Danfoss APP 53, APP 65, APP 78, APP 86, APP 92 Operating guide

Download

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 ................................................................................5

1.3 Manufacturer and customer service address .............................................6

1.4 Country speciﬁc information ............................................................6

1.4.1 United Kingdom ........................................................................6

2. Safety ..................................................................................6

2.1 General information.....................................................................6

2.2 Preferred system design.................................................................6

2.3 Commissioning and servicing the unit ...................................................7

2.4 Adhere to the following important points ...............................................7

2.5 In case of doubt .........................................................................7

3. Technical data ..........................................................................7

3.1 Approved applications and operational limits for the pumps .............................7

3.2 Application range .......................................................................7

3.3 Electric motor data......................................................................7

3.4 VFD and Direct on line ..................................................................7

3.5 Noise and vibration .....................................................................7

3.6 Dimension drawings ....................................................................7

3.7 Space requirement......................................................................8

3.8 Filtration................................................................................8

3.9 Properties of water ......................................................................8

3.10 Air bubbles .............................................................................8

3.11 Chemicals...............................................................................8

4. Arrival inspection, transportation, handling, lifting and storage ..........................8

4.1 Arrival inspection .......................................................................8

4.2 Warning ................................................................................8

4.3 General safety information ..............................................................8

4.4 Transport and handling .................................................................8

4.5 Return to supplier .......................................................................9

4.6 Storage .................................................................................9

5. Installation and commissioning.........................................................10

5.1 Important dimensions .................................................................10

5.2 Cleanliness.............................................................................10

5.3 Fluid temperature......................................................................10

5.4 Electrical data..........................................................................10

5.5 Local regulations.......................................................................10

5.6 Pre mounting checklist, based on Danfoss preferred system design .....................11

5.7 Lifting and positioning.................................................................11

5.8 Mount the diﬀerent equipment ........................................................11

5.9 Electrics ...............................................................................11

5.10 Instrumentation .......................................................................11

5.11 Connections ...........................................................................12

5.12 Ensure free ﬂow .......................................................................12

5.13 Verify setting of safety/relief valves .....................................................12

5.14 Flush the pump ........................................................................12

5.15 Bleed and remove air from the pump...................................................12

5.16 Verify direction of rotation .............................................................12

5.17 Commissioning ........................................................................12

5.18 Check the ﬁlter condition...............................................................12

5.19 Instruct operator and maintenance personnel ..........................................12

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

6. Operation of pump unit ...............................................................13

6.1 General safety information.............................................................13

6.2 What to listen and look for .............................................................13

7. Maintenance and service of the pump unit .............................................13

7.1 General safety information .............................................................13

7.2 Service and inspection interval for the pump ...........................................13

7.3 Shut down of the system ...............................................................13

7.4 Disassembling and assembling the pump unit ..........................................14

7.5 Assembling the pump unit .............................................................14

7.6 Procedure for mounting the pump onto the electric motor..............................14

7.7 Getting the pump unit back into operation .............................................14

7.8 Storage of the pump ...................................................................14

8. Troubleshooting and scrapping criteria .................................................15

8.1 General safety information .............................................................15

8.2 Operational conditions which can cause pump failures..................................15

8.3 Mechanical failure......................................................................15

8.4 Electrical failure........................................................................15

8.5 Responsibility..........................................................................15

8.6 Scrapping criteria ......................................................................15

Appendices .......................................................................................17

1. Data sheet for APP pumps 53-92 AI167386503010en-001301) ...................

2. Instruction for APP pumps 53-92 (180R9368) ............................................43

3. Electric motors (180R9230) ..............................................................55

4. Bowex coupling manual .................................................................61

5. Recommended service intervals (AX281930801330en-000401) ..........................85

6. Parts list (AX191786502906en-001101) ...................................................89

7. Trouble shooting (521B1447) ...........................................................101

8. Right and wrong (180R9042) ..........................................................113

........19

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:

Typ e Serial no.

APP 53 XXXXXX08-XXX

APP 65 XXXXXX08-XXX

APP 78 XXXXXX08-XXX

APP 86 XXXXXX08-XXX

APP 92 XXXXXX08-XXX

PUMP

Type APP 78 Code no. 180BXXXX

Serial no. XXXXXX08-XXX

MADE IN DENMARK

Danfoss A/S, 6430 Nordborg, 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.

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.

• If any changes are made without written approval the warranty will automatically become void.

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.

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.

All personnel being responsible for operation and maintenance of the pump unit must read and fully understand these instructions, especially the section “Safety”, before:

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

Indicates a situation which will or could result in personal injury and/or damage to the pump

Electrical hazard - Indicates a highvoltage warning

Safety glasses required

• 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.

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.

Hearing protection required

Safety shoes required

Safety helmet required

Protective garments must be wor n

Protective garments must be worn

Danger HOT. Do not touch

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 5

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

2. Safety

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: highpressurepumpss@danfoss.com Homepage: hpp.danfoss.com

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

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

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.

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 wor n

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.

Danger

Installation and maintenance must always take place during complete shutdown in an unpressurised condition. The drive unit must be secured against 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.

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.

inadvertent

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.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

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.

3. Technical data

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.

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.

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.

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.

3.4 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 53APP 65APP 78APP 86APP

MAWT 878 1,118 1,257 1,112 1,112

MAST 1,700 1,70 0 1,70 0 1,70 0 1,70 0

MAWT: Maximum allowable working torque MAST: Maximum allowable starting torque

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.

For system integration of the pump, please see appendix 1, Data sheet and appendix 2, Instruction.

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 7

3.6 Dimension drawings

Dimensions of the diﬀerent pumps can be found in appendix 1, Data sheet.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

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.

3.8 Filtration

(10µm absolute [ß Requirements are speciﬁed in appendix 1, Data

≥ 5000])

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.

3.9 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.

3.10 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 lowpressure 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. Arrival inspection, transportation, handling, lifting and storage

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.

4.2 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.

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!

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Pumps which have a weight above 20 kilos must be handled by using lifting eyes and slings.

Wrong lifting:

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.

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 9

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

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!

5.3 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

Media filter

Feed

PI PI

5.5 Local regulations

Commissioning must always be done in accordance with valid regulations and local standards.

Permeate

Fresh water

permeat flush

Brine

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

5.6 Pre mounting checklist, based on Danfoss preferred system design

Table 1: Check points when assembling and commissioning system

Check points Comment OK ?

Ensure that the environmental conditions are safe. See Arrival inspection,

CP1

Minimum and maximum start-up temperature for ﬂuid and

CP2

pump.

Filtration condition (10 µm absolute (ß

CP3

Power supply for electric motor and VFD. See Data sheet for the used

CP4

Safety circuit / breaker must be sized for the motor and

CP5

environment (corrosion and humidity)

Bolts and screws must conform to environmental conditions

CP6

as well as ﬂuid and torque requirements.

Instrumentation, pressure switch should be designed to

CP7

conform to the environment (corrosion and humidity).

Check the factory settings of the safety/relief valves or

CP8

pressure relief valves (page 11).

Check the settings of the pressure transmitter/switch (3) set

CP9

at min. inlet pressure (page 11).

Check that all pressure indicators (PI) are selected to be able

CP10

to measure the system pressure range (page 11).

Check that the coupling is installed according to manufac-

CP 11

turers instruction

Ensure all pipings have been ﬂushed and are correct installed

CP12

Check piping for possible air gaps.

CP13

transportation, handling, lifting and storage, chapter 4.

See Data sheet or Instruction, appendices 1 and 2.

≥ 5000) See Danfoss requirements in

Data sheet and Instruction, appendices 1 and 2

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.

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.

5.8 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.

5.9 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.

5.10 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.

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 11

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

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.

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.

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.

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.

5.14 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.

5.16 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.

5.18 Check the ﬁlter condition

Evaluate contamination found in ﬁlter, replace ﬁlter elements, if necessary.

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.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

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.

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.

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.

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 13

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.

7.3 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.

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.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

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.

I) Carefully pull the pump out of the bell

housing by using lifting equipment, if necessar y.

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.

7.4 Disassembling and assembling the pump unit

A) Remove all connections from the pump.

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).

7.6 Procedure for mounting the pump onto the electric motor

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.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

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.

8.3 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.

8.4 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.

8.6 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.

