of the couplings
4.2
Advice for finish bore
4.3
Assembly of the coupling
4.4
Displacements - alignment of the couplings
5 Start-up
6 Breakdowns, causes and elimination
7 Disposal
8 Spares inventory, customer service addresses
3
6
6
6
7
7
7
8
8
8
8
8
8
10
11
12
15
16
18
18
9 Enclosure A Advice and instructions regarding the use in atmospheres
potentially explosive
9.1
9.2
Intended use in hazardous locations
Inspection intervals for couplings in
9.3
Inspection of torsional backlash
9.4
Standard values of wear
potentially explosive atmospheres
9.5
marking of coupling for potentially explosive atmospheres
9.6
EU Certificate of conformity
18
18
19
20
20
21
22
Please observe protection note ISO 16016.
Drawn:
Verified:
62 | © Danfoss | DCS (im) | 2021.12
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
1 Technical data
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
KTR-N
Sheet:
Edition:
40114 EN
3 of 22
7
Illustration 1: BoWex-ELASTIC ® type HEW1
Table 1: Dimensions – type HEW1 and HEW2
Illustration 2: BoWex-ELASTIC ® type HEW2
Size
42
48
65
80
G 80
100
125
G 125
150
G 150
200
G 200
Max. finish bore
[mm] d
2
48
48
65
80
85
100
125
125
160
160
180
180 d
3
50
55
75
80
95
110
125
125
160
160
200
200
D
68
68
96
124
124
152
192
192
225
225
250
200
D
2
162
180
224
295.27
333.4
438.15
438.15
489
542.9
542.9
641.35
250
8
8
16
8
6
8
8
8
6
6
12
12 z x M
M6
M6
M8
M10
M10
M12
M12
M12
M16
M16
M16
M16
Table 1: Continuation of Dimensions – type HEW1 and HEW2
Dimensions [mm]
350
416
440
470
504
568
600
D
4
146
164
205
266
302
478
478
530
585
585
683
683
D
5
180
200
245
318
358
Size
42
48
65
80
G 80
100
125
G 125
150
G 150
200
G 200
14
14
14
18
18
26
26 l
3
15
17
28
17
22
111.5
170
170
150
150
220
220 l
4
50
55
75
80
90
113
158
158
145
145
214
214 l
5
42
45
63
70
78
Dimensions [mm]
5
5
26
-
E
4
4
5
-
-
-
-
-
57
45
45
70
70
85
85
E
1
32
32
42
45
55
327
327
380
380
480
480
L
HEW
132
137
1
187
215
235
278
L
HEW
2
104
109
150
-
-
160
185
207
-
Weight with max. bore
[kg]
4.3
5.5
13.2
19.7
25.9
48.5
67.2
76.6
110
113.4
195
200
158
175
175
225
225
280
280
D
6
85
92
125
130
145
110
140
140
150
150
175
175 l
1
50
50
70
90
90
0.0204
0.0752
0.1449
0.2748
0.8356
0.9498
1.4492
2.7206
2.7809
6.6418
6.6099
Mass moment of inertia [kgm 2 ]
J
A
0.0121
J
L
0.0015
0.0019
0.0071
0.0285
0.0422
0.1050
0.2617
0.3034
0.5303
0.5861
1.1406
1.3419
80
99
95
100
108
149
149 l
2
45
45
55
70
80
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 63
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
1 Technical data
Table 2: Torques – type HEW1 and HEW2
Size
42
48
65
80
G 80
100
Elastomer hardness
[Shore A]
40 / T40
50 / T50
65 / T65
40 / T40
50 / T50
65 / T65
40 / T40
50 / T50
65 / T65
40 / T40
50 / T50
65 / T65
40 / T40
50 / T50
65 / T65
40 / T40
50 / T50
65 / T65
BoWex ® HEW Compact
T
KN
Torque [Nm]
T
K max.
500
750
950
1200
1250
1600
2000
2000
2500
3200
130
150
180
200
230
280
350
400
1500
2250
2850
3600
3750
4800
6000
6000
7500
9600
390
450
540
600
690
840
1050
1200
Size
125
G 125
150
G 150
200
G 200
Elastomer hardness
[Shore A]
40 / T40
50 / T50
65 / T65
40 / T40
50 / T50
65 / T65
T40
T50
T65
T40
T50
T65
T40
T50
T65
T40
T50
T65
KTR-N
Sheet:
Edition:
40114 EN
4 of 22
7
T
KN
Torque [Nm]
T
K max.
9000
7000
9200
11500
9500
12500
16000
11500
15000
19500
3000
4000
5000
4000
5200
6500
5500
7000
9000
12000
15000
12000
16000
20000
16500
21000
27000
21000
27600
34500
28500
37500
48000
34500
45000
58500
Illustration 3: BoWex-ELASTIC ® type HEW1
Table 3: Dimensions – type HEW Compact
Illustration 4: BoWex-ELASTIC ® type HEW2
Size
Max. finish bore [mm] d
1
42-130 42
65-180 65
80-225 75 d
2
D
1
D
2
D
3
D
4 l
1
Dimensions [mm] l
2 l
3 l
4
E L L
1
z M
42 90 65 78 131 42 42 45 37 34 118 98 6 M6
65 130 96 110 180 60 55 55 47 30 145 122 8 M10
Weight with pilot bored coupling [kg]
3.4
9.0
80 145 124 120 225 70 90 77 51 50 210 158 10 M12 18.9
100-305 100 100 200 152 175 305 90 110 90 73 58 258 187 16 M12 40.2
125-365 125 125 235 192 205 365 120 140 150 90 68 328 240 12 M16 75.0
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
Mass moment of inertia with pilot bored coupling
[kgm 2 ]
J
1
J
2
0.003 0.001
0.014 0.006
0.035 0.029
0.152 0.087
0.36 0.26
KTR-N dated 2013-06-10
64 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
1 Technical data
Table 4: Technical data - HEW Compact
Operating speed n max.
[rpm]
Perm. damping power P
KW
[W] C
60 °C 80 °C 90 °C dyn.
with
60 °C
[Nm/rad]
Size
Elastomer hardness
[Shore A]
T
KN
[Nm]
Torque
T
Kmax
[Nm]
T
KW
[Nm]
42
65
80
100
125
T70
T50
T65
T70
T40
T50
T65
T50
T65
T70
T50
T65
T70
T50
T65
BoWex ® HEW-ZS
150 450 45
180 540 54
210 630 63
400 1200 120
500 1500 150
575 1725 173
900 2700 270
1100 3300 330
1300 3900 390
2000 6000 600
2600 7800 780
3000 9000 900
3000 9000 900
4000 12000 1200
5000 15000 1500
7300
5500
4400
3200
2900
24 12 6
48 24 12
96 48 24
156 78 39
192 96 48
780
2400
2900
2850
7800
9500
5000
13000
16500
17000
44000
50000
15000
25000
62000
KTR-N
Sheet:
Edition:
Relative damping
1.2
0.6
0.8
1.2
0.6
0.8
1.2
0.6
0.8
1.2
0.6
0.8
1.2
0.6
0.8
Resonance factor V
R
2 /
5.2
10.5
7.9
5.2
10.5
7.9
5.2
10.5
7.9
5.2
10.5
7.9
5.2
10.5
7.9
40114 EN
5 of 22
7
Radial spring stiffness
C r
[N/mm]
178
600
710
379
955
1240
420
1090
1450
760
1850
2250
476
750
1930
Illustration 5: BoWex-ELASTIC ® type HEW-ZS (size 48 to G 80)
Table 5: Dimensions – type HEW-ZS 1)
Size
48
65
80
G 80
100
125
G 125
55
75
80
95
110
125
125
Max. finish bore [mm] d
3 d
4
28
45
D
2
180
224
8
8
65 295.27 8
65 333.4 8
90 438.15 8
120 438.15
120 489
16
8 z x M
M6
M8
M10
M10
M12
M12
M12
D
4
164
205
266
302
350
416
440
Illustration 6: BoWex-ELASTIC ® type HEW-ZS (size 100 to G 125)
Dimensions [mm]
D
5
200
245
318
358
478
478
530
D
6
92
125
130
145
158
175
175
D
7
78
110
145
145
180
225
225
D
8
45
72
100
100
135
180
180 l
1
50
55
90
90
80
80
80 l
2
45
55
70
80
80
99
95 l
3
17
28
17
22
16
18
15
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 65
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
1 Technical data
Table 5: Continuation of Dimensions – type HEW-ZS 1)
KTR-N
Sheet:
Edition:
40114 EN
6 of 22
7
Size l
4
Dimensions [mm] l
5 l
6
100
48
65
80
G 80
55
75
80
90
45
63
70
78
45
56
75
75
100
125
111.5
170
110
171
76
76
G 125 170 157 76
1) Torques of BoWex-ELASTIC ® type HEW-ZS see table 2.
120
Spacer HEW-ZS
L
Z
[mm]
140
180
250
Weight with max. bore
[kg]
6.9
16.0
25.5
34.2
54.0
84.2
93.5
Mass moment of inertia [kgm 2 ]
J
A
J
L
0.0203 0.0050
0.0747 0.0160
0.1447 0.0699
0.2752 0.1412
0.8459 0.0992
1.1814 0.3017
1.6853 0.3690
BoWex-ELASTIC ® couplings with attachments that may generate heat, sparks and static charging (e. g. combinations with brake drums, brake disks, overload systems such as torque limiters, fans etc.) are not permissible for the use in potentially explosive atmospheres.