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 15

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

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

Appendices .......................................................................................17

1. Data sheet for APP pumps 53-92 AI167386503010en-0013

2. Instruction for APP pumps 53-92 (180R9368) ............................................43

3. Electric motors (180R9230) ..............................................................55

4. Bowex coupling manual .................................................................61

5. Recommended service intervals (AX281930801330en-000401) ..........................85

6. Parts list (AX191786502906en-001101) ...................................................89

7. Trouble shooting (521B1447) ...........................................................101

8. Right and wrong (180R9042) ..........................................................113

01) ...........................19

Data sheet

APP Pumps

APP pumps

APP 53 / APP 65 / APP 78 / APP 86 / APP 92

APP 53-86

hpp.danfoss.com

ro-solutions.com

Data sheet | APP 53-92 Pumps

Table of Contents

1. Introduction ...........................................................................21

2. Beneﬁts................................................................................21

3. Application examples ..................................................................21

4 Technical data .........................................................................22

4.1 APP 53-92..............................................................................22

5. Performance curves....................................................................24

5.1 APP 53 ﬂow at diﬀerent rpm............................................................24

5.2 APP 65 ﬂow at diﬀerent rpm............................................................25

5.3 APP 78 ﬂow at diﬀerent rpm............................................................26

5.3 APP 86 ﬂow at diﬀerent rpm............................................................27

5.4 APP 92 ﬂow at diﬀerent rpm............................................................28

6. Flushing valve curves ..................................................................29

6.1 APP 53-92 integrated ﬂushing valve ....................................................29

7. Motor requirements....................................................................29

7.1 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

10. Dimensions and connections...........................................................33

10.1 APP 53.................................................................................33

10.2 APP 65 - 92.............................................................................34

10.3 APP 53-92 with IE3 motor, IEC 315S - 4 ..................................................36

10.4 APP 53-92 with IE3 motor, IEC 315M - 4..................................................36

10.5 APP 53-92 with IE3 motor, IEC 315L 1-4 .................................................37

10.6 APP 53-92 with IE3 motor, IEC 315L 2 - 4 ................................................37

11. Pump connections .....................................................................38

11.1 APP 53 - 92.............................................................................38

12. VCM 3” Victaulic........................................................................39

12.1 Technical data .........................................................................39

12.2 Flow versus pressure ...................................................................40

13. Accessories ............................................................................41

14. Service and warranty...................................................................41

20 | © Danfoss | DCS (im) | 2021.12

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).

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)

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.

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 Danfoss APP pumps are built into a broad range

• 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).

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

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 21

Data sheet | APP 53-92 Pumps

4.1 APP 53-924 Technical data

Pump size APP 53/1500 APP 65/1500 APP78 /1500 A PP 8 6/1700 APP 92 /178 0

Code number 180B7806 180B7807 180B7808 180B7809 180B7810

Geometric displacement

Pressure

Max. outlet pressure (MAWP)

Min. inlet operating pressure

Max. inlet operating pressure

Max. inlet pressure peak

Min. outlet pressure

Speed

Min. speed continuous

Max. speed continuous

Flow

Min. ﬂow

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

1200 rpm

1500 rpm

170 0 rp m

178 0 rp m

cm³/rev. 617 778 888 888 888 in³/rev. 37. 7 47. 3 54.2 54.2 54.2

barg 83 83 83 70 70

psig 1,200 1,200 1,200 1,015 1,015

barg 2 2 2 2.5 3.5

psig 29 29 29 36 50

barg 5 5 5 5 5

psig 73 73 73 73 73

barg 10 10 10 10 10

psig 145 145 145 145 145

barg 30 30 30 30 30

psig 435 435 435 435 435

rpm 700 700 700 700 700

rpm 1,500 1,500 1, 500 1,700 1,780

m³/h 24 32 36 36 36

gpm 106 141 158 158 15 8

m³/h 24 32 36 36 36

gpm 106 141 158 158 15 8

m³/h 35 45 52 52 52

gpm 15 4 198 228 228 228

m³/h 42 54 62 62 62

gpm 187 238 275 275 275

m³/h 53 68 78 78 78

gpm 235 299 345 345 345

m³/h 88 88

gpm 387 387

m³/h 92

gpm 405

% 88 88 89 89 89

% 89 89 90 89 89

% 88 89 89 88 88

% 88 88

% 87

22 | © Danfoss | DCS (im) | 2021.12

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Data sheet | APP 53-92 Pumps

Pump size APP 53/150 0 APP 65/15 00 APP 78/1500 APP 86/1700 APP 92 /1780

Code number 180B7806 180B7807 180B7808 180B7809 18 0B7810

Technical speciﬁcations

Media temperature

Ambient temperature

Weight (dry)

Weight (operation)

°C 2–50 2-50 2–50 2-50 2-50

°F 36–122 36-122 3 6–122 36-122 36-12 2

°C 0–50 0-50 0–50 0-50 0-50

°F 32–122 32-12 2 32–122 32-12 2 32-122

kg 196 196 196 19 6 196

lb 432 432 432 432 432

kg 204 204 204 204 204

lb 450 450 450 450 450

Sound pressure level

Footprint with IE3 motor

db(A) 84-95 84-95 84-93 84-96 84-96

m² 1.49 1.49 1. 50 1.50 1.50

Foot² 16.0 17. 0 16.1 16.1 16.1

Typical motor size

Max.speed at max. pres-

sure

Max. allowable working pressure at continuous operation. The pump is designed according to EN809, i.e. to

withstand hydrostatic test pressure (HTP) of 1.3 x MAWP. For lower and higher pressure, please contact Danfoss.

Dependent on the NaCI concentration.

Typical eﬃciency at max. pressure after a system has been commissioned and run in.

Maximum area covered with recommended IE3 motor conﬁgurations (excl. of space to service pump)

IE3 and NEMA motors, 4-pole, current insulated ND non drive end bearing

Operating with water

kW 132 16 0 160 200 200

HP 200 250 250 300 300

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 23

Data sheet | APP 53-92 Pumps

100,00

120,00

140,00

160,00

180,00

200,00

220,00

240,00

260,00

280,00

300,00

320,00

340,00

360,00

380,00

400,00

Flow [gpm]

Speed [RPM]

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.

5.1 APP 53 ﬂow at diﬀerent rpm

90,00

85,00

80,00

75,00

70,00

65,00

60,00

55,00

50,00

Flow [m3/h]

45,00

40,00

35,00

30,00

25,00

20,00

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 ﬂow x Rated rpm

Required rpm =

Rated ﬂow

24 | © Danfoss | DCS (im) | 2021.12

Speed [RPM]

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Data sheet | APP 53-92 Pumps

20,00

25,00

30,00

35,00

40,00

45,00

50,00

55,00

60,00

65,00

70,00

75,00

80,00

85,00

90,00

Flow [m3/h]

Speed [RPM]

100,00

120,00

140,00

160,00

180,00

200,00

220,00

240,00

260,00

280,00

300,00

320,00

340,00

360,00

380,00

400,00

Flow [gpm]

Speed [RPM]

5.2 APP 65 ﬂow at diﬀerent rpm

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 25

Data sheet | APP 53-92 Pumps

20,00

25,00

30,00

35,00

40,00

45,00

50,00

55,00

60,00

65,00

70,00

75,00

80,00

85,00

90,00

Flow [m3/h]

Speed [RPM]

5.3 APP 78 ﬂow at diﬀerent rpm

26 | © Danfoss | DCS (im) | 2021.12

400,00

380,00

360,00

340,00

320,00

300,00

280,00

260,00

240,00

Flow [gpm]

220,00

200,00

180,00

160,00

140,00

120,00

100,00

Speed [RPM]

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Data sheet | APP 53-92 Pumps

100,00

120,00

140,00

160,00

180,00

200,00

220,00

240,00

260,00

280,00

300,00

320,00

340,00

360,00

380,00

400,00

Flow [gpm]

Speed [RPM]

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

Flow [m3/h]

45,00

40,00

35,00

30,00

25,00

20,00

Speed [RPM]

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 27

Data sheet | APP 53-92 Pumps

20,00

25,00

30,00

35,00

40,00

45,00

50,00

55,00

60,00

65,00

70,00

75,00

80,00

85,00

90,00

95,00

100,00

Fl ow [m3/h]

Speed [RP M]

100,00

120,00

140,00

160,00

180,00

200,00

220,00

240,00

260,00

280,00

300,00

320,00

340,00

360,00

380,00

400,00

420,00

Fl ow [gpm]

Speed [RPM]

5.4 APP 92 ﬂow at diﬀerent rpm

28 | © Danfoss | DCS (im) | 2021.12

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

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

100

200

300

400

500

Flow [l/min]

600

The power requirements can be determined using one of the following guiding equations:7. Motor requirements

l/min x barg 16.7 x m

/h x barg 0.35x gpm x psig Required power = [kW] or [kW] or Calc. factor Calc. factor Calc. factor

1 hp = 0.75 kW 1 gpm = 3.79 l/min

1 m

/h = 4.40 gpm 1 kW = 1.34 hp 1 l/min = 0.26 gpm 1 gpm = 0.23 m

7.1 Calculation factor at 60 barg / 870 psig for APP 53-92

Name rpm

APP 53 1500 528

APP 65 150 0 534

APP 78 150 0 534

APP 86 170 0 528

APP 92 178 0 522

Calculation

factor

[Hp]

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 29

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.

Duplex

316L

100

160 1600

1000

10 000

16000

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

Super Duplex

100 000

160000

CI ppm

NaCI ppm

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.

30 | © Danfoss | DCS (im) | 2021.12

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.

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

≥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.

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.

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

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) .

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.

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.

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.

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 31

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

Media filter

PI PI

Fresh water

permeat flush

Brine

Permeate

32 | © Danfoss | DCS (im) | 2021.12

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Data sheet | APP 53-92 Pumps

connections

10.1 APP 5310. Dimensions and

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 33

Data sheet | APP 53-92 Pumps

10.2 APP 65 - 92

34 | © Danfoss | DCS (im) | 2021.12

APP 65 - 92

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

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.

Non-standard conﬁguration, turned 90 degrees left.

Non-standard conﬁguration, turned 45 degrees left.Standard conﬁguration

Non-standard conﬁguration, turned 180 degrees .

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 35

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

36 | © Danfoss | DCS (im) | 2021.12

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

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

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 37

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

) The installation instuction for Style 77DX is located in the Victaulic document I-100 Field Installation

Diameter

(A)

87. 8 m m

(3.46 inch)

87. 8 m m

(3.46 inch)

Victaulic

3” Vic. OSG

(B)

Length

(C)

61.0 mm (2.40”)

65.0 mm (2.56”)

Material Max. Pressure Code number

Super

Duplex

Super

Duplex

10 barg

(145 psi g)

80 barg

(1160 ps ig)

180Z1991

180Z1992

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.

When using multiple pumps in parallel, the non-return valve

12.1 Techni cal data

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.

Diameter

valve

)

mm (inch)

87. 7

(3.45)

Typ e Connection

VCM 92

The check valve is mounted directly in the outlet port with a ﬂange with 8 screws M12 x 25.

Wetted parts materials: Super Duplex, PEEK, PP, Hasteloy; FKM, NBR

The installation instuction for Style 77DX is located in the Victaulic document I-100 Field Installation

3” outlet check

Victaulic (outlet connection)

3” Vic. OSG

Length mm (inch)

180.5 (7.10)

Material2

Super

Duplex

Max.

pressure barg (psig)

83 (1.200) 180H0058

Code number

Handbook (htpp://static.victaulic.com)

VCM VCM 92

Min. ﬂow continously

Max. ﬂow continously

Max pressure MAWP

Opening pressure barg 0.05- 0.08

Pressure loss at max. ﬂow barg < 0.45

m³/h 20

gpm 88

m³/h 92

gpm 405

barg 83

psig 1200

psig 0.73-1.16

psig < 6.5

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 39

Data sheet | APP 53-92 Pumps

0,05

0,1

0,15

0,2

0,25

0,3

0,35

0,4

0,45

0,5

20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

dP [ bar ]

Flow [ m3/h ]

Flow versus pre ssure f or VCM 92

80 100 120 140 160 180 200 220 240 260 280 300 320 340 360 380 400 420 440

dP [ PSI ]

Flow [ GPM]

Flow versus pre ssure f or VCM 92

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

40 | © Danfoss | DCS (im) | 2021.12

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Data sheet | APP 53-92 Pumps

13. Accessories

14. Service and warranty

Accessories Typ e Code num-

Coupling APP 53 - APP 92 IEC 315 Diameter: motor Ø80 mm, pump Ø50 180Z4066 Coupling APP 53 - APP 92 IEC 280 Diameter: motor Ø75 mm, pump Ø50 180Z4081 Coupling kit APP 53 - APP 92 incl. bell housing IEC 315 Ø80/Ø50. IEC 315 Ø660/310 180Z4083 Coupling kit APP 53 - APP 92 incl. bell housing IEC 280 Ø75/Ø50. IEC280 Ø550/265 18 0Z4082 Base frame incl. vibration dampeners IEC 315 180Z06 61

Warranty

Danfoss APP pumps are designed for long operation, low maintenance and reduced lifecycle costs.

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 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.

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. 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:

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).

- Insuﬃcient ﬁltration

- Insuﬃcient bleeding and venting

- Running the pump at speed outside speciﬁcations.

Repair

In case of irregular function of the APP pump,

please contact Danfoss High Pressure Pumps.

- 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.

ber

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 41

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

1. Identiﬁcation ......................................................................... 44

2. System design .........................................................................45

2.1 Open-ended systems with direct water supply..........................................45

2.2

Preferred RO system design without ERD .................................................45

2.3 Preferred RO system design with ERD...................................................46

2.4 Preferred RO system design with pumps and ERDs in parallel ...........................46

2.5 Reversible pumps ......................................................................46

3. Building up the pump unit with BoWex coupling........................................46

3.1 Assembly of the coupling ..............................................................46

3.2 Alignment between the motor and pump shaft.........................................46

3.3 Overall assembly with coupling BoWex-ELASTIC®, type HEW compact ...................47

3.3.1 Mounting ..............................................................................48

3.4 Direction of rotation ...................................................................49

3.5 Orientation ............................................................................49

3.6 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

1. Identiﬁcation

7. Service and warranty...................................................................53

PUMP

Type APP 78 Code no. 180BXXXX

Serial no. XXXXXX08-XXX

MADE IN DENMARK

Danfoss A/S, 6430 Nordborg, Denmark

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).

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.

To protect the pump from being damaged by peaks of high-pressure in case the pump stops momentarily, it is required to mount a lowpressure relief valve on the inlet line.

Note: The inlet connection must be properly tightened, as possible entrance of air will cause cavitation.

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 startup, 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

Media filter

PI PI

Fresh water

permeat flush

Brine

Permeate

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.

The setup of “open-end system” ensures that the inlet pressure does not exceed 10 barg (145 psig), when a nonreturn valve is mounted in the inlet.

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. β10 ≥ 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.

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 may cause damage to the coupling.

). Disregarding this advice

coupling

max. 0. 5 mm

max. 0.02 i nch

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 ta ble

Component

Thread size M5 M6 M8 M10

Torque [Nm] 2 4.8 10 17

Quantity Description

1 1 Elastomer part

2 1 Hub

4 1 Coupling ﬂange

7 2

Cap screws DIN EN ISO 4762

Setscrews DIN EN ISO 4029

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).

Please observe the manufacturer’s instructions regarding the use of adhesives. Do not apply glue on the rubber surfaces.

2. 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

Instruction | APP Pump Instruction APP 53-92

3-5 mm [0.12-0.20 inch]

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

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.

45 degrees. Please see Data sheet 521B1340.

We recommend to install ﬂexible soft hoses both

3.6 Protection from too high pressures

in the inlet and outlet lines.

The pump should be protected against too high pressure by means of a safety valve or a pressure relief valve.

The valve outlet must not be connected directly to the pump suction line. It must be connected directly to the drain.

Outlet

Outlet Inlet

4. Building up the pump unit with jaw coupling

Inlet

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.

IMPORTANT

When using jaw coupling it is critiacal that the recommended measurements are kept.

max. 0. 25 mm

max. 0.01 inch

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).

Instruction | APP Pump Instruction APP 53-92

Bolts and nuts torque

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.

1: Bolts 100 Nm ± 10 2: Nuts 100 Nm ± 10 3: Torque se table below

75 Nm ± 5 Nm

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.

4.2 Connections

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.

Thread size

Torque [Nm]

M5 M6 M8 M10

2 4.8 10 17

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.

Internal ﬂushing valve

Instruction | APP Pump Instruction APP 53-92

6. Operation

6.1 Temperat ure

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.

NaCl vs. temperature

Duplex

316L

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.

Super Duplex

100

1000

160 1600

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).

For APP 92 min. inlet pressure shall be 3.5 barg (50 psig) and max. outlet pressure shall be 70 barg (1015 psig).

10 000

16000

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.

100 000

160000

CI ppm

NaCI ppm

Note: The pump unit should include a pressure gauge on the high-pressure side.

Instruction | APP Pump Instruction APP 53-92

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

AN220686503013en-000901 | 180R9368 | 521B1392 | 54

Electric Motors

Motor Manual

hoyermotors.com

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.

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.

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.

Before commissioning, measure the insulation impedance. If values are ≤ 10MΩ 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.

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.

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.

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.

Tightening torques for terminal board screws:

Thread M5 M6 M8 M10 M12 M16 M20 M24

T.(Nm) 2.5 3.5 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,

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021

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

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.

Typical duty hours for lifetime lubricated bearings.

Frame size Poles Typical lifetime

56 - 160 2 - 8 40,000h

180 2 35,000h

200 2 27,000h

225 2 23,000h

180 - 225 4 - 8 40,000h

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.

Frame

size

160 20 4200 7000 8500 8500

180 20 4200 7000 8500 8500

200 25 3100 6500 8500 8500

225 25 3100 6500 8500 8500

250 35 2000 6000 7000 7000

280 35 2000 6000 7000 7000

315 50 1500 5500 6500 6500

355 60 1000 4000 5000 6000

400 80 800 3000 4000 6000

Grease

(g)

2 pole

(h)

4 pole

(h)

6 pole

(h)

8 pole

(h)

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.

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.

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

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).

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.

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.

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.

Maintenance, repairs and replacement on this type must only be carried out by qualiﬁed specialists.