A separate analysis must be performed.
2 Advice
2.1 Coupling selection
!
For a long-lasting and failure-free operation of the coupling it must be selected according to the selection instructions (according to DIN 740 part 2) for the particular application (see catalogue drive technology "BoWex-ELASTIC ®" ).
If the operating conditions (performance, speed, modifications on engine and machine) change, the coupling selection must be reviewed.
Please make sure that the technical data regarding torque refer to the elastomer part only.
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility.
For drives subject to torsional vibrations (drives with cyclic stress due to torsional vibrations) it is necessary to perform a torsional vibration calculation to ensure a reliable selection. Typical drives subject to torsional vibrations are e. g. drives with diesel engines, piston pumps, piston compressors etc. If requested, KTR will perform the coupling selection and the torsional vibration calculation.
2.2 General advice
Please read through these operating/assembly instructions carefully before you start up the coupling.
Please pay special attention to the safety instructions!
The BoWex-ELASTIC ® coupling is suitable and approved for the use in potentially explosive atmospheres. When using the coupling in potentially explosive atmospheres, please observe the special advice and instructions regarding safety in enclosure A.
The operating/assembly instructions are part of your product. Please store them carefully and close to the coupling.
The copyright for these operating/assembly instructions remains with KTR .
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
66 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
2 Advice
2.3 Safety and advice symbols
STOP
Warning of potentially explosive atmospheres
Warning of personal injury
KTR-N
Sheet:
Edition:
40114 EN
7 of 22
7
This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may result in death caused by explosion.
This symbol indicates notes which may contribute to preventing bodily injuries or serious bodily injuries that may result in death.
! Warning of product damages
General advice
This symbol indicates notes which may contribute to preventing material or machine damage.
This symbol indicates notes which may contribute to preventing adverse results or conditions.
Warning of hot surfaces
This symbol indicates notes which may contribute to preventing burns with hot surfaces resulting in light to serious bodily injuries.
2.4 General hazard warnings
STOP
With assembly, operation and maintenance of the coupling it has to be made sure that the entire drive train is secured against accidental switch-on. You may be seriously hurt by rotating parts. Please make absolutely sure to read through and observe the following safety indications.
All operations on and with the coupling have to be performed taking into account "safety first".
Please make sure to switch off the power pack before you perform your work on the coupling.
Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on or removing the fuse for current supply.
Do not reach into the operating area of the coupling as long as it is in operation.
Please secure the coupling against accidental contact. Please provide for the necessary protection devices and covers.
2.5 Intended use
You may only assemble, operate and maintain the coupling if you
have carefully read through the operating/assembly instructions and understood them
had technical training
are authorized by your company
The coupling may only be used in accordance with the technical data (see table 1 to 4 in chapter 1). Unauthorized modifications on the coupling design are not admissible. We will not assume liability for any damage that may arise. In the interest of further development we reserve the right for technical modifications.
The BoWex-ELASTIC type HEW, HEW Compact and HEW-ZS described in here corresponds to the technical status at the time of printing of these operating/assembly instructions.
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 67
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
KTR-N
Sheet:
Edition:
40114 EN
8 of 22
7
2 Advice
2.6 Reference to EC Machinery Directive 2006/42/EC
The couplings supplied by KTR should be considered as components, not machines or partly completed machines according to EC Machinery Directive 2006/42/EC. Consequently KTR does not have to issue a declaration of incorporation. For details about safe assembly, start-up and safe operation please refer to the present operating/assembly instructions considering the warnings.
3 Storage, transport and packaging
3.1 Storage
The coupling hubs are supplied in preserved condition and can be stored at a dry and roofed place for 6 - 9 months.
With favourable storage conditions the properties of the elastomer part remain unchanged up to 5 years.
!
The storage rooms must not include any ozone-generating devices like e. g. fluorescent light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Please make sure that condensation is not generated. The best relative air humidity is less than 65 %.
3.2 Transport and packaging
!
In order to avoid any injuries and any kind of damage please always make use of proper transport and lifting equipment.
The couplings are packed differently each depending on size, number and kind of transport. Unless otherwise contractually agreed, packaging will follow the in-house packaging specifications of KTR.
4 Assembly
The coupling is generally supplied in individual parts. Before assembly the coupling has to be inspected for completeness.
4.1 Components of the couplings
Components of BoWex-ELASTIC
Component
1
2
4
5
7
Quantity
® , type HEW1 and HEW2
Description
1
1
1 see table 1
2
Elastomer part
Hub
1)
Coupling flange
Cap screws DIN EN ISO 4762
Setscrews DIN EN ISO 4029
1)
1) With size 150 nuts as per DIN EN ISO 4014 are required additionally.
Illustration 7: BoWex-ELASTIC ® type HEW1
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Illustration 8: BoWex-ELASTIC ® type HEW2
Replacing:
Replaced by:
KTR-N dated 2013-06-10
68 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
4 Assembly
4.1 Components of the couplings
Components of BoWex-ELASTIC ® , type HEW compact
Component Quantity
1
2
4
5
7
1
1
Description
Elastomer part
Hub
1 Coupling flange see table 3 Cap screws DIN EN ISO 4762
2 Setscrews DIN EN ISO 4029
KTR-N
Sheet:
Edition:
40114 EN
9 of 22
7
Illustration 9: BoWex-ELASTIC
Components of BoWex-ELASTIC ® , type HEW-ZS
Component Quantity
1
2
3
4
4.1
4.2
4.3
5
6
7
1
1
Elastomer part
Hub spec.
Intermediate flange hub
Coupling flange
Description
1
1
1
1
Additional flange
Flange hub see table 5 Cap screws DIN EN ISO 4762 see table 1 Cap screws DIN EN ISO 4762 see table 5 Cap screws DIN EN ISO 4762
2 Setscrews DIN EN ISO 4029
® type HEW Compact
Illustration 10: BoWex-ELASTIC ® type HEW-ZS (size 48 to G 80)
Table 6: Cap screws DIN EN ISO 4762
Size
Quantity z (component 4.3)
Quantity z (component 6)
48
-
8
65
-
12
Please observe protection note ISO 16016.
Drawn:
Verified:
Illustration 11: BoWex-ELASTIC ® type HEW-ZS (size 100 to G 125)
80
-
12
2017-04-24 Shg/Hk
2017-04-24 Shg
G 80
-
12
100
15
12
Replacing:
Replaced by:
125
12
12
G 125
12
12
KTR-N dated 2013-06-10
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 69
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
4 Assembly
4.2 Advice for finish bore
STOP
The maximum permissible bore diameters d (see table 1 to 5 in chapter 1 - technical data) must not be exceeded. If these figures are disregarded, the coupling may tear. Rotating particles may cause danger to life.
Bores on the hubs/coupling flange machined by the customer have to observe concentricity or axial runout (see illustration
12).
Please make absolutely sure to observe the figures for Ø d max
.
Carefully align the hub or coupling flange when the finish bores are drilled.
Provide for a setscrew according to DIN EN ISO 4029 with a cup point or an end plate to fasten the hub or coupling flange axially.
!
KTR-N
Sheet:
Edition:
40114 EN
10 of 22
7
Illustration 12: Concentricity and axial runout
The customer bears the sole responsibility for all machining processes performed subsequently on unbored or pilot bored as well as finish machined coupling components and spare parts. KTR does not assume any warranty claims resulting from insufficient remachining.
Table 7: Setscrews DIN EN ISO 4029
Size
Thread size
Tightening torque
T
A
[Nm]
42 48 65 80 G 80 100 125 G 125 150 G150 200 G 200
M8 M8 M10 M10 M10 M12 M16 M16 M16 M16 M20 M20
10 10 17 17 17
Table 8: Recommended fit pairs acc. to DIN 748/1
40 80 80 80 80 140 140 above
50
Bore [mm] up to
50
Shaft tolerance k6 m6
Bore tolerance
H7
(KTR standard)
If a feather keyway is intended to be used in the hub, it should correspond to the tolerance ISO JS9 (KTR standard) with normal operating conditions or ISO P9 with difficult operating conditions (frequently alternating torsional direction, shock loads, etc.).
The transmittable torque of the shaft-hub-connection must be reviewed by the customer and is subject to his responsibility.
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
70 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
KTR-N
Sheet:
Edition:
40114 EN
11 of 22
7
4 Assembly
4.3 Assembly of the coupling
We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy before assembly.
Heating the hubs lightly (approx. 80 °C) allows for an easier mounting on the shaft.
Please pay attention to the ignition risk in potentially explosive atmospheres!
STOP
Touching the heated hubs causes burns.
Please wear safety gloves.
!
!
With the assembly please make sure that the distance dimension E (see table 1 and 4) is observed to allow for axial clearance of the sleeve while being in operation.
Disregarding this advice may cause damage to the coupling.
With the assembly please make sure that the spline of the hub is fully covered by the internal spline of the elastomer. (Please observe mounting dimensions L, L
Disregarding this advice may cause damage to the coupling.