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021 |

Connection diagram Anschlußdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexión Collegamento Schemat polacsen

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021 |

Hoyer Motors, Motor Manual, April 2019

Head Ofﬁces

Over Hadstenvej 42 · DK-8370 Hadsten

T +45 86 98 21 11 · F +45 86 98 17 79

hoyermotors@hoyermotors.com

19 Jingwu Middle Road · Beilun District

T +86 574 26 28 15 77 · F + 86 574 2628 1573

hoyermotors@hoyermotors.cn

Important notice.

Denmark

CVR no. 17 63 06 95

hoyermotors.com

China

Ningbo 315821 · Zhejiang

hoyermotors.cn

Text and data in this catalogue are not binding and we reserve the right to implement changes without further notice.

Branch Ofﬁces

Landsberger Straße 155 · 80687 München

Germany

T +49 89 700 88 235 · F +49 89 543 56 333

germany@hoyermotors.com

hoyermotors.com

Sweden

Liljeholmsstranden 5 · PO box 44017

SE-100 73 Stockholm

T +46 8 446 877 13

sweden@hoyermotors.com

hoyermotors.com

Vasteland 78 · 3011 BN, Rotterdam

Tel. +31 10 420 35 20 · Fax.+31 10 420 44 51

benelux@hoyermotors.com

302ho · Code square · 3150-1 · Daejeo 2-dong

Gangseo-gu · Busan · Korea

T +82 51 996 0251 · F +82 51 996 0252

korea@hoyermotors.com

Benelux

hoyermotors.com

Korea

hoyermotors.com

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 1 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Type HEW1

Type HEW2

Type HEW Compact

Type HEW-ZS

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

of 22

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

BoWex-ELASTIC®

highly flexible flange coupling types

HEW Compact and HEW-ZS and their combinations

for finish bored, pilot bored and unbored couplings

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 61

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 2 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Table of contents

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

of 22

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.

1 Technical data 3

2 Advice 6

2.1 Coupling selection 6

2.2 General advice 6

2.3 Safety and advice symbols 7

2.4 General hazard warnings 7

2.5 Intended use 7

2.6 Reference to EC Machinery Directive 2006/42/EC 8

3 Storage, transport and packaging 8

3.1 Storage 8

3.2 Transport and packaging 8

4 Assembly 8

4.1 Components of the couplings 8

4.2 Advice for finish bore 10

4.3 Assembly of the coupling 11

4.4 Displacements - alignment of the couplings 12

5 Start-up 15

6 Breakdowns, causes and elimination 16

7 Disposal 18

8 Spares inventory, customer service addresses 18

9 Enclosure A Advice and instructions regarding the use in potentially explosive

atmospheres 18

9.1 Intended use in hazardous locations 18

9.2 Inspection intervals for couplings in potentially explosive atmospheres 19

9.3 Inspection of torsional backlash 20

9.4 Standard values of wear 20

9.5 marking of coupling for potentially explosive atmospheres 21

9.6 EU Certificate of conformity 22

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 3 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Illustration 1: BoWex-ELASTIC® type HEW1

Illustration 2: BoWex-ELASTIC® type HEW2

Max. finish bore

[mm]

d3 D D2

z x M

162 6 M6

146

180

180 8 M6

164

200

224 8 M8

205

245

125

124

295.27 8 M10

266

318

130

G 80

124

333.4 8 M10

302

358

145

100

110

152

438.15 8 M12

350

478

158

110

125

192

438.15

M12

416

478

175

140

G 125

125

192

489 8 M12

440

530

175

140

150

160

225

542.9 6 M16

470

585

225

150

100

G 150

160

225

542.9 6 M16

504

585

225

150

108

200

180

200

250

641.35

M16

568

683

280

175

149

G 200

180

200

250

M16

600

683

280

175

149

Weight with

[kg]

Mass moment of

inertia [kgm2]

l5 E E1

HEW

42 4 32

132

104

4.3

0.0121

0.0015

45 4 32

137

109

5.5

0.0204

0.0019

63 5 42

187

150

13.2

0.0752

0.0071

70 5 45

215

160

19.7

0.1449

0.0285

G 80

78 5 55

235

185

25.9

0.2748

0.0422

100

111.5

113

278

207

48.5

0.8356

0.1050

125

170

158 - 45

327 - 67.2

0.9498

0.2617

G 125

170

158 - 45

327 - 76.6

1.4492

0.3034

150

145 - 70

380 - 110

2.7206

0.5303

G 150

150

145 - 70

380 113.4

2.7809

0.5861

200

220

214 - 85

480 195

6.6418

1.1406

G 200

220

214 - 85

480 200

6.6099

1.3419

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

1 Technical data

Table 1: Dimensions – type HEW1 and HEW2

Size

Dimensions [mm]

Sheet:

of 22

Table 1: Continuation of Dimensions – type HEW1 and HEW2

Size

Dimensions [mm]

max. bore

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 63

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 4 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Elastomer

[Shore A]

Torque [Nm]

Elastomer

[Shore A]

Torque [Nm]

40 / T40

130

390

40 / T40

3000

9000

50 / T50

150

450

50 / T50

4000

12000

65 / T65

180

540

65 / T65

5000

15000

40 / T40

200

600

40 / T40

4000

12000

50 / T50

230

690

50 / T50

5200

16000

65 / T65

280

840

65 / T65

6500

20000

40 / T40

350

1050

T40

5500

16500

50 / T50

400

1200

T50

7000

21000

65 / T65

500

1500

T65

9000

27000

40 / T40

750

2250

T40

7000

21000

50 / T50

950

2850

T50

9200

27600

65 / T65

1200

3600

T65

11500

34500

40 / T40

1250

3750

T40

9500

28500

50 / T50

1600

4800

T50

12500

37500

65 / T65

2000

6000

T65

16000

48000

40 / T40

2000

6000

T40

11500

34500

50 / T50

2500

7500

T50

15000

45000

65 / T65

3200

9600

T65

19500

58500

Illustration 3: BoWex-ELASTIC® type HEW1

Illustration 4: BoWex-ELASTIC® type HEW2

Mass moment of

[kgm2]

l4 E L

L1 z M

42-130

131

118

98 6 M6

3.4

0.003

0.001

65-180

130

110

180

145

122 8 M10

9.0

0.014

0.006

80-225

145

124

120

225

210

158

M12

18.9

0.035

0.029

100-305

100

200

152

175

305

110

258

187

M12

40.2

0.152

0.087

125-365

125

235

192

205

365

120

140

150

328

240

M16

75.0

0.36

0.26

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

1 Technical data

Table 2: Torques – type HEW1 and HEW2

Size

G 80

100

BoWex

hardness

HEW Compact

TKN T

Sheet:

TKN T

K max.

Size

125

G 125

150

G 150

200

G 200

hardness

of 22

K max.

Table 3: Dimensions – type HEW Compact

Size

Max. finish

bore [mm]

Dimensions [mm]

Weight with

pilot bored

coupling [kg]

inertia with pilot

bored coupling

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 5 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Perm. damping

power PKW [W]

Radial

[N/mm]

T50

150

450

780

0.6

10.5

178

T65

180

540

2400

0.8

7.9

600

T70

210

630

2900

1.2

5.2

710

T50

400

1200

120

2850

0.6

10.5

379

T65

500

1500

150

7800

0.8

7.9

955

T70

575

1725

173

9500

1.2

5.2

1240

T50

900

2700

270

5000

0.6

10.5

420

T65

1100

3300

330

13000

0.8

7.9

1090

T70

1300

3900

390

16500

1.2

5.2

1450

T50

2000

6000

600

17000

0.6

10.5

760

T65

2600

7800

780

44000

0.8

7.9

1850

T70

3000

9000

900

50000

1.2

5.2

2250

T40

3000

9000

900

15000

0.6

10.5

476

T50

4000

12000

1200

25000

0.8

7.9

750

T65

5000

15000

1500

62000

1.2

5.2

1930

Illustration 5: BoWex-ELASTIC® type HEW-ZS (size 48 to G 80)

Illustration 6: BoWex-ELASTIC® type HEW-ZS (size 100 to G 125)

Max. finish

bore [mm]

z x M

180 8 M6

164

200

224 8 M8

205

245

125

110

295.27

M10

266

318

130

145

100

G 80

333.4 8 M10

302

358

145

100

110

438.15

M12

350

478

158

180

135

125

120

438.15

M12

416

478

175

225

180

G 125

125

120

489 8 M12

440

530

175

225

180

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

1 Technical data

Table 4: Technical data - HEW Compact

Size

100

125

BoWex

Elastomer

hardness [Shore A]

HEW-ZS

TKN

[Nm]

Torque

Kmax

[Nm]

speed n

Operating

max.

[rpm]

7300 24 12 6

5500 48 24 12

4400 96 48 24

3200 156 78 39

2900 192 96 48

60 °C 80 °C 90 °C

with

dyn.

60 °C

[Nm/rad]

Sheet:

Relative

damping



of 22

Resonance

 /



factor V

spring

stiffness

Table 5: Dimensions – type HEW-ZS1)

Size

Dimensions [mm]

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 65

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 6 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Spacer HEW-ZS

LZ [mm]

Weight

[kg]

Mass moment of

inertia [kgm2]



6.9

0.0203

0.0050



16.0

0.0747

0.0160



25.5

0.1447

0.0699

G 80



34.2

0.2752

0.1412

100

111.5

110



54.0

0.8459

0.0992

125

170

171



84.2

1.1814

0.3017

G 125

170

157



93.5

1.6853

0.3690

BoWex-ELASTIC® couplings with attachments that may generate heat, sparks and static

A separate analysis must be performed.

For a long-lasting and failure-free operation of the coupling it must be selected according to

is subject to his responsibility.

The BoWex-ELASTIC® coupling is suitable and approved for the use in potentially explosive atmos-

advice and instructions regarding safety in enclosure A.

2.1 Coupling selection

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

1 Technical data

Table 5: Continuation of Dimensions – type HEW-ZS

Dimensions [mm]

Size

Torques of BoWex-ELASTIC® type HEW-ZS see table 2.

2 Advice

l4 l5 l6 100 120 140 180 250 JA JL

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.

Sheet:

with

max.

bore

of 22

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

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!

pheres. When using the coupling in potentially explosive atmospheres, please observe the special

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.

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 7 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

This symbol indicates notes which may contribute to pre-

result in death caused by explosion.

STOP

This symbol indicates notes which may contribute to pre-

result in death.



This symbol indicates notes which may contribute to pre-

ous bodily injuries.

STOP

With assembly, operation and maintenance of the coupling it has to be made sure that the

indications.

2.3 Safety and advice symbols

2.5 Intended use

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

2 Advice

Warning of potentially explosive atmospheres

Warning of personal injury

Warning of product damages

General advice

Warning of hot surfaces

2.4 General hazard warnings

Sheet:

venting bodily injuries or serious bodily injuries that may

This symbol indicates notes which may contribute to pre-

venting material or machine damage.

This symbol indicates notes which may contribute to pre-

venting adverse results or conditions.

venting burns with hot surfaces resulting in light to seri-

of 22

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

 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.

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 status at the time of printing of these operating/assembly instructions.

type HEW, HEW Compact and HEW-ZS described in here corresponds to the technical

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 67

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 8 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

The storage rooms must not include any ozone-generating devices like e. g. fluorescent

than 65 %.

In order to avoid any injuries and any kind of damage please always make use of proper

Compo-

nent

Elastomer part

Hub

Coupling flange

see table 1 1)

Cap screws DIN EN ISO 4762 1)

Setscrews DIN EN ISO 4029

Illustration 7: BoWex-ELASTIC® type HEW1

Illustration 8: BoWex-ELASTIC® type HEW2

3 Storage, transport and packaging

3.1 Storage

4 Assembly

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

of 22

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.

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.

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

3.2 Transport and packaging

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.

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®, type HEW1 and HEW2

Quantity Description

With size 150 nuts as per DIN EN ISO 4014 are required additionally.

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 9 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Component

Quantity

Description

Elastomer part

Hub

Coupling flange

see table 3

Cap screws DIN EN ISO 4762

Setscrews DIN EN ISO 4029

Illustration 9: BoWex-ELASTIC® type HEW Compact

Component

Quantity

Description

Elastomer part

Hub spec.

Intermediate flange hub

Coupling flange

4.1

Additional flange

4.2

Flange hub

4.3

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

Setscrews DIN EN ISO 4029

Illustration 10: BoWex-ELASTIC® type HEW-ZS (size 48 to G 80)

Illustration 11: BoWex-ELASTIC® type HEW-ZS (size 100 to G 125)

Size

G 80

100

125

G 125

Quantity z (component 4.3)

- - - - 15

Quantity z (component 6)

4.1 Components of the couplings

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

4 Assembly

Components of BoWex-ELASTIC®, type HEW compact

Sheet:

of 22

Components of BoWex-ELASTIC®, type HEW-ZS

Table 6: Cap screws DIN EN ISO 4762

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 69

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 10 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

STOP

The maximum permissible bore diameters d (see table 1 to 5

runout

The customer bears the sole responsibility for all machining processes performed subse-

Size

G 80

100

125

G 125

150

G150

200

G 200

Thread size

M10

M12

M16

M20

Tightening torque

TA [Nm]

Bore [mm]

above

up to

(KTR standard)

50 m6

4.2 Advice for finish bore

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

4 Assembly

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

 Please make absolutely sure to observe the figures for Ø d  Carefully align the hub or coupling flange when the finish

 Provide for a setscrew according to DIN EN ISO 4029 with a

quently 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.

Operating/Assembly instructions

have to observe concentricity or axial runout (see illustration

12).

max

bores are drilled.

cup point or an end plate to fasten the hub or coupling flange axially.

Sheet:

Illustration 12: Concentricity and axial

of 22

Table 7: Setscrews DIN EN ISO 4029

10 10 17 17 17 40 80 80 80 80 140 140

Table 8: Recommended fit pairs acc. to DIN 748/1

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.

Shaft tolerance Bore tolerance

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 11 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:



We recommend to inspect bores, shaft, keyway and feather key for dimensional accuracy 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.

With the assembly please make sure that the distance dimension E (see table 1 and 4) is ob-

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

Disregarding this advice may cause damage to the coupling.

Size

100

125

G 125

Tightening torque TA [Nm]

355

Size

G 80

100

125

G 125

Tightening torque

TA [Nm]

4.3 Assembly of the coupling

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

of 22

4 Assembly

before assembly.

Please wear safety gloves.

served to allow for axial clearance of the sleeve while being in operation.

spline of the elastomer. (Please observe mounting dimensions L, L

 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 TA specified in table 9.

Table 9: Cap screws DIN EN ISO 4762

HEW1

, L

HEW2

or L

HEW - ZS

 Mount the hub, flange hub with additional flange or the coupling flange onto the shaft of the driving and driven

side.

, L

 Shift the power packs in axial direction until the mounting dimension L, L

achieved.

 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

Table 10: Cap screws DIN EN ISO 4762

41 69 120 120 190 295 295

specified in table 10.

HEW1

HEW2

or. L

HEW-ZS

has been

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 71

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 12 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Size

G 80

100

125

G 125

150

G 150

200

G 200

Tightening torque

TA [Nm]

Size

100

125

Tightening torque

TA [Nm]

If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all

with Loctite (average strength).

Please observe the manufacturer’s instructions regarding the use of adhesives.

In order to ensure a long service life of the coupling and avoid danger with the use in poten-

the displacement figures (see tables 13 and 14) are permissible.

4.3 Assembly of the coupling

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

of 22

4 Assembly

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

Table 11: Cap screws DIN EN ISO 4762

 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

11.

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

Table 12: Cap screws DIN EN ISO 4762

specified in table 11.

14 14 35 69 69 120 120 120 295 295 410 410

specified in table

specified in table 12.

14 69 120 120 250

screw connections must be secured against working loose additionally, e. g. conglutinating

Do not apply glue on the rubber surfaces.

4.4 Displacements - alignment of the couplings

The BoWex-ELASTIC 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 the machined surfaces of the flange hub.

tially 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

HEW couplings accept a position deviation of the machine parts to be connected up to

HEW coupling has to be aligned from the coupling hub on the shaft side towards one of

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 13 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Radial displacement

Angular displacement

Axial displacement

4.4 Displacements - alignment of the couplings

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

of 22

4 Assembly

Please note:

 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 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.

coupling.

Examples of the displacement combinations specified in illustration 14:

Example 1:

= 30 %

K

= 70 %

K

Example 2:

= 60 %

K

= 40 %

K

= Kr + Kw  100 %

total

Illustration 13: Displacements

Illustration 14: Combina-

tions of displacement

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 73

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 14 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Elastomer

[Shore A]

Size

65 HE

80 HE

125 HE

150 HE

200 HE

G 65 HE

G 80 HE

G 125 HE

G 150 HE

G 200 HE

Perm. radial displacement

Kr [mm]

40 3)

1.1

1.2

1.6

1.8

2.2

2.5

2.8

3.0

50 3)

1.0

1.1

1.5

1.7

2.0

2.3

2.5

2.7

2) 3)

0.5

0.7

0.8

1.0

1.1

1.3

1.5

Perm. radial displacement

Kr [mm]

40 3)

0.8

1.1

1.4

1.6

2.0

2.2

2.5

2.8

50 3)

0.7

1.0

1.3

1.5

1.8

2.0

2.2

2.5

2) 3)

0.4

0.5

0.6

0.8

1.0

1.2

40 3)

3.6

3.8

5.1

5.7

6.5

7.5

8.0

8.5

50 3)

3.3

3.5

4.7

5.3

6.0

6.9

7.5

8.0

2) 3)

1.5

1.7

2.2

2.4

3.0

3.3

4.0

4.5

Perm. angular displace-

Kw [°]

40 3)

1.0

50 3)

0.75

2) 3)

0.5

40 3)

0.5

50 3)

0.4

2) 3)

0.25

Max. angular displace-



Kw max. [°]

Perm. axial displacement

Ka [mm]

Size

42-130

65-180

80-225

100-305

125-365

Elastomer hardness

[Shore A]

T50

T65

T70

T50

T65

T70

T50

T65

T70

T40

T52

T65

Max. axial displacement

K

[mm]

Max. radial displacement

K

[mm] ±

Max. radial displacement

K

[mm]

Max. angular displace-

K

[°]

Max. angular displace-

K

[°]

4.4 Displacements - alignment of the couplings

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

4 Assembly

Table 13: Displacement figures

Displacement figures

with n = 1500 rpm



with n = 3000 rpm

Max. radial displacement

ment with n = 1500 rpm

Perm. angular displacement with n = 3000 rpm

For short-term start-up operation

With size 125 = 70 ShA

applies for compound T as well

K

r max.