HEW1
, L
HEW2
or L
HEW - ZS
.)
Applies with type HEW-ZS only (size 100 to G 125)!
Screw the flange hub (component 4.2) with the additional flange (component 4.1) at the tightening torques T
A specified in table 9.
Table 9: Cap screws DIN EN ISO 4762
Size
Tightening torque T
A
[Nm]
Mount the hub, flange hub with additional flange or the coupling flange onto the shaft of the driving and driven side.
100
355
125
355
G 125
355
Shift the power packs in axial direction until the mounting dimension L, L achieved.
HEW1
, L
HEW2
or. L
HEW-ZS
has been
If the power packs have already been firmly assembled, shifting the hub, flange hub or the coupling flange or coupling flange axially on the shafts allows for adjusting the mounting dimension.
Fasten the hub, flange hub or coupling flange by tightening the setscrews DIN EN ISO 4029 with a cup point
(tightening torques see table 7).
Valid for type HEW-ZS only!
Mount the hub spec. (component 2) in front of the intermediate shaft hub (component 3) and screw the components at the tightening torques T
A
specified in table 10.
Table 10: Cap screws DIN EN ISO 4762
Size
Tightening torque
T
A
[Nm]
Please observe protection note ISO 16016.
48
41
Drawn:
Verified:
65
69
80
120
2017-04-24 Shg/Hk
2017-04-24 Shg
G 80
120
100
190
Replacing:
Replaced by:
125
295
G 125
295
KTR-N dated 2013-06-10
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 71
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
KTR-N
Sheet:
Edition:
40114 EN
12 of 22
7
4 Assembly
4.3 Assembly of the coupling
Valid for type HEW only!
Mount the elastomer part (component 1) in front of the coupling flange (component 4) and screw the components at the tightening torques T
A
specified in table 11.
Table 11: Cap screws DIN EN ISO 4762
Tightening torque
T
A
Size
[Nm]
42
14
48
14
65
35
80
69
G 80 100
69 120
125 G 125 150 G 150 200 G 200
120 120 295 295 410 410
Position the elastomer part (component 1) in front of the flange hub with additional flange or coupling flange.
Hand-tighten the components first. Afterwards tighten the screws at the tightening torque T
A
11.
specified in table
Valid for type HEW Compact only!
Mount the coupling flange (component 4) in front of the elastomer part (component 1) and screw the components at the tightening torques T
A
specified in table 12.
Table 12: Cap screws DIN EN ISO 4762
Size
Tightening torque
T
A
[Nm]
42
14
65
69
80
120
100
120
125
250
If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite (average strength).
!
Please observe the manufacturer’s instructions regarding the use of adhesives.
Do not apply glue on the rubber surfaces.
4.4 Displacements - alignment of the couplings
The BoWex-ELASTIC ® HEW couplings accept a position deviation of the machine parts to be connected up to the data specified in table 13.
With alignment, the radial and angular displacement should be kept as small as possible, because the service life is increased in this way if the operating conditions are otherwise maintained.
The BoWex-ELASTIC ® HEW coupling has to be aligned from the coupling hub on the shaft side towards one of the machined surfaces of the flange hub.
!
In order to ensure a long service life of the coupling and avoid danger with the use in potentially explosive atmospheres, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures specified (see table 11).
If the figures are exceeded, the coupling will be damaged.
The more accurate the alignment of the coupling, the longer is its service life.
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.
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
72 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
4 Assembly
4.4 Displacements - alignment of the couplings
Please note:
KTR-N
Sheet:
Edition:
40114 EN
13 of 22
7
The displacement figures specified in tables 13 and 14 are maximum figures which must not arise in parallel. If radial and angular displacements arise at the same time, the permissible displacement values may only be used proportionally (see illustration 14).
The displacement figures specified are general standard figures that apply up to an ambient temperature of
80 °C, ensuring a sufficient service life of the BoWex-ELASTIC ® coupling.
Displacement figures between the speeds specified have to be interpolated accordingly. If necessary, please ask about the displacement for the corresponding coupling type.
Please inspect with a dial gauge, ruler or feeler whether the permissible displacement figures of tables 13 and
14 can be observed.
Radial displacement
Examples of the displacement combinations specified in illustration 14:
Example 1:
Example 2:
K
K
K
K r r w w
= 30 %
= 70 %
= 60 %
= 40 %
K total
= K r
+ K w
100 %
Please observe protection note ISO 16016.
Drawn:
Verified:
© Danfoss | DCS (im) | 2021.12
Angular displacement
Illustration 13: Displacements
Illustration 14: Combinations of displacement
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
Axial displacement
KTR-N dated 2013-06-10
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 73
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
4 Assembly
4.4 Displacements - alignment of the couplings
Table 13: Displacement figures
KTR-N
Sheet:
Edition:
40114 EN
14 of 22
7
Displacement figures
Perm. radial displacement with n = 1500 rpm
K
r
K
[mm]
Perm. radial displacement with n = 3000 rpm
Max. radial displacement
K
K r r max.
[mm]
[mm]
Perm. angular displacement with n = 1500 rpm w
[°]
Perm. angular displacement with n = 3000 rpm
K w
[°]
1)
Elastomer hardness
[Shore A]
40
50
65
40
3)
3)
3)
2) 3)
50 3)
65
40 3)
2) 3)
50 3)
65
40 3)
2) 3)
50 3)
65
40 3)
2) 3)
50
65
3)
2) 3)
1)
Max. angular displacement
Kw max. [°]
1)
[mm]
Perm. axial displacement
K a
2) With size 125 = 70 ShA
40 / 50 / 65
40 / 50 / 65
For short-term start-up operation
3) applies for compound T as well
2) 3)
2) 3)
42 HE
1.5
1.0
0.75
0.5
0.5
0.4
0.25
1.1
1.0
0.5
0.8
0.7
0.4
3.6
3.3
1.5
±2
48 HE
1.5
±2
Table 14: Displacement figures of HEW Compact
1.7
1.0
0.75
0.5
0.5
0.4
0.25
1.2
1.1
0.5
1.1
1.0
0.4
3.8
3.5
0.7
1.4
1.3
0.5
5.1
4.7
2.2
1.0
0.75
0.5
0.5
0.4
0.25
80 HE
1.8
1.7
0.8
1.6
1.5
0.6
5.7
5.3
Size
65 HE
G 65 HE G 80 HE
1.6
1.5
100 HE
2.4
1.0
0.75
0.5
0.5
0.4
0.25
3.0
1.0
0.75
0.5
0.5
0.4
0.25
2.2
2.0
1.0
2.0
1.8
0.8
6.5
6.0
1.5
±2
1.5
±2
1.5
±3
125 HE 150 HE 200 HE
G 125 HE G 150 HE G 200 HE
2.5
2.3
1.1
2.2
2.0
0.8
7.5
6.9
3.3
1.0
0.75
0.5
0.5
0.4
0.25
2.8
2.5
1.3
2.5
2.2
1.0
8.0
7.5
4.0
1.0
0.75
0.5
0.5
0.4
0.25
4.5
1.0
0.75
0.5
0.5
0.4
0.25
3.0
2.7
1.5
2.8
2.5
1.2
8.5
8.0
1.5
±3
1.5
±5
1.5
±5
Displacement figures
Elastomer hardness
[Shore A]
Max. axial displacement
K a
[mm]
Max. radial displacement with n=1500 rpm
K r
[mm] ±
Max. radial displacement with n=3000 rpm
K r
[mm]
Max. angular displacement with n=1500 rpm
K w
[°]
Max. angular displacement with n=3000 rpm
K w
[°]
42-130
T50 T65 T70
± 2
±1.1 ±1
± 2 ± 2
±1 ±0.75 ±0.5 ±1 ±0.75 ±0.5 ±1 ±0.75 ±1
± 2
±0.5 ±1.6 ±1.5 ±0.7 ±1.8 ±1.7 ±2.2 ±2.2 ±2
± 2
±1 ±2.5 ±2.3 ±1.1
±0.55 ±0.5 ±0.25 ±0.8 ±0.75 ±0.35 ±0.9 ±0.85 ±1.1 ±1.1 ±1 ±0.5 ±1.25 ±1.15 ±0.55
±1 ±0.75 ±0.5 ±1 ±0.75 ±0.5
±0.5 ±0.4 ±0.25 ±0.5 ±0.4 ±0.25 ±0.5 ±0.4 ±0.5 ±0.5 ±0.25 ±0.25 ±0.5 ±0.4 ±0.25
Please observe protection note ISO 16016.
Drawn:
Verified:
65-180
Size
80-225 100-305
T50 T65 T70 T50 T65 T70 T50 T65 T70 T40
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
125-365
T52 T65
KTR-N dated 2013-06-10
74 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
KTR-N
Sheet:
Edition:
40114 EN
15 of 22
7
5 Start-up
Before start-up of the coupling, please inspect the tightening of the setscrews in the hubs, the alignment and the distance dimension L, L
HEW1
, L
HEW2
or L
HEW-ZS
and adjust, if necessary, and also inspect all screw connections for the tightening torques specified, dependent on the type of coupling.