K

[mm] 1)

ment

[°]

Table 14: Displacement figures of HEW Compact

hardness

40 / 50 / 65

42 HE 48 HE

2) 3)

1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5

2) 3)

±2 ±2 ±2 ±2 ±3 ±3 ±5 ±5

100 HE

Sheet:

of 22

Displacement figures

with n=1500 rpm

with n=3000 rpm

ment with n=1500 rpm

ment with n=3000 rpm

T50 T65 T70

± 2 ± 2 ± 2 ± 2 ± 2

±1.1 ±1 ±0.5 ±1.6 ±1.5 ±0.7 ±1.8 ±1.7 ±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 ±1 ±0.75 ±1 ±1

±0.5 ±0.4 ±0.25 ±0.5 ±0.4 ±0.25 ±0.5 ±0.4 ±0.5 ±0.5

±0.75

±0.5 ±1 ±0.75 ±0.5

±0.25 ±0.25

±0.5 ±0.4 ±0.25

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 15 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

If used in potentially explosive atmospheres the setscrews to fasten the hubs as well as all screw

(average strength).

If the couplings are used in locations subject to dust explosion and in mining the user must

equipment of equipment group ll.

If you note any irregularities with the coupling during operation, the drive unit must be

machine components must be considered.

If coated (priming, paintings, etc.) couplings are used in potentially explosive atmospheres,

exceeding 200 µm are prohibited for explosion group llC.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

of 22

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 the tightening torques specified, dependent on the type of coupling.

connections must be secured against working loose additionally, e. g. conglutinating with Loctite

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.

HEW1

, L

HEW2

or L

and adjust, if necessary, and also inspect all screw connections for

HEW-ZS

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

During operation of the coupling, please pay attention to

 different operating noise  vibrations occurring.

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 potential breakdowns mentioned can be hints only. To find out the cause all operating factors and

Coating of coupling:

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

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 75

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 16 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

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.

Hazard notes for po-

mospheres

Micro friction by faulty

1) Set the unit out of operation

3) For inspection of wear see item 5.4

1) Set the unit out of operation

4) For inspection of wear see item 5.4

1) Set the unit out of operation

5) Find out the reason for overload

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

of 22

6 Breakdowns, causes and elimination

The below-mentioned failures can result in a use of the BoWex-ELASTIC tion 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.

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 atmos-

pheres or does not correspond to EU directive 2014/34/EU.

 Maintenance intervals are not observed.

coupling other than intended. In addi-

Breakdowns Causes

alignment on the

Different operating noise and/or vibra-

tions occuring

Fracture of elasto-

mer part / spline

spline of the elasto-

Screws for axial fastening of hubs work-

Fracture of elastomer

part / spline caused

by high dynamic

energy / overload

mer part

ing loose

tentially explosive at-

Danger of ignition due to

hot surfaces

none

Elimination

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)

2) Inspect alignment of coupling

3) Tighten the screws to fasten the hubs and secure against working loose

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

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 17 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Hazard notes for po-

mospheres

1) Set the unit out of operation

4) Inspect alignment

1) Set the unit out of operation

5) Instruct and train the service staff

1) Set the unit out of operation

6) Find out the reason for vibrations

1) Set the unit out of operation

perature

1) Set the unit out of operation

tions 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.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

6 Breakdowns, causes and elimination

Breakdowns Causes

Operating parame-

ters do not meet with

the performance of

the coupling

Fracture of elasto-

mer part / spline

Operating error of the

Vibrations of drive

Ambient/contact tem-

Excessive wear on

the spline of the

elastomer part, frac-

ture of elastomer

peratures which are

too high for the elas-

tomer part, max.

permissible e. g. T4 =

- 30 °C/+ 80 °C

unit

tentially explosive at-

Danger of ignition due to

none

hot surfaces

Sheet:

Elimination

2) Review the operating parameters and select a bigger coupling (consider mounting space)

3) Assemble new coupling size

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

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

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 tem-

of 22

e. g. contact with

aggressive liq-

uids/oils, influence by

ozone, too high am-

bient temperature

etc. causing a physi-

cal change of the

elastomer part

none

2) Disassemble the coupling and remove

3) Inspect coupling components and re-

4) Insert elastomer part, assemble coupling

5) Inspect alignment, adjust if necessary

6) Make sure that other physical modifica-

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 77

remainders of the elastomer part

place coupling components that are damaged

components

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 18 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:



KTR does not assume any liability or warranty for the use of spare parts and accessories

Temperature class

Ambient or operating temperature Ta

Max. surface temperature 1)

T4, T3, T2, T1

- 30 °C to + 80 °C

115 °C 2)

- 30 °C to + 65 °C

100 °C

- 30 °C to + 50 °C

85 °C

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

of 22

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.

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 potentially explosive atmospheres

BoWex-ELASTIC

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:

Explanation: The maximum surface temperatures each result from the maximum permissible ambient or operating temperature Ta plus the

maximum temperature increase

1) The ambient or operating temperature T the BoWexELASTIC

2) The maximum surface temperature of + 115 °C applies for the use in locations which are potentially subject to dust explosion, too.

couplings are suitable for the use according to EU directive 2014/34/EU.

T of 35 K which has to be taken into account.

elastomer parts used.

is limited to + 80 °C due to the permissible permanent operating temperature of

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 19 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

For couplings which are classified in category 3G or 3D the operating and assembly in-

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

fail.

Illustration 15: BoWex-ELASTIC® type HEW1

9 Enclosure A

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

Advice and instructions regarding the use in potentially explosive atmospheres

9.2 Inspection intervals for couplings in potentially explosive atmospheres

Explosion group Inspection intervals

II 2GD c IIB

T4, T5, T6

structions 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

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

of 22

BoWex-ELASTIC

 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

, the elastomer part must be re-

S

max.

placed immediately, irrespective of the inspection intervals.

 Visual inspection of the elastomer part

(cracks, holes or anything similar).

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 79

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 20 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

To inspect the torsional backlash the power pack which is switched off needs to be secured

Here the elastomer part must not be axially displaced from its position of wear.

In order to ensure a long service life of the coupling and avoid danger with the use in poten-

If the figures are exceeded, the coupling will be damaged.

9 Enclosure A

9.4 Standard values of wear

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

Advice and instructions regarding the use in potentially explosive atmospheres

9.3 Inspection of torsional backlash

against accidental switch-on.

 Turn the hub opposite the direction of drive.

 Mark elastomer part and hub (see Illustration 16).

 Turn the hub in the direction of drive and measure the torsional backlash S

 When reaching the torsional backlash S

the elastomer part must be replaced.

max

max.

of 22

If the torsional backlash is  S

Reaching the limits for replacing depends on the operating conditions and the existing operating parameters.

tially explosive atmospheres, the shaft ends must be accurately aligned. Please absolutely observe the displacement figures specified (see tables 13 and 14).

Illustration 16: Marking of the elastomer part and hub

[mm] / friction  X

max.

[mm], the elastomer part must be replaced.

max.

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 21 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Illustration 17: Elastomer part in new condition

Illustration 18: Wear of elastomer part

Limits of wear each hub

Wear

max.

[mm]

Torsional back-

lash S

max.

[mm]

Wear

max.

[mm]

Torsional back-

lash S

max.

[mm]

1.0

1.7

100

1.8

3.1

1.0

1.8

125

2.0

3.5

1.4

2.5

G 125

2.0

3.5

1.6

2.7

150

2.0

3.5

G 80

1.6

2.7

Short labelling: (standard)

Complete labelling:

II 2G c IIB T6, T5 resp. T4

II 2D c T 115 °C - 30 °C  Ta  + 80 °C

The customer bears the sole responsibility for all machining processes performed subse-

9 Enclosure A

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

Advice and instructions regarding the use in potentially explosive atmospheres

9.4 Standard values of wear

Table 15:

Size

of 22

9.5 marking of coupling for potentially explosive atmospheres

The ATEX marking of the BoWex-ELASTIC the following details:

The labelling with explosion group llB includes the explosion group llA.

quently 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.

coupling is done on the polyamide flange of the elastomer specifying

II 2GD c IIB T X

- 30 °C  Ta  + 50 °C, + 65 °C resp. + 80 °C

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 81

BoWex-ELASTIC®

Type HEW, HEW Compact and HEW-ZS

KTR-N

Edition:

40114 EN 2 7

Please observe protection

note ISO 16016.