If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all screw connections must be secured against working loose additionally, e. g. conglutinating with Loctite
(average strength).
Finally the coupling protection against accidental contact must be fitted. It is required in accordance with DIN EN
ISO 12100 (Safety of Machinery) and the directive 2014/14/EU and must protect against
access with the little finger
falling down of solid foreign objects.
The cover may provide for openings intended for necessary heat dissipation. These openings have to comply with
DIN EN ISO 13857.
The cover must be electrically conductive and included in the equipotential bonding. Bellhousings (magnesium share below 7.5 %) made of aluminium and damping rings (NBR) can be used as connecting element between pump and electric motor. The cover may only be taken off with standstill of the unit.
If the couplings are used in locations subject to dust explosion and in mining the user must make sure that there is no accumulation of dust in a dangerous volume between the cover and the coupling. The coupling must not operate in an accumulation of dust.
For covers with unlocked openings on the top face no light metals must be used if the couplings are used as equipment of equipment group ll ( if possible, from stainless steel ).
If the couplings are used in mining (equipment group l M2), the cover must not be made of light metal. In addition, it must be resistant to higher mechanical loads than if it is used as equipment of equipment group ll.
During operation of the coupling, please pay attention to
different operating noise
vibrations occurring.
!
If you note any irregularities with the coupling during operation, the drive unit must be switched off immediately. The cause of the breakdown must be specified by means of the table „Breakdowns“ and, if possible, be eliminated according to the proposals. The p otential breakdowns mentioned can be hints only. To find out the cause all operating factors and machine components must be considered.
Coating of coupling:
If coated (priming, paintings, etc.) couplings are used in potentially explosive atmospheres, the requirements on conductibility and coating thickness must be considered. In case of paintings up to 200 µm electrostatic load does not have to be expected. Multiple coatings exceeding 200 µm are prohibited for explosion group llC.
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 75
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
KTR-N
Sheet:
Edition:
40114 EN
16 of 22
7
6 Breakdowns, causes and elimination
The below-mentioned failures can result in a use of the BoWex-ELASTIC ® coupling other than intended. In addition to the specifications given in these operating and assembly instructions please make sure to avoid such failures.
The errors listed can only be clues to search for the failures. When searching for the failure the adjacent components must generally be considered.
If used other than intended the coupling can become a source of ignition.
EU directive 2014/34/EU requires special care by the manufacturer and the user.
General failures with use other than intended:
Important data for the coupling selection were not forwarded.
The calculation of the shaft-hub-connection was not considered.
Coupling components with damage occurred during transport are assembled.
If the heated hubs are assembled, the permissible temperature is exceeded.
The clearance of the components to be assembled is not coordinated with one another.
Tightening torques have been fallen below/exceeded.
Components are mixed up by mistake/assembled incorrectly.
No original KTR components (purchased parts) are used.
Old/already worn out elastomer parts or those stored for too long are used.
The coupling used/the coupling protection used is not suitable for the operation in potentially explosive atmospheres or does not correspond to EU directive 2014/34/EU.
Maintenance intervals are not observed.
Breakdowns Causes
Hazard notes for potentially explosive atmospheres
Elimination
Different operating noise and/or vibrations occuring
Fracture of elastomer part / spline
Micro friction by faulty alignment on the spline of the elastomer part
Screws for axial fastening of hubs working loose
Fracture of elastomer part / spline caused by high dynamic energy / overload
Danger of ignition due to hot surfaces none
1) Set the unit out of operation
2) Eliminate the reason for misalignment
(e. g. loose foundation bolts, breaking of the engine mount, heat expansion of unit components, modification of the installation dimension E of the coupling)
3) For inspection of wear see item 5.4
1) Set the unit out of operation
2) Inspect alignment of coupling
3) Tighten the screws to fasten the hubs and secure against working loose
4) For inspection of wear see item 5.4
1) Set the unit out of operation
2) Disassemble the coupling and remove remainders of the elastomer part
3) Inspect coupling components and replace coupling components that are damaged
4) Insert elastomer part, assemble coupling components
5) Find out the reason for overload
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
76 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
6 Breakdowns, causes and elimination
Breakdowns Causes
Hazard notes for potentially explosive atmospheres
Fracture of elastomer part / spline
Excessive wear on the spline of the elastomer part, fracture of elastomer
Operating parameters do not meet with the performance of the coupling
Operating error of the unit
Vibrations of drive
Ambient/contact temperatures which are too high for the elastomer part, max. permissible e. g. T4 =
- 30 °C/+ 80 °C e. g. contact with aggressive liquids/oils, influence by ozone, too high ambient temperature etc. causing a physical change of the elastomer part none
Danger of ignition due to hot surfaces none
KTR-N
Sheet:
Edition:
Elimination
40114 EN
17 of 22
7
1) Set the unit out of operation
2) Review the operating parameters and select a bigger coupling (consider mounting space)
3) Assemble new coupling size
4) Inspect alignment
1) Set the unit out of operation
2) Disassemble the coupling and remove remainders of the elastomer part
3) Inspect coupling components and replace coupling components that are damaged
4) Insert elastomer part, assemble coupling components
5) Instruct and train the service staff
1) Set the unit out of operation
2) Disassemble the coupling and remove remainders of the elastomer part
3) Inspect coupling components and replace coupling components that are damaged
4) Insert elastomer part, assemble coupling components
5) Inspect alignment, adjust if necessary
6) Find out the reason for vibrations
1) Set the unit out of operation
2) Disassemble the coupling and remove remainders of the elastomer part
3) Inspect coupling components and replace coupling components that are damaged
4) Insert elastomer part, assemble coupling components
5) Inspect alignment, adjust if necessary
6) Inspect and adjust ambient/contact temperature
1) Set the unit out of operation
2) Disassemble the coupling and remove remainders of the elastomer part
3) Inspect coupling components and replace coupling components that are damaged
4) Insert elastomer part, assemble coupling components
5) Inspect alignment, adjust if necessary
6) Make sure that other physical modifications of the elastomer part are excluded
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.
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 77
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
KTR-N
Sheet:
Edition:
40114 EN
18 of 22
7
7 Disposal
In respect of environmental protection we would ask you to dispose of the packaging or products on termination of their service life in accordance with the legal regulations and standards that apply, respectively.
Metal
Any metal components have to be cleaned and disposed of by scrap metal.
Nylon materials
Nylon materials have to be collected and disposed of by a waste disposal company.
8 Spares inventory, customer service addresses
A basic requirement to ensure the readiness for use of the coupling is a stock of the most important spare parts on site.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at www.ktr.com.
KTR does not assume any liability or warranty for the use of spare parts and accessories which are not provided by KTR and for the damages which may incur as a result.
9 Enclosure A
Advice and instructions regarding the use in potentially explosive atmospheres
Type HEW1 and HEW2: hub / elastomer / coupling flange
Annex A applies for BoWex-ELASTIC ® HEW1 and HEW2 only.
9.1 Intended use in hazardous locations
Conditions of operation in
BoWex-ELASTIC ®
potentially explosive atmospheres
couplings are suitable for the use according to EU directive 2014/34/EU.
Industry (with the exception of mining)
Equipment group II of category 2 and 3 ( coupling is not approved for equipment group 1 )
Media class G ( gases, fogs, steams ), zone 1 and 2 ( coupling is not approved for zone 0 )
Media class D ( dusts ), zone 21 and 22 ( coupling is not approved for zone 20 )
Explosion group IIB ( explosion class IIA are included in IIB )
Temperature class:
Temperature class
T4, T3, T2, T1
T5
T6
Ambient or operating temperature T a
Max. surface temperature
115 °C 2)
1)
- 30 °C to + 80 °C
- 30 °C to + 65 °C 100 °C
85 °C
Explanation:
The maximum surface temperatures each result from the maximum permissible ambient or operating temperature T a
plus the maximum temperature increase
1) The ambient or operating temperature T
- 30 °C to + 50 °C
T of 35 K which has to be taken into account. a
is limited to + 80 °C due to the permissible permanent operating temperature of the BoWexELASTIC sion, too.
® elastomer parts used.
2) The maximum surface temperature of + 115 °C applies for the use in locations which are potentially subject to dust explo-
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
78 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
9 Enclosure A
Advice and instructions regarding the use in
KTR-N
Sheet:
Edition:
40114 EN
19 of 22
7
potentially explosive atmospheres
9.2 Inspection intervals for couplings in
Explosion group
3G
3D
II 2GD c IIB
T4, T5, T6
potentially explosive atmospheres
Inspection intervals
For couplings which are classified in category 3G or 3D the operating and assembly instructions that are usual for standard operation apply. During the standard operation which has to be subject to the ignition risk analysis the couplings are free from any ignition source. Merely the temperature increase produced by self-heating and depending on the coupling type has to be considered: for BoWex-ELASTIC ® : T = 35 K
An inspection of the torsional backlash and a visual inspection of the elastomer set must be performed after 3000 operating hours for the first time, at the latest after 6 months after start-up of the coupling.
If you note insignificant or no wear on the elastomer part upon this initial inspection, further inspections can each be performed after 6000 operating hours or at the latest after 18 months, provided that the operating parameters remain the same.