Drawn:

2017-04-24 Shg/Hk

Replacing:

KTR-N dated 2013-06-10

Verified:

2017-04-24 Shg

Replaced by:

Rheine,

2017-04-24

i. V.

i. A.

Date

Reinhard Wibbeling

Andreas Huecker

9 Enclosure A

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operating/Assembly instructions

Sheet:

Advice and instructions regarding the use in potentially explosive atmospheres

9.6 EU Certificate of conformity

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 tives 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:

complies with the specifications of directive 2014/34/EU. One or several direc-

IBExU Institut für Sicherheitstechnik GmbH Fuchsmühlenweg 7

09599 Freiberg

2 of 22

Engineering/R&D

Product Manager

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 83

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Instruction

Recommended service intervals

APP pumps

APP 53 - 92

for APP 0.6-1.0 / APP 1.5-3.5 /

Recommended service intervals

APP (W) 5.1-10.2 / APP 11-13 / APP 16-22

hpp.danfoss.com

ro-solutions.com

Instruction | Recommended service intervals for APP 53 - 92 pumps

Table of Contents

1. General information....................................................................86

2. Design/features .......................................................................86

3. Appendix 1 ............................................................................87

1. General information This guideline provides information on the

The recommendation is for guidance only. recommended service intervals. The recommendation is based upon good engineering practice and on experience gained from operation even under extreme conditions.

2. Design/features

Danfoss APP pumps are designed for long operation and low maintenance and life cycle costs.

If the Danfoss recommendations concerning

system-design (see our data sheet) are not

followed, the service life of the APP pumps might Provided that the pump has been running

be aﬀected. 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

The recommended service intervals on the diﬀer-

ent parts in the APP pumps appear from the

table below: recommended to inspect the pump and replace worn parts, if any.

Pos. Qt y. Description Material Service interval

APP 53 - 78

1 2 Housing, main bearing Duplex, PEEK No need for service No need for service

11, 14 1 End ﬂange/ motor ﬂange Duplex No wear part No wear part

121 1 Center ﬂange Duplex No wear part No wear part

31 2 Swash plate Super Duplex 48,000 hours 40,000 hours

66 18 Piston Super Duplex, PEEK and PP Recommended inspection on

a yearly basis and evaluated acc. to app. 1 Replace after 24,000 hours.

92 2 Valve plate Super Duplex 32,000 hours 24,000 hours

91, 95 2 Port plate Super Duplex, PEEK 32,000 hours 24,000 hours

61 2 Cylinder barrel Super Duplex 48,000 hours 40,000 hours

65 2 Retainer plate Super Duplex 48,000 hours 40,000 hours

64 2 Retainer ball Super Duplex 48,000 hours 40,000 hours

82 2 Retainer guide assembly Super Duplex, Duplex and PP48,000 hours 40,000 hours

Service interval APP 86 - 92

Recommended inspection on a yearly basis and evaluated acc. to app. 1 Replace after 8,000 hours

81 9 Spring Duplex 48,000 hours 40,000 hours

142 1 Stop for shaft seal Duplex No wear part No wear part

124 1 Shaft seal Hastelloy and NBR 24,000 hours 24,000 hours

125 1 Cover/ﬂange for shaft seal Super Duplex No wear part No wear part

93 8 Back-up ring PTFE 24,000 hours 24,000 hours

* O-ring (overall) NBR 24,000 hours 24,000 hours

* Screw (overall) AISI 316 24,000 hours 24,000 hours

* Pin (overall) AISI 316, Duplex or PEEK No wear part No wear part

152 1 Valve cone (ﬂushing valve) Duplex or PEEK 48,000 hours 48,000 hours

3 6 Bleeding screw Duplex No wear part No wear part

67 1 Key AISI 316 40,000 hours 40,000 hours

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.

Cavitation of the piston shoes. New inspection is required in 3,000-4,000 hours.

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. 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.

Abrasive wear of the piston shoes. All pistons must be replaced immediately.

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 12.2021

Cavitation of the piston shoes. All pistons must be replaced immediately.

Danfoss A/S

High Pressure Pumps Nordborgvej 81 DK-6430 Nordborg Denmark

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

1. Validity ................................................................................91

2. Parts list APP 53-92 - serial no. 07 or higher .............................................92

3. Exploded view APP 53-92 serial no. 07 or higher ........................................94

4. Parts list APP 53-86 - serial no. up to 06 .................................................95

5. Exploded view APP 53-86 - serial no. up to 06 ...........................................97

6. Tool sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Parts list | APP 53-92 Pumps

1. Validity You ﬁnd the serial number in the label of the

This Parts list contains two part list tables, for serial numbers:

pump.

• 07 and higher and

• up to 06

PUMP

Type APP 78 Code no. 180BXXXX

Serial no. XXXXXX07-XXX

MADE IN DENMARK

Danfoss A/S, 6430 Nordborg, 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.

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. Qt y. Des cription Material