If you note significant wear with the initial inspection so that it would be recommendable to replace the elastomer part, please find out the cause according to the table „Breakdowns“, if possible.
The maintenance intervals must be adapted to the modified operating parameters without fail.
BoWex-ELASTIC ®
Illustration 15: BoWex-ELASTIC ® type HEW1
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Here the backlash between the hub and the nylon spline must be inspected via torsional backlash, each separately from the driving and the driven side.
The friction/wear may only be X max.
of the original spline thickness before the elastomer part must be replaced.
When reaching the torsional backlash
S max.
, the elastomer part must be replaced immediately, irrespective of the inspection intervals.
Visual inspection of the elastomer part
(cracks, holes or anything similar).
Replacing:
Replaced by:
KTR-N dated 2013-06-10
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 79
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
KTR-N
Sheet:
Edition:
40114 EN
20 of 22
7
9 Enclosure A
!
Advice and instructions regarding the use in
9.3 Inspection of torsional backlash
potentially explosive atmospheres
To inspect the torsional backlash the power pack which is switched off needs to be secured against accidental switch-on.
Turn the hub opposite the direction of drive.
Here the elastomer part must not be axially displaced from its position of wear.
!
Mark elastomer part and hub (see Illustration 16).
Turn the hub in the direction of drive and measure the torsional backlash S max.
When reaching the torsional backlash S max
the elastomer part must be replaced.
!
Illustration 16: Marking of the elastomer part and hub
9.4 Standard values of wear
If the torsional backlash is S max.
[mm] / friction X max.
[mm], the elastomer part must be replaced.
Reaching the limits for replacing depends on the operating conditions and the existing operating parameters.
In order to ensure a long service life of the coupling and avoid danger with the use in potentially explosive atmospheres, the shaft ends must be accurately aligned.
Please absolutely observe the displacement figures specified (see tables 13 and 14).
If the figures are exceeded, the coupling will be damaged.
Please observe protection note ISO 16016.
Drawn:
Verified:
80 | © Danfoss | DCS (im) | 2021.12
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
9 Enclosure A
Advice and instructions regarding the use in
9.4 Standard values of wear
KTR-N
Sheet:
Edition:
40114 EN
21 of 22
7
potentially explosive atmospheres
Illustration 17: Elastomer part in new condition
Table 15:
Size
42
48
65
80
G 80
Limits of wear each hub
Wear
X max.
[mm]
1.0
1.0
1.4
1.6
1.6
Torsional backlash S max.
[mm]
1.7
1.8
2.5
2.7
2.7
Size
100
125
G 125
150
Illustration 18: Wear of elastomer part
Limits of wear each hub
Wear
X max.
[mm]
1.8
2.0
2.0
2.0
Torsional backlash S max.
[mm]
3.1
3.5
3.5
3.5
9.5
!
marking of coupling for potentially explosive atmospheres
The ATEX marking of the BoWex-ELASTIC ® the following details:
Short labelling: coupling is done on the polyamide flange of the elastomer specifying
II 2GD c IIB T X
(standard)
Complete labelling: II 2G c IIB T6, T5 resp. T4
- 30 °C T a
+ 50 °C, + 65 °C resp. + 80 °C
II 2D c T 115 °C - 30 °C T a
+ 80 °C
The labelling with explosion group llB includes the explosion group llA.
The customer bears the sole responsibility for all machining processes performed subsequently on unbored or pilot bored as well as finish machined coupling components and spare parts. KTR does not assume any warranty claims resulting from insufficient remachining.
Please observe protection note ISO 16016.
Drawn:
Verified:
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 81
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
BoWex-ELASTIC ®
Operating/Assembly instructions
Type HEW, HEW Compact and HEW-ZS
9 Enclosure A
Advice and instructions regarding the use in
9.6 EU Certificate of conformity
KTR-N
Sheet:
Edition:
40114 EN
22 of 22
7
potentially explosive atmospheres
EU Certificate of conformity
according to EU directive 2014/34/EU dated February 26, 2014 and to the legal regulations
The manufacturer - KTR Systems GmbH, D-48432 Rheine - states that the
BoWex-ELASTIC ® highly flexible flange couplings in an explosion-proof design described in these operating/assembly instructions are devices corresponding to article 1 (3) b) of directive 2014/34/EU and comply with the general safety and health requirements according to enclosure II of directive 2014/34/EU.
The BoWex-ELASTIC ® complies with the specifications of directive 2014/34/EU. One or several directives specified in the respective type examination certificate IBExU01ATEXB004_05 X were in part replaced by updated versions.
KTR Systems GmbH being the manufacturer confirms that the product mentioned above is in accordance with the specifications of the new directives, too.
According to article 13 (1) b) ii) of directive 2014/34/EU the technical documentation is deposited with the institution:
IBExU
Institut für Sicherheitstechnik GmbH
Fuchsmühlenweg 7
09599 Freiberg
Rheine, 2017-04-24
Date i. V.
Reinhard Wibbeling
Engineering/R&D i. A.
Andreas Huecker
Product Manager
Please observe protection note ISO 16016.
Drawn:
Verified:
82 | © Danfoss | DCS (im) | 2021.12
2017-04-24 Shg/Hk
2017-04-24 Shg
Replacing:
Replaced by:
KTR-N dated 2013-06-10
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 83
Operation guide | Installation, Operation and Maintenance APP 53-92 pumps
84 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Instruction
Instruction
Recommended service intervals
for APP 0.6-1.0 / APP 1.5-3.5 /
APP (W) 5.1-10.2 / APP 11-13 / APP 16-22
Instruction | Recommended service intervals for APP 53 - 92 pumps
Table of Contents 1.
2.
3.
General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Design/features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Appendix 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
1. General information This guideline provides information on the recommended service intervals. The recommendation is based upon good engineering practice and on experience gained from operation even under extreme conditions.
The recommendation is for guidance only.
2.
Pos.
152
3
67
*
*
93
*
81
142
124
125
92
91, 95
61
65
64
82
1
11, 14
121
31
66
Design/features
Qty.
8
1
1
9
1
1
6
1
2
2
2
2
2
2
1
2
2
1
18
Description
Danfoss APP pumps are designed for long operation and low maintenance and life cycle costs.
Provided that the pump has been running according to the Danfoss specifications, Danfoss guarantees one year service-free operation, however, max. 18 months from date of production. After one year of operation it is recommended to inspect the pump and replace worn parts, if any.
Housing, main bearing
End flange/ motor flange
Center flange
Swash plate
Piston
Valve plate
Port plate
Cylinder barrel
Retainer plate
Retainer ball
Retainer guide assembly
Spring
Stop for shaft seal
Shaft seal
Cover/flange for shaft seal
Back-up ring
O-ring (overall)
Screw (overall)
Pin (overall)
Valve cone (flushing valve)
Bleeding screw
Key
If the Danfoss recommendations concerning system-design (see our data sheet) are not followed, the service life of the APP pumps might be affected.
The recommended service intervals on the different parts in the APP pumps appear from the table below:
Material
Duplex, PEEK
Duplex
Duplex
Super Duplex
Service interval
APP 53 - 78
No need for service
No wear part
No wear part
48,000 hours
Super Duplex, PEEK and PP Recommended inspection on a yearly basis and evaluated acc. to app. 1 Replace after
24,000 hours.
Super Duplex
Super Duplex, PEEK
Super Duplex
Super Duplex
Super Duplex
Super Duplex, Duplex and
PP
32,000 hours
32,000 hours
48,000 hours
48,000 hours
48,000 hours
48,000 hours
Duplex
Duplex
Hastelloy and NBR
Super Duplex
PTFE
NBR
AISI 316
AISI 316, Duplex or PEEK
Duplex or PEEK
Duplex
AISI 316
48,000 hours
No wear part
24,000 hours
No wear part
24,000 hours
24,000 hours
24,000 hours
No wear part
48,000 hours
No wear part
40,000 hours
Service interval
APP 86 - 92
No need for service
No wear part
No wear part
40,000 hours
Recommended inspection on a yearly basis and evaluated acc. to app. 1
Replace after 8,000 hours
24,000 hours
24,000 hours
40,000 hours
40,000 hours
40,000 hours
40,000 hours
40,000 hours
No wear part
24,000 hours
No wear part
24,000 hours
24,000 hours
24,000 hours
No wear part
48,000 hours
No wear part
40,000 hours
86 180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021
Instruction | Recommended service intervals for APP 53 - 92 pumps
3. Appendix 1 Pistons:
The pistons are the heart of the pump regarding service.
If the pistons break down, the pump will suffer a breakdown.
In case of doubt - the pistons must be replaced.
The pictures below is ment as a guideline for evaluating the wear of the sliding surface.
Cavitation of the piston shoes.
New inspection is required in 3,000-4,000 hours.
Cavitation of the piston shoes.
All pistons must be replaced within the next
500-1,000 hours.
Cavitation of the piston shoes.
All pistons must be replaced within the next
100-200 hours.
Cavitation of the piston shoes.
All pistons must be replaced immediately.
Abrasive wear of the piston shoes.
All pistons must be replaced immediately.
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021
87
Danfoss A/S
High Pressure Pumps
Nordborgvej 81
DK-6430 Nordborg
Denmark
© Danfoss | DCS (im | 2021.09
AX281930801330en-000401 | 88
Parts list
APP Pumps
APP 53 / APP 65 / APP 78 / APP 86 / APP 92 hpp.danfoss.com
Parts list | APP 53-92 Pumps
Table of Contents
4.
5.
6.
2.
3.
Table of Contents
1. Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Parts list APP 53-92 - serial no. 07 or higher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Exploded view APP 53-92 serial no. 07 or higher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Parts list APP 53-86 - serial no. up to 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Exploded view APP 53-86 - serial no. up to 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Tool sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
90 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Parts list | APP 53-92 Pumps
1. Validity This Parts list contains two part list tables, for serial numbers:
• 07 and higher and
• up to 06
You find the serial number in the label of the pump.
PUMP
Type APP 78
Code no. 180BXXXX
Serial no. XXXXXX07-XXX
MADE IN DENMARK
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 A/S, 6430 Nordborg, Denmark
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 91
Parts list | APP 53-92 Pumps
2. Parts list
APP 53-92 - serial no. 07 or higher
Pos.
Qty.
Description Material
0001 2
0002 4
0003 6
0004 6
0005 51
0034 4
0064 2
0065 2
0061 2
0066 18
0066 18
0067 1
0068 1
0069 1
0070 2
0072 1
0073 1
0081 9
0082 2
0082 2
0082 2
0091 1
0006 2
0009 4
0010 4
0011 1
0014 1
0144 4
0145 4
0147 4
0031 1
0031 1
0031 1
0032 1
0032 1
0032 1
0033 2
0091 1
0092 2
0092 2
0095 1
0095 1
0093 18
0094 18
Complete Housing
Pin ø6 x 10
Bleeding plug G1/4”
O-ring (ø11 x 2 mm)
Cyl.screw M8 x 30 A4-80
1.4462/PEEK
A4
1.4410
NBR
A4-80
Screw M8 x 16 A4-80
O-ring (ø228x 4 mm)
O-ring (ø9.2 x 2.6 mm)
End flange
Motor flange APP 53 - 92
Threaded pin M16 x 80
Hex lock nut M16
Washer ø17xø30x3
Swash plate APP 53 (non-drive end)
A4
1.4410
Swash plate APP 65 (non-drive end) 1.4410
Swash plate APP 78-92 (non-drive end) 1.4410
Swash plate APP 53 (drive end)
Swash plate APP 65 (drive end)
Swash plate APP 78-92 (drive end)
Distance washer 1)
1.4410
1.4410
1.4410
PP
A4-80
NBR
NBR
1.4462
1.4462
A4
A4
Pin (ø10.5 x 20)
Retainer ball DLC
Ass. Retainer plate
Cyl.barrel with insert
Piston
Piston w. insert
Key (14 x 9 x 70
1.4410
1.4410/DLC
1.4410/PEEK
1.4410/PEEK
1.4410/PEEK
1.4410/PEEK
A4
Shaft APP H
Distance pipe APP 53-92
Pin (ø10.5 x 20)
Cone bushing DLC
1.4410
1.4462
1.4410
1.4410/DLC
Screw M16x75 DLC 1.4410/DLC
Compression spring (ø1.9 x ø11 x 45.3) 1.4462
Assembly spring guide APP 53-65
Assembly spring guide APP 78
1.4410/PP
1.4410/PP
Assembly spring guide APP 86-92
Port plate
1.4410/PP
1.4410/PEEK
Port plate 17
Int. Valve plate
Int. Valve plate 17
Port plate (shaft side)
Port plate (shaft side) 17
Back-up ring
O-ring (ø30.2 x 3 mm)
1.4410/PEEK
1.4410
1.4410
1.4410/PEEK
1.4410/PEEK
PTFE/Carbon
NBR x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
92 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Parts list | APP 53-92 Pumps
Parts list (continued)
APP 53-92 - serial no. 07 or higher
7
Pos.
Qty.
Description
0121 1
0122 1
0124 1
0125 1
0126 4
0140 1
0142 1
0151 1
0152 1
0153 1
0154 1
0155 1
1
0127 4
0128 50
0131 1
0132 2
0133 4
0134 1
0135 4
Center flange APP H
O-ring (ø80.0 x 2 mm)
Shaft seal
Cover for shaft seal
Pin (ø10.5 x 20)
Screw M6 x 12 A4-80
Screw M8 x 20 A4-80
3” Cover for Inlet port
O-ring (ø79 x 3.5)
Screw M8 x 16 A4-80
3” Cover for Outlet port
Screw M10 x 16 A4-80
Lifting eye M12 (DIN 580E)
Washer for shaft seal
O-ring (ø35 x 3)
Valve cone
Compression spring
Plug/guide
O-ring (ø47.2 x 3.5)
Instruction
1) Not mounted in APP 53
2) Only compatible with pump series 08 or higher
Material
1.4462
NBR
NBR
1.4462
1.4410
AISI 316
1.4462
NBR
1.4410
1.4462
1.4410
NBR
A4-80
A4-80
PP
NBR
A4-80
PP
A4-80 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 93
Parts list | APP 53-92 Pumps
3. Exploded view
APP 53-92 serial no. 07 or higher
94 | © Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701
Parts list | APP 53-92 Pumps
4. Parts list
APP 53-86 - serial no. up to 06
Pos.
Qty.
Description Material
0001 2
0002 4
0003 6
0004 6
Complete Housing
Pin ø6 x 10
Bleeding plug G1/4”
O-ring (ø11 x 2 mm)
0005 32 Cyl.screw M8 x 30 A4-80
0006 2 Screw M8 x 16 A4-80
0009 4
0010 4
0011 1
0014 1
0144 4
0145 4
0147 4
0031 1
O-ring (ø228x 4 mm)
O-ring (ø9.2 x 2.6 mm)
End flange
Motor flange APP H
Threaded pin M16 x 70
Hex lock nut M16
Washer ø17xø30x3
Swash plate APP 53 (non-drive end)
0031 1
0031 1
0032 1
0032 1
0032 1
0033 2
0034 4
Swash plate APP 65 (non-drive end) 1.4410
Swash plate APP 78-86 (non-drive end) 1.4410
Swash plate APP 53 (drive end)
Swash plate APP 65 (drive end)
1.4410
1.4410
Swash plate APP 78-86 (drive end)
Distance washer 1)
Pin (ø10.5 x 20)
1.4410
PP
1.4410
0064 2
0065 2
0065 2
0061 2
Retainer ball DLC
Ass. Retainer plate
Ass. Retainer plate 17
Cyl.barrel with insert
0066 18 Piston
0066 18 Piston w. insert
0067 1
0068 1
Key (14 x 9 x 70
Shaft APP H
1.4410/DLC
1.4410/PEEK
1.4410/PEEK
1.4410/PEEK
1.4410/PEEK
1.4410/PEEK
A4
1.4410
NBR
NBR
1.4462
1.4462
A4
A4
A4
1.4410
1.4462/PEEK
A4
1.4410
NBR
A4-80
A4-80
0069 1
0070 2
0072 1
0073 1
0081 9
0082 2
0082 2
0082 2
0091 1
0091 1
Distance pipe APP H
Pin (ø10.5 x 20)
Cone bushing DLC
Screw M16x75 DLC
Compression spring (ø1.9 x ø11 x 45.3) 1.4462
Assembly spring guide APP 53-65
Assembly spring guide APP 78
Assembly spring guide APP 86
Port plate
Port plate 17
0092 2
0092 2
Int. Valve plate
Int. Valve plate 17
0093 18 Back-up ring
0094 18 O-ring (ø30.2 x 3 mm)
0095 1
0095 1
Port plate (shaft side)
Port plate (shaft side) 17
1.4462
1.4410
1.4410/DLC
1.4410/DLC
1.4410/PP
1.4410/PP
1.4410/PP
1.4410/PEEK
1.4410/PEEK
1.4410/PP
1.4410/PP
PTFE/Carbon
NBR
1.4410/PEEK
1.4410/PEEK x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
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Parts list | APP 53-92 Pumps
Parts list (continued)
APP 53-86 - serial no.
up to 06
Pos.
Qty.
Description
0121 1 Center flange APP H
0122 1 O-ring (ø80.0 x 2 mm)
0124 1 Shaft seal
0125 1 Cover for shaft seal
0126 4 Pin (ø10.5 x 20)
0127 4 Screw M6 x 12 A4-80
0128 30 Screw M8 x 20 BUMAX
0131 1 3” Cover for Inlet port
0132 2 O-ring (ø79 x 3.5)
0133 4 Screw M8 x 16 A4-80
0134 1 3” Cover for Outlet port
0135 4 Screw M10 x 16 A4-80
0140 1 Lifting eye M12 (DIN 580E)
0142 1 Washer for shaft seal
0151 1 O-ring (ø35 x 3)
0152 1 Valve cone
0153 1 Compression spring
0154 1 Plug/guide
0155 1 O-ring (ø47.2 x 3.5)
1 Instruction
1) Not mounted in APP 53
Material
A4-80
PP
A4-80
AISI 316
1.4462
NBR
1.4410
1.4462
1.4410
NBR
1.4462
NBR
NBR
1.4462
1.4410
A4-80
A4-100
PP
NBR x x x x x x x x x x x x x x x x x x x x x x x x x x x x x
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Parts list | APP 53-92 Pumps
5. Exploded view
APP 53-86 - serial no. up to 06
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Parts list | APP 53-92 Pumps
6. Tool sets Note:
The parts listed are not sold separately, only in various kits.
Designation
Press bush
Cone bushing extractor
M6 Allen key
M8 Allen key
M8 x 140 (30 mm thread) Unbraco
M8 x 70 (full thread) Unbraco)
Valve plate fixation device
Tool bracket
Tool, washer
M16 pin
Nut M16 A4
ø17/30 x 3 washer
Screw M8 x 40 A4-80
Valve plate mount
24 mm, 1/2” socket
Flush valve tool
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
2
1
1
1
1
1
1
1
1
1
1
4
2
1
2
2
3
1
2
1
3
1
1
1
1
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Service guide
Trouble shooting guide
APP, APP S and APP S 674 pumps hpp.danfoss.com
Service guide | Trouble shooting guide for APP, APP S and APP S 674 pumps
Table of contents
4.
5.
2.
3.
6.
6.1
6.2
6.3
1.
Table of Contents
Table of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Trouble shooting fish bone chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
No flow/no pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Reduced flow/reduced pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
High torque on electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Noise from pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Noise from installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Typical signs of wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Valve plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Port plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Swash plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
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Trouble shooting fish bone chart
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Service guide | Trouble shooting guide for APP, APP S and APP S 674 pumps
1. No flow/no pressure
Cause
1.1 Dry running
(no water supply to the pump)
1.2 Pump reversing
(electric motor is running the wrong direction, i.e. counter-clockwise)
Remedy
If no water comes out of the pump:
1.1.1 Check that inlet valve is open.
1.1.2 Check that booster pump is running.
1.2.1 Change the phase on the electric motor to make it run clockwise.
WARNING:
- The pump must not run without water for more than a few seconds.
- If the pump takes in water from the high- pressure outlet line, it builds up pressure in pump housing and will eventually break down.
Comments
Mount a low pressure switch in front of the pump and check its set point/ function. The low pressure switch ensures that the pump does not start until the inlet pressure has reachedminimum inlet pressure (see User manual).
Rotation direction for the APP, APP S or APP S 674 pump is shown by an arrow on the label on the pump.
1.3 No rotation of electric motor
1.4 No rotation of pump
1.5 Axial load on pump shaft
(may cause high internal leakage)
Only applying to
APP 0.6 to APP 3.5 and
APP 21 to APP 26 only.
Also applying to APP S and APP S 674 pumps.
1.3.1 Check that main switch is switched on.
1.3.2 Check the electricity at the facility.
1.3.3 Ensure that motor relay is switched on.
1.3.4 Ensure that fuse is not blown.
1.3.5 Ensure that booster pump is started.
1.3.6 Check that the monitor switches are working correctly.
1.3.7 Disconnect pump from electric motor and check that the motor is capable of running with no load.
1.4.1 Ensure that coupling between electric motor and pump is connected.
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.
1.5.1 Ensure that the air gap between the two coupling parts is min 5 mm. It should always be possible to move the plastic part on the coupling at least 3 mm.
If motor-type relay or the electrical fuse is blown, check that electric motor is sized correctly.
To ensure easy mounting of the flexible coupling without using tools, the tolerances must be dimensioned accordingly.
WARNING:
Any axial and/or radial loads on the shaft must be avoided. Any axial or radial load will cause breakdown.
A - Bell housing
B - Flexible coupling
C - Motor shaft
1.6 Pump damage
(the internal parts may be damaged)
1.6.1 Contact Danfoss sales office for guidelines in how to troubleshoot internal pump parts.
A B
Instructions on internal elements
are available on hpp.danfoss.com.
C
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2. Reduced flow/reduced pressure
Cause
2.1 Wear on pump
Large internal leakage due to:
-
2.2 Low inlet pressure
2.3 Rotation speed (rpm)
Remedy
2.1.1 Dismantle the pump.
2.1.2 Check valve plate.
Valve plate has marks/scratches on the surface facing the port plate. Minor wear on valve plate can cause large internal leakage. See Index 6.1.
2.1.3 Check port plate.
Port plate has marks/scratches on the surface facing the valve plate. Minor wear on port plate can cause large internal leakage. See Index 6.2.
2.1.4 Check cylinder barrel.
Liners in cylinder barrel may be scratched or worn. Insert a piston in the liner and check the fit. If there is any space
(clearance) between liner and piston, liner or piston is worn.
2.1.5 Pre-treatment
Analyse fluid for content of particles.
- Check that filters are OK and working correctly.
2.1.6 Main filtration
Check that the correct filter type is used
(particles in fluid must not exceed 10 μm).
Danfoss High Pressure Pumps supplies filters, please contact the sales office.
Comments
Typical signs of wear:
Polished surface all over the swash plate.
Normally, only half of the swash plate = the pressure side is polished. See index 6.3.
If the ring is missing, the piston is very worn.
The filters can be bypassed, even if they are correctly mounted. Some filters can create channelling where particles can pass through the filter in tunnels. String wounded filters are typically channelling filters. A string wounded filter may have a filtration efficiency of only
50%, which will cause internal wear and must always be followed by a main filter .
2.1.7 Fluid type
The APP, APP S and APP S 674 pumps are designed for seawater operation; for any other fluid, please contact Danfoss High
Pressure Pumps sales office for further help.
Insufficient filtration means that too many or too large hard particles can pass the main filter because it is damaged, bypassed or simply too poor. Filtration efficiency must be 99.98%
(Beta = 5000) at 10 μm to prevent abnormal wear of the pump.
2.1.8 High fluid temperature
If fluid temperature is above 50 °C (122 ° F), stop the pump immediately.
Temperature > 50 °C (122 ° F) will cause wear on internal pump parts. Mount a temperature switch and check its set point / function. The temperature switch will ensure that the pump stops at fluid temperatures > 50 °C (122 ° F).
- Check internal parts (see above).
2.2.1 Check that booster pump supplies the right pressure/flow.
2.2.2 Check if filters require replacement.
2.3.1 If VFD-operated, check frequency.
2.3.2 Check that rotation speed of the electric motor is as stated on name plate on electric motor. Check that the motor rotor winding is not damaged.
If the pressure drop across the filters is too high, the booster pump does not deliver sufficient flow/pressure. No pressure or low pressure results in cavitation and insufficient internal lubrication causing wear on internal pump parts.
Mount a low-pressure switch in front of the pump and check its set point/ function. The low- pressure switch ensures that the pump does not start until the inlet pressure has reached 1 bar.
Speeds below min. limit (see User manual) result in insufficient internal lubrication causing wear on the internal pump parts.
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3. High torque on electric motor
Cause
3.1 Too high outlet pressure from pump
3.2 Pump starts against pressure
3.3 Constant torque
3.4 Water pump damage
Remedy
3.1.1 Check fluid salinity.
3.1.2 Check temperature.
3.1.3 Check pressure drop across RO membrane.
3.2.1 Check that electric motor is correctly sized.
3.2.2 Check internal parts (see item 2.1).
3.2.3 Systems with more than one electric motor installed:
Start motors simultaneously.
3.3.1 Please contact Danfoss High Pressure
Pumps sales office.
3.4.1 Dismantle pump and check for wear.
Comments
Pump conditions may change (more salt, lower water temperature or scaling of RO membrane) causing higher pressure, resulting in higher motor torque.
Pumps run in parallel with cascade start, may switch off the motor relay due to too high torque caused by high outlet pressure.
If the electric motor is too small for the APP, APP S or APP S 674 pump, it cannot provide sufficient torque.
Too heavy damage in the pump will increase friction causing a high torque (see item 6,
Typical signs of wear).
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4. Noise from pump
Cause
4.1 Air in fluid
4.2 Bleeding conditions of pump
4.3 Min/max nominal inlet pressure
4.4 Pump reversing
4.5 High rotation speed (rpm)
4.6 Outlet pressure
4.7 Soft start/stop
Remedy
4.1.1 Ensure that the entire inlet line is bled before starting up the system.
4.1.2 Ensure that air cannot enter into the inlet line.
4.2.1 Follow the instructions “Initial start-up” supplied with the new pump.
4.2.2 Ensure that the pump is completely bled before start-up.
Comments
Small air bubbles will accumulate and create large bubbles causing internal cavitation and thus making the pump very noisy.
WARNING:
The pump can only run few minutes with air in the fluid without being damaged.
The pump and the inlet line must be completely bled before start-up, otherwise the pump will cavitate and make high noise.
WARNING:
The pump can only run few minutes with air in the fluid without being damaged.
Too high inlet pressure causes too high pressure inside the pump damaging the pistons and eventually the pump.
4.3.1 Ensure that inlet pressure is within the limits specified in the User manual.
4.3.2 Check the pump for internal damage.
Inlet pressure below min. limit causes cavitation and insufficient internal lubrication resulting in wear on internal pump parts.
4.4.1 Dismantle pump and check if anything is broken or worn (See “1. No flow”, item 1.2
Pump reversing”).
WARNING:
The pump must not run without water for more than a few seconds. If the pump takes in water from the high-pressure outlet line, it builds up pressure and will eventually be damaged.
4.5.1 If electric motor rpm is too high, dismantle pump and check for damage.
4.5.2 If the rpm is within the specified range of the pump data sheet and abnormal noise remains, dismantle pump and check for damage.
Mount a low-pressure switch in front of the pump and check its set point/ function. The low-pressure switch will ensure that the pump does not start until the min. inlet pressure has been reached.
If pump rotates in wrong direction, it will take in water from the high-pressure outlet line.
Pressure will be built up inside the pump and it will eventually be damaged.
Higher rpm than specified in the pump data sheet results in wear of the pistons, i.e. pistons may be damaged.
High rpm will also increase pressure pulsations from the pump, and the noise level will increase.
4.6.1 If outlet pressure is too low, check set point of outlet pressure valve.
4.6.2 If outlet pressure is lower than mentioned in the pump data sheet, please contact
Danfoss High Pressure Pumps technical support.
4.6.3 If outlet pressure has exceeded its maximum, check set point of outlet pressure valve.
4.6.4 Check internal parts for wear/damage.
4.7.1 Check if noise is normal when the pump is running at operation speed.
4.7.2 If noise is abnormal at operation speed, check internal parts (see above).
If rpm is changed, noise frequency will also change.
At too low outlet pressure, the pump will create higher pressure pulsations and thus make noise. Too low pressure also causes insufficient internal lubrication and wear on internal parts.
Pump may eventually be damaged.
Too high outlet pressure may damage the pump.
Noise frequency changes during soft start-up/ stop.
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Service guide | Trouble shooting guide for APP, APP S and APP S 674 pumps
5. Noise from installation
Cause
5.1 Inlet/outlet connections (hoses/pipes)
5.2 Length/dimension of inlet/outlet line
5.3 Hose stiffness
5.4 Hoses/pipes mounted directly on frame
5.5 Vibration dampener under the electric motor
Remedy
5.1.1 Use flexible hoses at inlet/outlet connections. Danfoss can provide flexible hoses.
Please contact Danfoss High Pressure
Pumps sales office for further information.
5.1.2 Mount the connections to the frame by a vibration dampener mounting plate.
5.2.1 Increase pipe diameter and/or reduce the number of bends.
Comments
Non-flexible connections mounted directly on the frame will cause even small pressure pulsations from pump and create vibrations in the system/plant.
5.3.1 Use a more flexible hose. Danfoss can provide flexible hoses. Please contact
Danfoss High Pressure Pumps sales office for further information.
5.4.1 Mount the connections to the frame by a vibration dampener mounting plate.
5.5.1 Mount a vibration dampener below the motor/pump.
Too small pipes or too many bends may create too fast flow/turbulence through the pipes and thus increase the noise level.
Too stiff hoses cannot dampen the small pressure pulsations from the pump, and subsequently vibrations occur in the system/ plant.
If the hoses are mounted directly on the frame, the small pressure pulsations from the pump can be transferred to the frame and the rest of the system/plant.
When no dampener is installed below the electric motor, vibrations from the motor and pump may be transferred to the frame and the rest of the system/plant.
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Picture 2
Scratches
Picture 3
Service guide | Trouble shooting guide for APP, APP S and APP S 674 pumps
6. 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.
A worn valve plate has scratches, and/or a polished surface. Even small scratches will give a loss of flow.
A good way to identify a worn valve plate is to hold a straight knife edge over the valve plate. When holding it up to the light, it will be possible to see any space between the knife edge and the valve plate. See picture 3.
If any light can be seen between the two arrows on the picture, the valve plate is worn.
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.
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6.2 Port plate
Picture 1
Scratc hes
If the port plate has scratches, level differences or both between the arrows, the port plate must be replaced.
Even small scratches or wear will cause loss of flow.
To check: See item 6.1, picture 3.
Level d ifferenc g PEE
K tween
6.3 Swash plate
Picture 1 If the swash plate is polished 360°, it is an indication of insufficient filtration.
The surface of the swash plate must be plane and even at same level all over. 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 information.
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MAKING MODERN LIVING POSSIBLE
Service guide
Right and wrong
Trouble shooting guide for water hydraulic systems
water hydraulic systems
Pump location 4.
Design
1.
Choice of material
.
.
.
Rubber
Plastic
Stainless steel
.
Iron
.
Copper
.
Brass
.
Aluminium
Always use system components made of corrosion proof materials
Non-corrosion proof materials may cause damage
2.
< 10 m m abs.
Choice of filter
> 10 m m
Pump always to be placed below water surface level
Pump location above water surface level will cause damage
5.
Suction conditions
6.
System to be dimensioned to provide a suction pressure of the pump inlet of max. 0.1 bar vacuum
Poor suction conditions will cause malfunction and damage the pump
Pressure Relief valve
3.
Install a 10 micron absolute filter with pressure switch
Return filter with bypass valve and poorer filterability than 10 damage the system m
will
Filter location 7.
Pressure relief valve to be mounted vertically or with vertical outlet and connected to return hose or tank
Coupling the pressure relief valve outlet directly to the pump inlet may damage the pump
Water supply
Locate the return filter in the return line immediately before the tank
Placing the return filter upstream of the final load may damage the pump
System to be filled via filter
Filling system with unfiltered water causes damage
Installation
8.
Impurities 11.
Assembly of coupling
Prior to installation, burrs and chips and other impurities must be removed from pipes and hoses, eg with a felt plug
Chips or other impurities in the system may cause damage
9.
Sealing
The coupling must be easy and simple to assemble (see product instruction)
Never use force when assembling the coupling parts, as this will damage the motor/pump
12.
Coupling
= min. 3 mm 0 mm
Fittings in screwed components to be sealed with O-rings or bonded seals
Using teflon tape or packing yarn in joints may cause damage
10.
Grease
Ensure always to have 3 mm distance between coupling flanges
Insufficient distance and/or misalignment between the coupling flanges will damage the pump
13.
Water supply
Correctly limited quantities of grease prevent seizing
Too much grease may develop biofilm causing operational failures
Fill system with water before starting to ensure lubrication and cooling
Starting without water will cause damage
Wiring
14.
Level indicator
Level and temperature indicators must be fitted. Follow installation instructions
Missing or incorrectly connected level and temperature indicators cause damage
15.
1 ?
2
Rotation direction
Check pump drive motor rotation direction matches that of the pump prior to installation
Incorrect rotation direction will damage the pump
16.
Bleeding
Starting procedure
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. Add the cleaning agent to give 3% agent/water solution
4. Run the system for 60 min. and activate all components as
often as possible to ensure effective flushing with the
cleaning agent
5. Empty the system of the cleaning agent solution
Flushing procedure
6. Fill cold water through the return filter and bleed the
pump (Power Packs PPH 4 - 6.3 - 10 and 12.5 are
self-bleeding)
7. Run the system for 30 min. and activate all components as
often as possible
8. Empty the system of the water
9. Alternatively the system may be flushed by running the
unit without the return hose while continuously filling up
water. The flushing should continue until there is no trace
of cleaning agent in the return water
10. Change the return filter element, fill cold water through
the return filter and bleed the pump during start up
11. The system is now ready for operation
Starting procedure
Bleeding the pump will ensure correct cooling and lubrication
Insufficient bleeding may cause damage (not applicable to Power Packs)
60 min.
2-3 days
Observing the starting procedure will ensure problem-free operation
If the system is not cleaned before starting, the filter will clog
Trouble shooting
Open ended water systems
No water supply
No
.
Is water coming
out of the tap?
.
Are all taps open?
Yes
Yes
.
Is the control light
for “low pump suction
pressure” on?
.
The filter is clogging
No
.
Is water coming
through the filter?
Yes
No
.
Replace filter element
No
.
Is the water supply ok?
.
Is water supplied to the pump?
Yes
.
Is the electric motor of
the pump unit rotating?
No
Yes
.
Is the water in the tank
very hot? Ie above 50 o
Yes
No
.
Lower inlet
temperature or
provide better cooling
.
Is the power supply ok?
.
Are control lights on?
Yes
No
.
Is the filter clogged?
.
Is the filter control
light on?
Yes
.
Replace filter element
Contact serviceman
No
.
A blown fuse / or short
circuit?
. Check power supply
and fuses and contact
electrician
.
Turn on the tap for
water supply
Stamp
Trouble shooting
Closed water systems
The system does not work
.
Fill water into the system
.
Is the electric motor of
the pump unit rotating?
No
Yes
.
Is the water in the tank
very hot? Ie above 50 o
Yes
No
.
A blown fuse/or short
circuit?
.
Check power supply
and fuses and contact
electrician
No
.
Is the power supply ok?
.
Are control lights on?
Yes
.
Is the filter clogged?
.
Is the filter control
light on?
No
Yes
.
At temperatures
higher than 50 o the
pump drive cuts out.
Consequently the
cooler must be
checked/cleaned
.
Replace filter element
Contact serviceman
.
Trace leakage, if any
No
.
Is there sufficient water
in the tank?
Yes
Stamp
© Danfoss | DCS (im) | 2021.12
180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 120

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