0001 2 Complete Housing 1.44 62/PE EK

0002 4 Pin ø6 x 10 A4

0003 6 Blee ding plug G1/4” 1.4 410

0004 6 O-r ing (ø11 x 2 mm) NBR

0005 51 Cyl.screw M 8 x 30 A4-80 A4-8 0

0006 2 Screw M 8 x 16 A4-80 A4 -80

0009 4 O-r ing (ø228x 4 mm) NBR

0010 4 O- ring (ø9.2 x 2.6 mm) NBR

00 11 1 End ﬂange 1.4 462

0014 1 Motor ﬂ ange APP 53 - 92 1.4 462

0144 4 Thre aded pin M16 x 80 A4

0145 4 Hex lo ck nut M16 A4

0147 4 Washer ø17xø30x3 A4

0031 1 Swas h plate APP 53 (non-dr ive end) 1 .4410

0031 1 Swas h plate APP 65 (non-dr ive end) 1 .4410

0031 1 Swas h plate APP 78-92 (non- drive end) 1.4 410

0032 1 Swash plate APP 53 (dr ive end) 1 .4410

0032 1 Swash plate APP 65 (d rive end) 1 .4410

0032 1 Swash plate APP 78 -92 (drive end) 1.4410

0033 2 Distance washer

0034 4 Pin (ø10.5 x 20) 1.4 410

0064 2 Retainer ball DLC 1.4 410/D LC

0065 2 Ass. Retainer plate 1.441 0/PE EK

00 61 2 Cyl.barrel with insert 1.4 410/P EEK

0066 18 Piston 1. 4410/ PEEK

0066 18 Piston w. in sert 1.4 410/P EEK

0067 1 Key (14 x 9 x 70 A4

0068 1 Shaf t APP H 1. 4410

0069 1 Dista nce pipe APP 53-92 1.44 62

0070 2 Pin (ø10.5 x 20) 1. 4410

0072 1 Cone bushin g DLC 1.4 410/DL C

0073 1 Screw M16x75 DLC 1. 4410/D LC

0081 9 Compre ssion spring (ø1.9 x ø11 x 45.3) 1.44 62

0082 2 Asse mbly spring guid e APP 53-65 1.4 410/PP

0082 2 Asse mbly spring guid e APP 78 1.441 0/PP

0082 2 Asse mbly spring guid e APP 86-92 1.4 410/PP

0091 1 Port pl ate 1.4410/ PEE K

0091 1 Port pl ate 17 1. 4410/ PEEK

0092 2 Int. Valve plat e 1. 4410

0092 2 Int. Valve plat e 17 1. 4410

0095 1 Port p late (shaft side) 1.4 410/P EEK

0095 1 Port p late (shaft side) 17 1. 4410/ PEEK

0093 18 Back-up ring PTFE/Carbon

0094 18 O- ring (ø30.2 x 3 mm) NBR

180B463 4 - APP 53-92

Screw kit

180B4635 - AP P 53-92

Shaft s eal kit

180B4636 - A PP 53-92

Seal kit e xc. shaft sea l

180B4553 - APP 53

Piston k it

180B4554 - APP 6 5-92

Piston k it

180B4555 - APP 53- 65

Retainer kit

180B4566 - A PP 78

Retain er kit

180B4562 - APP 8 6-92

Retainer kit

180B4557 - APP 53- 65

Valve plate k it

180B4558 - APP 78 -92

Valve plate k it

180B4560 - A PP 53

Swash plat e kit

180B46 01 - APP 65

Swash plat e kit

180B4561 - APP 78- 92

Swash plat e kit

180B4556 - APP 53 -92

Flushing valve kit

180B4559 - APP 53 -92

Cylinder barrel kit

180B46 49 - APP 53-92

Port ﬂan ge kit

x x x x

x x x

x x x x

x x x

x x

x x x

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

Pos. Qt y. Des cription Material

0121 1 Ce nter ﬂange APP H 1.4 462

0122 1 O -ring (ø80.0 x 2 mm) NBR

0124 1 Shaf t seal NBR

0125 1 Cov er for shaft seal 1. 4462

0126 4 Pi n (ø10.5 x 20) 1.4410

0127 4 S crew M6 x 12 A4-80 A4-80

0128 50 Screw M8 x 20 A 4-80 A4-80

0131 1 3” Cov er for Inlet por t PP

0132 2 O -ring (ø79 x 3.5) NBR

0133 4 Sc rew M8 x 16 A4-80 A4-80

0134 1 3” Cov er for Outlet por t PP

0135 4 Sc rew M10 x 16 A4-80 A4-80

0140 1 Lif ting eye M12 (DIN 580E) AISI 316

0142 1 Washer f or shaft seal 1.4 462

0151 1 O -ring (ø35 x 3) NBR

0152 1 Val ve cone 1.441 0

0153 1 Compression spring 1.4 462

0154 1 Plug/guide 1. 4410

0155 1 O -ring (ø47.2 x 3.5) NBR

1 Instruction

180B463 4 - APP 53-92

Screw kit

180B4635 - AP P 53-92

Shaft s eal kitseal ki t

180B4636 - A PP 53-92

Seal kit e xc. shaft sea l

180B4553 - APP 53

Piston k it

180B4554 - APP 6 5-92

Piston k it

180B4555 - APP 53- 65

Retainer kit

180B4566 - A PP 78

Retain er kit

180B4562 - APP 8 6-92

Retainer kit

180B4557 - APP 53- 65

Valve plate k it

180B4558 - APP 78 -92

Valve plate k it

180B4560 - A PP 53 Swash

plate ki t

180B46 01 - APP 65

Swash plat e kit

180B4561 - APP 78- 92

Swash plat e kit

180B4556 - APP 53 -92

Flushing valve kit

180B4559 - APP 53- 92

Cylinder barrel kit

x x x

x x

x x x x x x x x x x x x x x x x

180B46 49 - APP 53-92

Port ﬂan ge kit

Not mounted in APP 53

Only compatible with pump series 08 or higher

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

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

Qt y.

Pos.

0001 2 Complete Housing 1.4462/PEEK

0002 4 Pin ø6 x 10 A4

0003 6 Bleeding plug G1/4” 1. 4410

0004 6 O-ring (ø11 x 2 mm) NBR

0005 32 Cyl.screw M8 x 30 A4-80 A4-80

0006 2 Screw M8 x 16 A4-80 A4-80

0009 4 O-ring (ø228x 4 mm) NBR

0010 4 O-ring (ø9.2 x 2.6 mm) NBR

0011 1 End ﬂange 1.4462

0014 1 Motor ﬂange APP H 1.4462

0144 4 Threaded pin M16 x 70 A4

0145 4 Hex lock nut M16 A4

0147 4 W ash er ø17 xø3 0x3 A4

0031 1 Swash plate APP 53 (non-drive end) 1. 4410

0031 1 Swash plate APP 65 (non-drive end) 1. 4410

0031 1 Swash plate APP 78-86 (non- drive end) 1.4 410

0032 1 Swash plate APP 53 (drive end) 1. 4410

0032 1 Swash plate APP 65 (drive end) 1. 4410

0032 1 Swash plate APP 78-86 (drive end) 1. 4410

0033 2 Distance washer

0034 4 Pin (ø10.5 x 20) 1.4 410

0064 2 Retainer ball DLC 1. 4410/ DLC

0065 2 Ass. Retainer plate 1.4410/PEEK

0065 2 Ass. Retainer plate 17 1.4410/PEEK

00 61 2 Cyl.barrel with insert 1.4410/PEEK

0066 18 Piston 1.4410/PEEK

0066 18 Piston w. insert 1.4410/PEEK

0067 1 Key (14 x 9 x 70 A4

0068 1 Shaf t APP H 1. 4410

0069 1 Distance pipe APP H 1.4462

0070 2 Pin (ø10.5 x 20) 1.4 410

0072 1 Cone bushing DLC 1.4 410/DLC

0073 1 Screw M16x75 DLC 1. 4410/ DLC

0081 9 Compression spring (ø1.9 x ø11 x 45.3) 1.4 462

0082 2 Assembly spring guide APP 53- 65 1.4 410/P P

0082 2 Assembly spring guide APP 78 1. 4410/ PP

0082 2 Assembly spring guide APP 86 1. 4410/ PP

0091 1 Port plate 1.4410/PEEK

0091 1 Port plate 17 1.4410/PEEK

0092 2 Int. Valve plate 1.4410/P P

0092 2 Int. Valve plate 17 1.4410/P P

0093 18 Back-up ring PTFE/Carbon

0094 18 O-ring (ø30.2 x 3 mm) NBR

0095 1 Port plate (shaft side) 1.4410/PEEK

0095 1 Port plate (shaft side) 17 1.4410/PEEK

Description Material

180B4552 - APP 53-86

Screw & seal kit

180B4553 - APP 53

Piston kit

180B4554 - APP 65-86

Piston kit

180B4555 - APP 53-65

Retainer kit

180B4566 - APP 78

Retainer kit

180B4562 - APP 86

Retainer kit

180B4557 - APP 53-65

Valve plate kit

180B4558 - APP 78- 86

Valve plate kit

180B4560 - APP 53

Swash plate k it

180B4601 - APP 65

Swash plate k it

x x x

x x x x

x x

x x x x

x x x

x x

x x x

180B4561 - APP 78-86

Swash plate k it

180B4556 - APP 53-86

Flushing valve kit

180B4559 - APP 53-86

Cylinder barrel kit

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 95

Parts list | APP 53-92 Pumps

Parts list (continued)

APP 53-86 - serial no.

up to 06

Qt y.

Pos.

0121 1 Center ﬂange APP H 1.4462 0122 1 O-ring (ø80.0 x 2 mm) NBR 0124 1 Shaft seal NBR 0125 1 Cover for shaft seal 1.4462 0126 4 Pin (ø10.5 x 20) 1.4 410 0127 4 Screw M6 x 12 A4-80 A4-80 0128 30 Screw M8 x 20 BUMAX A4-10 0 0131 1 3” Cover for Inlet port PP 0132 2 O-ring (ø79 x 3.5) NBR 0133 4 Screw M8 x 16 A4-80 A4-80 0134 1 3” Cover for Outlet port PP 0135 4 Screw M10 x 16 A4-80 A4-80 0140 1 Lifting eye M12 (DIN 580E) AISI 316 0142 1 Washer for shaft seal 1.4462 0151 1 O-ring (ø35 x 3) NBR 0152 1 Valve cone 1. 4410 0153 1 Compression spring 1.4 462 0154 1 Plug/guide 1.4410 0155 1 O-ring (ø47.2 x 3.5) NBR

Description Material

1 Instruction

180B4552 - A PP 53-86

Screw & seal kit

180B4553 - APP 53

Piston kit

180B4554 - APP 65-86

Piston kit

180B4555 - APP 53-65

Retainer kit

180B4566 - APP 78

Retainer kit

180B4562 - APP 86

Retainer kit

180B4557 - APP 53-65

Valve plate kit

180B4558 - APP 78- 86

Valve plate kit

180B4560 - APP 53

Swash plate k it

180B4601 - APP 65

Swash plate k it

180B4561 - APP 78-86

Swash plate k it

180B4556 - APP 53-86

Flushing valve kit

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

180B4559 - APP 53-86

Cylinder barrel kit

Not mounted in APP 53

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Parts list | APP 53-92 Pumps

5. Exploded view APP 53-86 - serial no. up to 06

220 Nm ± 22 Nm

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 97

Parts list | APP 53-92 Pumps

6. Tool sets

Note: The parts listed are not sold separately, only in various kits.

Designation

Press bush 1

Cone bushing extractor 1

M6 Allen key 1

M8 Allen key 1

M8 x 140 (30 mm thread) Unbraco 1

M8 x 70 (full thread) Unbraco) 3

Valve plate ﬁxation device 3

Tool bracket 1

Tool, washer 2

M16 pin 1

Nut M16 A4 4

ø17/30 x 3 washer 1

Screw M8 x 40 A4-80 1

Valve plate mount 1

24 mm, 1/2” socket 1

Flush valve tool 1

Torque wrench 60-340 Nm 1

Fork wrench 13 mm 2

Fork wrench 24 mm 1

Fork wrench 30 mm 1

Distance adapter 1

Screwdriver 5.5 x 1 mm 2

Screw (M8 x 16 mm) 2

Screw (M6 65 mm) 2

Shaft tool 1

180Z0665 Tool set APP 53-92

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Parts list | APP 53-92 Pumps

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 99

Danfoss APP 53, APP 65, APP 78, APP 86, APP 92 Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual