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APP 1.5-3.5 - Depco Pump Company

1. Se TT TT OTTO dp d PPTL ETT TY ip 11 IIS q IVIS 37 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Parts list APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 24 Tool sets Note The parts listed are not sold separately only in various kits Designation 180B4188 Tool set APP 0 6 1 0 Compact 180B4162 Tool set APP 5 1 10 2 180B4230 Tool set APP 11 13 180B4222 Tool set APP 16 22 180B4172 Tool set APP 21 43 180B4142 Tool set APP 0 6 1 0 180B4148 Tool set APP 1 5 3 5 Shaft bush EN Press bush Drift Torx T30 Shaft bush 18 Press bush 18 Allen key 4 mm Allen key 5 mm Allen key 6 mm Shaft bush 35 Shaft seal extractor O35 Press bush 35 Adjustable pin wrench Combination wrench 10 mm Combination wrench 13 mm Nut M8x6 5x13 Guide bolt M8x140 Shaft seal extractor 45 Press bush 45 Eye bolt M8 Press bush for valve plate Stop for retainer plate Screw M8x20 Screw M8x70 PITT x x tt tt x tt bu pa 111 BITT TE P txt ft T xixixix lap PI T T xixixix eff PIT xixix TT xixix PIT px PITT fr PITT fee PIT ep PITT PITT xixix PITT det Danfoss A S High Pressure Pumps DK 6430 Nor
2. Wd p ds uone10o14 ub v JO suoisueuuip u16ue1 Z S uo pajunou sedid sesoH be ss uus SOH Ce 19 1n0 33 U1 sedid sesou suon uuo 3 nno lul Le Wd 2 eJnssaJd 3e ui MOT eu Bulsianas duing b eJnssaJd au Jeuruou XEW UIIN p dune suonipuo Buipee g 2 C ping ut av o d4nssaud moly pa gt npay Z piny ubiH 8 L T adh p n 2 jeus31ul duind ut sean LT uonenJy Uten OU 14 1 4 G LT 4015 11 15 3JOS Cp ainssaid anno 9 7 abewep dund 1938M y E anbio 3uv3suo ee ainssaid suree syeys duing ee duind eJnssaJd anno ufu ool Le 3jeus dund uo 3240 JeIXV G L dung 971 duund 10138301 ON inss id MOU ON L JOJOUI 21112 JO UONEJOJON Cl duing z L C Buluun Aig 41 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Instruction Trouble shooting guide for APP and APP S 674 pumps 1 Noflow no pressure 1 1 Dry running If no water comes out of the pump Mount a low pressure switch in front of the no water supply to the pump pump and check its set point function The low 1 1 1 Check that inlet valve is open pressure switch ensures th
3. To ensure easy mounting of the flexible coupling without using tools the tolerances must be dimensioned accordingly Note Any axial and or radial loads on the shaft must be avoided The pump should be connected to the rest of the plant with flexible hoses 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Data sheet APP pumps APP 1 5 3 5 11 2 Open ended system with direct water supply In order to eliminate the risk of cavitation a positive inlet pressure is always to be main tained Please see technical data part 3 for specific pressure values 1 Place the filter 1 in the water supply line in front of the pump 2 Place a monitoring pressure switch 2 set at min inlet pressure between filter and pump inlet The monitoring switch must stop the pump at pressures lower than min inlet pressure Please see technical data part 3 for specific pressure values 11 3 RO system with APP pump 1 Dimension the inlet line to obtain mini 6 For easy system bleeding and flushing a mum pressure loss large flow minimum bypass non return valve 6 is integrated in pipe length minimum number of bends the APP pump connections and fittings with small pressure losses 7 A non return valve 7 in outlet can be installed in order to avoid backspin of the 2 Place an inlet filter 1 in front of the APP pump The volume of water in the pump 2 Please consult section 9 membran
4. The pumps are based on the axial piston principle enabling a very light and compact design The design ensures that lubrication of the moving parts in the pumps is provided by the fluid itself No oil lubrication is thus required Shaft sealing Mounting flange Retaining ring Piston shoe Valve plate Swash plate Cylinder barrel Spring Port plate Connecting flange Housing with bearing Flushing valve 2 3 4 5 6 7 6 9 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 All parts included in the pumps are designed to provide long service life i e long service life with a constantly high efficiency and minimum of service required The pumps are fixed displacement pumps in which the flow is proportional to the number of revolutions of the input shaft and the pump displacement regardless of any counter pressure The pumps are supplied with an integrated flushing valve that allows the salt water to flow from inlet to the outlet when the pump is not running O JC fm TN Data sheet 2 Benefits 3 Technical data APP pumps APP 1 5 3 5 e One of the smallest and lightest pumps on o the market e Can be powered by a combustion engine e Long service life No preventive maintenance required in the vvarranty period e Generates insignificant pulsations in the high pressure line Danfoti No oil lubricant required Integrated flushing valve All parts of the pump a
5. Insufficient bleeding may cause dam age not applicable to Power Packs Starting procedure Cleaning procedure 1 Fill cold water into the system via the return filter and bleed the pump Power Packs PPH 4 6 3 10 and 12 5 are self bleeding 2 Start and bleed the system without pressure by opening the bypass valve 3 Add the cleaning agent to give 3 agent water solution 4 Run the system for 60 min and activate all components as often as possible to ensure effective flushing with the cleaning agent 5 Empty the system of the cleaning agent solution Flushing procedure 6 Fill cold water through the return filter and bleed the pump Power Packs PPH 4 6 3 10 and 12 5 are self bleeding 7 Run the system for 30 min and activate all components as often as possible 8 Empty the system of the water 9 Alternatively the system may be flushed by running the unit without the return hose while continuously filling up water The flushing should continue until there is no trace of cleaning agent in the return water 10 Change the return filter element fill cold water through the return filter and bleed the pump during start up 11 The system is now ready for operation Starting procedure looooooooo j 4 ooooooooo o00000000 Observing the starting procedure will If the system is not cleaned before ensure problem free operation starting the filter will clog Trouble shooting Open ended water syst
6. 2 1 Duplex 33 1 Pin 6x10 PEEK Ov 1 Cylinder barrel Super Duplex PEEK 1 Spring Duplex O UJ 1 Spring guide PEEK Retainer ball AN 4 1 Super Duplex O UT 1 Retainer plate Super Duplex 7 Piston Super Duplex PEEK AN 1 Key 5x5x20 AISI 316 1 Port plate Super Duplex PEEK N 1 Valve plate Super Duplex 7 Back up ring PTFE O N N UJ 4 7 O ring 13x2 0 NB 121 1 Port flange Duplex JJ x B 122 1 O ring 83x2 NBR 123 1 O ring 40x2 NBR AISI 316 NBR Wetted parts PP Dry parts AISI 316L 126 1 Pin 4x9 PEEK 124 1 Shaft seal 125 1 Mounting flange N 7 4 Screw M6x45 AISI 316 128 2 Screw M6x16 AISI 316 129 2 Bleeding plug Duplex UJ 1 2 O ring 4 5x1 5 NBR 152 1 Valve cone PEEK UT UJ 1 Spring Duplex 5 1 Plug guide Duplex 155 1 O ring 11 11x1 78 NBR Instruction 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 Parts list 3 gt m 50 om ea zu LI et 9 GL 31495 0309 Got 449 2 03 31141 06S d EFUN 8 D YE A 4301 bL 0F Y 101 S67 N N I S z m F WN Z m 62 1222 11141 8 8 WI pL Ox aJd Sez L FUN y red
7. 21 Exploded view APP 21 26 22 Parts list APP 30 43 23 Exploded view APP 30 1200 and APP 43 1700 24 Tool sets 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Not included Parts list 1 General PAHT and PAHT G pumps This parts list provides an overview of the content of the various service sets for the PAHT 2 6 3 PAHT G 2 6 3 PAHT 10 12 5 PAHT G 10 12 5 PAHT 20 32 PAHT G 20 32 PAHT 50 90 PAHT G 50 90 PAHT 256 308 PAHT G 256 308 as well as exploded views of the pumps 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 33 Parts list 6 Parts list APP 1 5 2 5 and APM 1 8 2 9 34 APP 0 6 43 APM 0 8 2 9 APPW 5 1 10 2 Note The parts listed are not sold separately only in various kits Parts for APM 1 8 2 9 are equivalent to the parts for APP 1 5 2 5 except for the valve plate sets Exploded view see next page 80B4177 Retainer set APP 1 5 1 8 APM 1 8 2 0 80B4144 Retainer set APP 2 2 2 5 APM 2 5 2 9 80B4147 Seal set APP 1 5 3 5 80B4146 Cylinder barrel set APP 1 5 2 5 80B4145 Valve plate set APP 1 5 2 5 80F4007 Valve plate set APM 1 8 2 9 80B4143 Piston set APP 1 5 2 5 80B4136 Flushing valve set APP 1 5 3 5 HH 7 pem _ zl mews fase 1 omnee Jena xf sms lm LII LL Retainer ball Super Duplex 66 5 Piston Super
8. 11 2013 EC Declaration of Conformity The Manufacturer SVEND H YER A S Over Hadstenvej 42 DK 8370 Hadsten Denmark Hereby declares that The products HOYER MOTORS 3 phased induction motors Aluminium motors MS A22 MS 56 180 HMA A22 HMA 56 180 Cast iron motors Y2E A22 Y2E 80 400 HMC A22 HMC 80 400 Are in conformity with the following Standards EN 60 034 1 and EN 60 072 Directive Low Voltage Directive 2006 95 EC Year of CE marking CE Signed by p Ger 77 ars Hoyer Managing Director Date December 2010 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 25 Tlf 45 86 98 21 11 Main office Svend H yer A S Over Hadstenvej 42 DK 8370 Hadsten Tel 45 86 98 21 11 Fax 45 86 98 17 79 E mail svendhoyer svendhoyer dk http www svendhoyer dk Sverige Svend H yer AB Malm v gen 18 S 331 42 Varnamo Tel 46 37 04 77 13 Fax 46 37 01 00 46 E mail svendhoyer svendhoyer se http www svendhoyer se Norge Svend H yer AS Torvet 1 N 3256 Larvik Tel 47 33 18 00 11 Faks 47 33 18 00 13 e mail svendhoyer svendhoyer no http www svendhoyer no Deutschland Svend Hoyer A S Over Hadstenvej 42 DK 8370 Hadsten Tlf 0800 1890415 Fax 45 87 61 21 19 E mail svendhoyer svendhoyer dk http www svendhoyer de HOYER Svend Hoyer A S Over Hadstenvej 42 DK 8370 Hadsten T 45 86 98 21 11 F 45 86 98 17 79 svendhoye
9. TDS without consulting your local Danfoss pump distributor 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 A 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 180R9267 IOM APP Pumps v02 09 2013 3 9 Airbubbles Large bubbles in a pressurised RO system can result in damage to piping equipment and the pump All air must be bleeded from both the low pressure and high pressure side before the RO system is pressurised Special consideration should be given in order to minimize air bubbles in the feed flow Air bubbl
10. The APP pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor A Use of the pump in other applications not suitable for the pump unit can cause damages to the pump unit with risk of personal injury For system integration of the pump please see appendix 1 Data sheet and appendix 2 Instruction 180R9267 IOM APP Pumps v02 09 2013 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 o Do not mount the pump without the bell housing and a flexible coupling o Do not try to start the unit before the system components are mounted bleeded and adjusted o Flush the system throughly before connecting the pump or pump unit Check rotation direction of the motor before mounting the pump 2 5 Incase 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 See appendix 1 Data sheet 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 Noise and vibration Noise level for a pump unit with a standard motor measured according to EN ISO 3744
11. 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 tank 5 1 Temperature Fluid temperature Min 3 C to max 50 C Ambient temperature Min 0 C to max 50 C In case of lower operating temperatures please contact the Danfoss Sales Organization 5 2 Pressure The inlet pressure must be min 0 9 bar 13 psi and max 5 bar 72 5 psi abs At lower pressures the pump will cavitate resulting in damage to the pump Max pressure on the pump s outlet line should be limited at 80 bar 1160 psi continuously Short term pressure peaks e g in connection with closing of a valve of up to 100 bar 1450 psi are acceptable NB The pump unit should include a pressure gauge on the high pressure side 5 3 Dryrunning When running the pump must always be connected to the water supply in order to avoid damage if it should run dry In systems with water tank it is recommended to build in a level gauge in the tank to avoid the risk of running dry 5 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 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 5 5 Storage Storage temperature Min 40 C to max 470 C W
12. to the pump Electrical hazard Indicates a high voltage warning Safety glasses required Hearing protection required Safety shoes required Safety helmet required Q san Protective garments must be vvorn must be vvorn NE Do not touch A LE Electrical hazard User manual 2 Safety Installation Operation and Maintenance APP Pumps APP 1 5 3 5 1 3 Manufacturer and customer service address Danfoss A S Danfoss High Pressure Pumps RO Solutions Nordborgvej 81 D25 DK 6430 Nordborg Denmark Telephone 45 7488 4024 Fax 45 7445 3831 Email ro solutions danfoss com Homepage www ro solutions com A 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 e Death or fatal injuries e Costly damages and claims ANS 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 equip ment from overloads wi
13. v02 09 2013 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 A 5 5 Local regulations Commissioning must always be done in accordance with valid regulations and local standards Permeate LS 1 l User manual Davis Installation Operation and Maintenance APP Pumps APP 1 5 3 5 5 6 Pre mounting checklist based on Danfoss preferred system design Table 1 Check points when assembling and commissioning system CP1 Ensure that the environmental conditions are safe See Arrival inspection transportation handling lifting and storage chapter 4 CP2 Minimum and maximum start up temperature for fluid and See Data sheet or Instruction pump appendices 1 and 2 Filtration condition 10 um absolute 8 x 5000 See Danfoss requirements in Data sheet and Instruction appendices 1 and 2 Power supply for electric motor and VFD See Data sheet for the used motor and VFD 5 Safety circuit breaker must be sized for the motor and See Data sheet for the used environment corrosion and humidity safety circuit CP6 Bolts and screws must conform to environmental conditions as well as fluid and torque requirements i 7 CP4 P C CP7 Instrumentation pressure switch should be designed to See Data sheet for the used conform to the environment corrosion and humidity
14. 2010 see appendix 1 Data sheet Possibilities to reduce noise and vibration are described in the same Data sheet 3 5 Dimension drawings Dimensions of the different pumps can be found in appendix 1 Data sheet 3 6 Spacerequirement 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 User manual 4 Arrival inspection transportation handling lifting and storage Installation Operation and Maintenance APP Pumps APP 1 5 3 5 A A 3 7 Filtration 10um absolute f3 x 5000 Requirements are specified in appendix 1 Data sheet and in appendix 2 Instruction Danfoss recommends not to build a filter bypass function or to use filters with an integrated bypass If the above recommendation is not followed the warranty for the pump will automatically become void It should be possible to monitor the condition of the filter via the differential delta pressure across the filter Using insufficient filtration or a filter bypass can cause a failure or decreased service life of the pump 3 8 Properties of water It is recommended NOT to use the pumps in feed water concentrations higher than 50 000 ppm
15. Declaration of Conformity 5 7 Electric motor 6 7 8 9 10 11 12 13 15 16 P Electrical failure 16 PIDIN us a ra ees 9 11 12 16 Electrical hazatd n 6 7 POSITIONING PRSE 12 alas JE EN EEE 12 Preferred system design 7 11 Pre mounting s 5 gx sio 11 F Protection usu ok Aug a hem hes 6 7 8 10 Failure 15 uxo iau oy hoe ae xe 8 16 Filter condition za 13 R Filtration ox 9 12 14 16 Relief valve 12 13 14 FOW x sce ko m kakene 7 9 13 14 Responsibility 6 7 0 10 uo 11 12 15 16 3 10 15 PIS re 8 11 13 1011000 09 oni 8 13 Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products vvithout notice This also applies to products already on order provided that such alterations can be made vvithout subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 18 180R9267 IOM APP Pumps v02 09 2013 MAKING MODERN LIVING POSSIBLE p User manual Appendices for Installation Operation and Maintenance Manual APP pumps APP 1 5 3 5 APP 1 5 3 5 ro solu
16. N N o 7 2 J N N N NA NJ 00 UT A N N 0 I mm lt m Un 4 Intermittent pressure is acceptable for less than seconds per minute r speeds above 3000 rpm the pump must be boosted at a pressure of 2 5 bar 29 0 72 5 psi Data sheet APP pumps APP 1 5 3 5 4 Flushing valve The diagram shows pressure differences across the flushing valve APP 1 5 3 5 flushing valve characteristic Flow l min Pressure bar 5 Flow at different rpm Using the diagram shown below it is easy to select the pump which fits the application best if the flow required and the rotation speed rpm of the pump are known 1500 2000 2500 3000 rpm Furthermore this diagram shows that the flow can be controlled 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 rom can be determined as Required flow x Rated rpm Required rom Rated flow 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Data sheet APP pumps APP 1 5 3 5 6 Power requirements weus mn Ia fee Jam linin um aeo asss weus Ian l ns sem oam Jun seo 4686 wens se m Lu soonv Jon zo 4686 wess 4022 Ja me Lann Jam Jam seo asss wess n 252 no sor sozu Jam zc l
17. dossier Contact person Used harmonised standards DS EN ISO 12100 2011 Personne de contact pour le dossier technique Manager d partement qualit Normes harmonis es appliqu es DS EN ISO 12100 2011 Signature du fabricant Titre PTE tt RAI 2013 05 27 Datum Welm Friedrichsen Leiter F amp E 2013 05 27 Date Welm Friedrichsen Director R amp D 180R9267 IOM APP Pumps v02 09 2013 2013 05 27 Date Welm Friedrichsen Directeur R amp D User manual 1 Introduction Danfotk Installation Operation and Maintenance APP Pumps APP 1 5 3 5 1 1 General The APP pumps and pump units are manufac tured by Danfoss A S and are sold and marketed by a net of authorized distributors world wide This manual contains the necessary instructions for the installation operation and service of the pumps used in a Sea Water Reverse Osmosis SWRO system or Brackish Water Reverse Osmosis BWRO system In case the pump delivered is ATEX certified the additional ATEX instruction must also be read The APP pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor A 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 A All personnel being responsible for operation and maintenance of the pump unit must read and fully understand
18. oA 14 B Installation 6 7 8 11 12 14 15 16 Start UD oo SEENDE 8 O ENE 8 9 13 15 Instruction s ra 3 6 7 8 9 10 12 14 15 Storage Zum e Reg e Aere da 9 10 12 15 nstrumentation 6 12 s 3 EEE 6 C TOCOCLOT x es xe Son Gee Be oe oe 6 Maa 6 7 8 9 11 12 13 14 Ge de Fed E oa 11 SYSTEMS 604648444 Bed ed om ee 7 8 CHECK points 12 M Chemicdies ax oct desir 9 Maintenance 6 7 10 13 14 T Cleanliness 11 14 Mechanical failure 16 Table of Contents 2 Commissioning 6 8 11 12 13 15 16 Mounting sesos SR 8 11 13 15 Technical data 3 m 8 mews caw 8 Connections 7 9 10 11 12 15 Temperature 7 10 11 12 13 14 16 Coupling 8 12 13 15 16 N Transportation 6 9 12 15 Nameplate 9 11 12 13 Trouble shooting 14 16 D Ke ENE 8 14 A 6 7 13 16 V Datasheet 7 8 9 10 11 12 14 L 5000000 AR dx 7 11 12 13 14 16 Declaration of Conformity 57 EEE 0 ria als 16 Design 7 8 9 11 12 13 14 16 Lifting o 6 9 10 12 15 W Distributor us o RR 6 7 8 9 Local regulations 6 7 8 11 12 16 Warning bork A E 6 9 DIM NSIONS c ux se ee es oe va 8 11 Disassembling 15 o Operation 6 7 8 9 13 14 15 16 E Operational conditions 7 16 EC
19. of the safety relief valves If they are within specifications you can continue 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 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 180R9267 IOM APP Pumps v02 09 2013 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 M
20. peak pressures higher pointing upwards than 200 bar 2900 psi The valve outlet must not be connected 3 4 Protection from too high pressures directly to the pump suction line It shall be The pump should be protected against too high connected directly to the tank pressure by means of a pressure relief valve or a bypass unloading valve placed on the pressure side 3 5 Connections Pressure Tank Bleeding Parallel key 5 x 5 x 20 DIN 6885 APP 0 6 1 0 RE 77 G1 2x 15 Hexagon G1 2x15 G 3 4 x 17 NV 6 NV 4 14 deep 25Nm 25Nm 5Nm 25Nm 25Nm 15Nm torque 18 Ibf ft 18 Ibf ft 3 5 Ibf ft 18 Ibf ft 18 Ibf ft 11 Ibf ft Recommended torque values refer to steel washers containing a rubber sealing element 18 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Instruction 4 5 Initial start up Operation APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 Before start up loosen the top bleeding plug C When water appears from the bleeding plug retighten the plug With its inlet line connected to the water supply or the tank the pump is now started with open outlet port At the initial start of the system the pump should be run without pressure for about 5 minutes thus removing possible impurities from pipes hoses etc However the system should be flushed before start up without the connected pump WARNING Make sure that the direction of rotation of the
21. pressure 4 4 Pump reversing 4 5 High rotation speed rpm 4 6 Outlet pressure 4 7 Soft start stop 4 1 1 Ensure that the entire inlet line is bled before starting up the system 4 1 2 Ensure that air cannot enter into the inlet line 4 2 1 Follow the instructions Initial start up supplied with the new pump 4 2 2 Ensure that the pump is completely bled before start up 4 3 1 Ensure that inlet pressure is within the limits specified in the User manual 4 3 2 Check the pump for internal damage 4 4 1 Dismantle pump and check if anything is broken or worn See 1 No flow item 1 2 Pump reversing WARNING The pump must not run without water for more than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure and will eventually be damaged If electric motor rpm is too high dismantle pump and check for damage If the rom is within the specified range of the pump data sheet and abnormal noise remains dismantle pump and check for damage If outlet pressure is too low check set point of outlet pressure valve If outlet pressure is lower than mentioned in the pump data sheet please contact Danfoss High Pressure Pumps technical support If outlet pressure has exceeded its maximum check set point of outlet pressure valve Check internal parts for wear damage 4 7 1 Check if noise is normal when the pump is running at operation speed 4 7 2 If nois
22. these instructions especially the section Safety before e Transportation of the pump unit e Lifting the unit e Installing the pump unit e Connecting the pump unit to the water system e Connecting the electric motor and instru mentation e Commissioning the unit e Servicing the pump unit mechanical and electrical parts e 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 A Changing the pumps or pump units opera tional limits and hardware e Changes to the delivered pump or motor pump unit may only be done with a written approval from Danfoss High Pressure Pumps e Operation outside the Danfoss specifications requires a written approval from Danfoss High Pressure Pumps 180R9267 IOM APP Pumps v02 09 2013 e f any changes are made without written approval the warranty will automatically become void It is important that these instructions are always available to the personnel concerned 1 2 Symbols Indicates something to be noted by the reader Indicates a situation which will or could result in damage to the pump and its function Indicates a situation which will or could result in personal injury and or damage
23. 1 5 3 5 Validity This manual is valid for APP pumps with the following code numbers serial numbers EE 5 APP 3 5 180B3032 o 4 180R9267 IOM APP Pumps v02 09 2013 EC Declaration of Conformity Danfoss A S Danfoss High Pressure Pumps Nordborgvej 81 6430 Nordborg Denmark EG Konformit tserkl rung gem EG Richtlinie 2006 42 EG Hiermit erkl ren wir dass die Maschine gem 2006 42 EG entwickelt ist Beschreibung der Maschine Hochdruck Pumpe Maschinentyp APP 0 6 1 0 APP 1 5 3 5 APP 5 1 10 2 APP 11 13 APP 16 22 APP 21 43 Seriennummer N A Technisches Dossier Kontaktperson Leiter Qualit tsabteilung Angewandte harmonisierte Normen DS EN 150 12100 2011 Hersteller Unterschrift Titel EC Declaration of Conformity according to Directive 2006 42 EC We hereby declare that the machine is designedaccording to the directive 2006 42 EC Machine description High pressure pump Machine designation APP 0 6 1 0 APP 1 5 3 5 APP 51 10 2 APP 11 13 APP 16 22 APP 21 43 D claration de conformit CE conform ment la Directive 2006 42 CE Par la pr sente nous d clarons que la machine est concue conform ment la Directive 2006 42 Description de la machine Pompe haute pression Type de machine APP 0 6 1 0 APP 1 5 3 5 APP 5 1 10 2 APP 11 13 APP 16 22 APP 21 43 Serial number Num ro de s rie N A N A Technical
24. 35 2000 6000 7000 7000 215 50 1500 5500 6500 6500 555 60 1000 4000 5000 6000 400 80 800 3000 4000 6000 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 Motor Manual The table values are based on an ambient temperature of 25 G 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 6 Special note for Atex Zone 22 motors Notice for the use of electrical equipment in areas with combustible dust Designation of motor according to EC directive Ex II 3D T125 C IP55 The dust hazardous 3 phase asynchronous motors are in accordance with European standard EN 50281 1 1 Combustible dust areas will be found in agricultural areas and in industrial environments Only one electrical installation may be installed in one specified area zone Only certificated cable glands for category 2D may be used Unused glands must be closed Connections must be made in such a way as to ensure that a permanently safe elec
25. 4 3 Generals atento Matias risa 9 4 4 NTN NNN 9 4 5 FUN VED re 10 4 6 L EE A 10 2 Installation and COMMISSIONING zona Ra la H 5 1 Important dimensions ee 11 5 2 EEE EE E 11 5 3 Fluid tempera EEN 11 5 4 RS ed ee src pr PP DERE IURE UAR EE MICRO RE RAE Uc RE RU d 11 5 5 Local regulat CEET 11 5 6 Pre mounting checklist based on Danfoss preferred system design 11 5 7 Biy oli el d 12 5 8 MounttiyediflerentequUipment Ss 12 5 9 L L T C 12 510 Je det 07 EG e ET EIU EM E 12 511 GOL NE a EN RE i 12 5 12 Ensure ree OW a na a 13 5 13 Verify setting of safety relief valveS 13 5 14 F LUDTDE DUIS eee EEE PE EEE ET RE RE 13 5 15 Bleed and remove air from the pump 13 5 16 VERITY direction OF TOLAUON AA en 13 5 17 COMMIESIONIN PTE EE RI D 13 5 18 Check the filter condition au sara C239 309 9 ee CENE Gao seen 13 5 19 Instruct operator and maintenance personnel 13 6 OP or DUMPING Jaer 14 6 1 General safety Inforiati Ol ox ecd adn bada ada Pe D 14 6 2 Whattodisten and Took IOl ssi pe ark ea AH bon SHE ACERO EOM 14 180R9267 IOM APP Pumps v02 09 2013 User manual Installation Operation and Maintenance APP Pumps APP 1 5 3 5 7 Maintenance and servi
26. 5 Appendices v04 11 2013 47 Instruction Trouble shooting guide for APP and APP S 674 pumps 6 2 Port plate Picture 1 ye Ifthe port plate has scratches level differences or both between the arrows ibd the port plate must be replaced Even small scratches or wear will cause loss of flow To check See item 6 1 picture 3 6 3 Swash plate Picture 1 d Ifthe swash plate is polished 360 it is an indication of insufficient filtration The surface of the svvash plate must be plane and even at same level all over To check this please see item 6 1 picture 3 If the surface has any marks scratches it is vvorn damaged and a new one is required Please contact Danfoss High Pressure Pumps sales office for further infor mation Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 48 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 MAKING MODERN LIVING POSSIBLE Right and wrong Trouble shooting guide fo
27. Duplex PEEK Super Duplex PEEK BR X 24 1 Shaft seal AISI 316 NBR m 1 Leg o Mounting flange Wetted part PP Dry part AISI 316 VT ewe AP RR ER pp e MTT TITT RITT eee RITT T lil 17 RITT ERR RITT ed e11111 11 T1 TITT ey el l l TR 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 Parts list Exploded view APP 1 5 2 5 and APM 1 8 2 9 7 hi iq 707 1191 S62 b FUND o Biq nae Masse VF UN Zl w WJalbL 0F 1966 Ur WN y V Sip Y S10P c V 40p V 410p ON UOI EI USD CO aaa m b RES s V V 35 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Parts list 8 Parts list APP 3 0 3 5 36 APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 Note The parts listed are not sold separately only in various kits Exploded view see next page Designation 180B4152 Cylinder barrel set APP 3 0 3 5 180B4151 Valve plate set APP 3 0 3 5 180B4150 Retainer set APP 3 0 3 5 180B4149 Piston set APP 3 0 3 5 180B4134 Swash plate set APP 3 0 180B4135 Swash plate set APP 3 5 180B4136 Flushing valve set APP 3 5 in T S m QA QA o o u l m LA r ca o co 1 Housing Duplex PEEK 1 Pin 4x14 AISI 316 UJ 1 Swash plate Super Duplex Centre bolt UJ
28. MAKING MODERN LIVING POSSIBLE Dane User manual Installation Operation and Maintenance Manual APP pumps APP 1 5 3 5 APP 1 5 3 5 ro solutions com User manual Table of Contents Installation Operation and Maintenance APP Pumps APP 1 5 3 5 e 0 75 EEE PETE IERI ERE RUMP RES 4 EU Declaration Of COMMONLY REE ARA NER 5 1 TIM OGUCHOR EE 6 1 1 Ce a ee 6 1 2 PPP EEE 0000000000 6 1 3 Manufacturer and customer service address 7 2 7 21 General 19 eege ENEE EE 7 2 2 Preferred system ENEE asd d b 7 2 3 Commissioning and servicing the unit suo Xr Rx RAY Ra SERES UG naga ead 8 2 4 Adhere to the following important points 8 2 5 lli case arl a TERESE EE OC ER eee 8 3 ENE EN RE NE REE 8 3 1 Approved applications and operational limits for the pumps 8 3 2 Application ANG PP e 8 3 3 EICCUNIC motora ata 00 9 0 aa 8 3 4 Noiscancd scarico EEE NEED EEE 8 ER LUT s E EE EE 8 3 6 Space requirement NN 8 3 7 9 3 8 PN 9 3 9 s aaa an 9 3 10 Sacs TR M JVY M E 9 4 Arrival inspection transportation handling lifting and storage 9 4 1 o o EEE E eens 9 4 2 Y Ul E 9
29. a r Jansen m r asanegus superou m m sm p e Ji Jeng Jee 124 215 Shaft seal Hastelloy and NBR It is good practice to change the seal after each disassembly of the pump E Cover flange for shaft seal Super Duplex 5 7 9 Back up ring PTFE 24 000 hours 1 1 1 1 1 4 1 1 1 1 O ring overall 24 000 hours ox eui 67 depends on pump size 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Instruction 3 Appendix 1 Danfoti Recommended service intervals for APP pumps Pistons In case of doubt the pistons must be replaced The pistons are the heart of the pump regarding service The pictures below is ment as a guideline for evaluating the wear of the sliding surface If the pistons break down the pump will suffer a breakdown Cavitation of the piston shoes Cavitation of the piston shoes New inspection is required in 3 000 4 000 hours All pistons must be replaced within the next 500 1 000 hours Cavitation of the piston shoes Cavitation of the piston shoes All pistons must be replaced within the next All pistons must be replaced immediately 100 200 hours Abrasive wear of the piston shoes All pistons must be replaced immediately 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 29 Instruction Recommended service intervals for APP pumps Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danf
30. al load on pump shaft 5 Ensure that the air gap between the two To ensure easy mounting of the flexible may cause high internal leakage coupling parts is min 5 mm It should coupling without using tools the tolerances Only applying to always be possible to move the plastic part must be dimensioned accordingly APP 0 6 to APP 3 5 and on the coupling at least 3 mm APP 21 to APP 26 only WARNING Also applying to APP S 674 pumps Any axial and or radial loads on the shaft must be avoided Any axial or radial load will cause breakdown A Bell housing B Flexible coupling C Motor shaft 1 6 Pump damage 1 6 1 Contact Danfoss sales office for guidelines Instructions on internal elements the internal parts may be damaged in how to troubleshoot internal pump 180R9092 180R9085 for APP 0 6 1 0 parts 180R9091 180R9147 180R9089 for APP 1 5 3 5 180R9093 180R9090 for APP 5 1 10 2 180R9228 180R9227 for APP 11 13 and APP 16 22 180R9121 180R9139 for APP 21 43 180R9281 for APP S 674 3 0 3 5 180R9280 for APP S 674 5 1 9 0 180R9278 for APP S 674 21 38 are available on www ro solutions com 42 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Instruction Trouble shooting guide for APP and APP S 674 pumps 2 Reduced flow reduced pressure 2 1 Wear on pump 2 1 1 Dismantle the pump Typical signs of wear Large internal leakage due to 2 1 2 Check valve plate Polished surface all over the swash plate Valve plate has mar
31. and other impurities must be removed from pipes and hoses eg with a felt plug Fittings in screwed components to be sealed with O rings or bonded seals Chips or other impurities in the system may cause damage E m x Using teflon tape or packing yarn in joints may cause damage Grease Correctly limited quantities of grease prevent seizing E ky mi GC Too much grease may develop biofilm causing operational failures Assembly of coupling The coupling must be easy and simple Never use force when assembling the to assemble see product instruction coupling parts as this will damage the motor pump Coupling Insufficient distance and or misalign ment between the coupling flanges will damage the pump Ensure always to have 3 mm distance between coupling flanges Water supply EEEEEEEEEI iooooooooo 299099090 Fill system with water before starting Starting without water will cause to ensure lubrication and cooling damage Level indicator 00900000 looooooooo Level and temperature indicators must be fitted Follow installation instructions Missing or incorrectly connected level and temperature indicators cause damage Rotation direction Check pump drive motor rotation direction matches that of the pump prior to installation Incorrect rotation direction will damage the pump Bleeding 833533858 000000000 282999999 Bleeding the pump will ensure correct cooling and lubrication
32. arked according to the Low Voltage Directive 2006 95 EC 2 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 Itis 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 lt 10M 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 3 Installation The motor must be fixed on a stable clear and flat founda tion 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 co
33. articles can pass the main filter please contact Danfoss High Pressure because it is damaged bypassed or simply too Pumps sales office for further help poor Filtration efficiency must be 99 98 Beta 5000 at 10 um to prevent abnormal wear of the pump High fluid temperature If fluid temperature is above 50 C stop the Temperature gt 50 C will cause wear on internal pump immediately pump parts Mount a temperature switch and check its set point function The temperature switch will ensure that the pump stops at fluid temperatures gt 50 C Check internal parts see above 2 2 Low inlet pressure 2 2 1 Check that booster pump supplies the If the pressure drop across the filters is too high right pressure flow the booster pump does not deliver sufficient 2 2 2 Check if filters require replacement flow pressure No pressure or low pressure results in cavitation and insufficient internal lubrication causing wear on internal pump parts Mount a low pressure switch in front of the pump and check its set point function The low pressure switch ensures that the pump does not start until the inlet pressure has reached 1 bar 2 3 Rotation speed rpm 2 3 1 If VFD operated check frequency Speeds below min limit see User manual 2 3 2 Check that rotation speed of the electric result in insufficient internal lubrication causing motor is as stated on name plate on wear on the internal pump parts electric motor Check that th
34. asas The power requirements can be determined using one of the following guiding equations l min x bar 16 7 x m3 h x bar 0 26 x gpm x psi Required power kW or 1 or kW Calc factor Calc factor Calc factor hp 0 75 kW 1kW 1 34hp 1gpm 3 79 1 min 11 min 0 26gpm 1m h 4 40gpm 1gpm 0 23 m3 h 7 Temperature and 7 1 Operation corrosion Fluid temperature Ambient temperature 2 C to 50 C 35 6 F to 122 F dependent on 2 C to 50 C 35 6 F to 122 F the NaCl concentration The chart below illustrates the corrosive If the water pump is operated at high salinity resistance of different types of stainless steel always flush the water pump with fresh water at related to NaCl concentration and temperature operation stop in order to minimize the risk of crevice corrosion All critical parts of the APP water pump is made of Super Duplex eV ES TN NT ere 1111 60 TA e TNT IN TE NAT 100 000 1600 160000 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 7 Data sheet 8 Noise level 9 Filtration 8 APP pumps APP 1 5 3 5 7 2 Storage Storage temperature 40 C to 70 C 40 F to 158 F provided that the pump is drained of fluid and stored plugged The table indicates the approximate noise level in dB A measured at a distance of 1 m from the pump in a reverberation room Danfoti Frost pr
35. at the pump does 1 1 2 Check that booster pump is running not start until the inlet pressure has reached minimum inlet pressure see User manual 1 2 Pump reversing 1 2 1 Change the phase on the electric motor to Rotation direction for the APP or APP S 674 electric motor is running the wrong direction make it run clockwise pump is shown by an arrow on the label on the i e counter clockwise pump WARNING The pump must not run without water for more than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure in pump housing and will eventually break down 1 3 No rotation of electric motor 1 3 1 Check that main switch is switched on If motor type relay or the electrical fuse is 1 3 2 Check the electricity at the facility blown check that electric motor is sized 1 3 3 Ensure that motor relay is switched on correctly 1 3 4 Ensure that fuse is not blown 1 3 5 Ensure that booster pump is started 1 3 6 Check that the monitor switches are working correctly 1 3 7 Disconnect pump from electric motor and check that the motor is capable of running with no load 1 4 No rotation of pump 4 1 Ensure that coupling between electric motor and pump is connected Check if coupling is damaged Check that electric motor is sized correctly Check that the electrical installation is correctly sized Contact Danfoss Sales office for guidelines in how to troubleshoot internal pump parts 1 5 Axi
36. ater into the system s the filter control Replace filter element light on Contact serviceman Trace leakage if any Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved DK 6430 Nordborg Denmark User manual Appendices for IOM APP Pumps APP 1 5 3 5 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 55 User manual Appendices for IOM APP Pumps APP 1 5 3 5 Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 56 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013
37. ce of the pump unit 14 7 1 General NOT AN 14 12 Service and inspection interval for the pump 14 7 3 Sh bdownolt thes SEE EEE EEN 14 7 4 Disassembling and assembling the pump unit 15 7 5 Assembling the pulmpinib raya Rad aqar lap bee are tae 15 7 6 Procedure for mounting the pump onto the electric motor 15 77 Getting the pump unit back into operation 15 7 8 ETEN NG 15 8 Troubleshooting and scrapping EISES 16 8 1 General safety information ae 16 8 2 Operational conditions which can cause pump failures 16 8 3 MANE 16 8 4 FRE eg 16 8 5 KE eg io EE 16 8 6 PN 16 Sls 41 ao gt A ETNE Ee 18 Appendices for Installation Operation and Maintenance Manual 1 2 Data sheet for APP 1 5 3 5 pumps 1521508550 RR ya aa Yar rn k er 3 APP pump instruction APP 0 6 3 5 180R9065 me rra 13 ION EIBCERETHOLOIS 1190892 21 Recommended service intervals for APP pumps 180R9199 27 APP parts list NN 31 Troubleshooting GUIDE erica it ERA AS 39 Rigntand Wrong RE 49 180R9267 IOM APP Pumps v02 09 2013 3 User manual Installation Operation and Maintenance APP Pumps APP
38. dborg Denmark Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 38 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 MAKING MODERN LIVING POSSIBLE Guideline Trouble shooting guide for APP and APP S 674 pumps ro solutions com Instruction Table of Contents Trouble shooting guide for APP and APP S 674 pumps 40 Trouble shooting guide for APP and APP S 674 pumps Trouble shooting fish bone chart k 2 6 1 6 2 6 3 No flovv no pressure Reduced flow reduced pressure High torque on electric motor Noise from pump Noise from installation Typical signs of wear Valve plate Port plate Swash plate 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Trouble shooting guide for APP and APP S 674 pumps Instruction Trouble shooting q lv dWnd d t Sam e amp o c o 2 Ba U01 8 8ISUI WO1 9SION S dund uioJJ asion r 1030UJ 214329 9 ay Jadwep uoneJqiA S 3 1030U UO INDIO YBIH
39. e too fast flow turbulence through the pipes and thus increase the noise level Too stiff hoses cannot dampen the small pressure pulsations from the pump and subsequently vibrations occur in the system plant If the hoses are mounted directly on the frame the small pressure pulsations from the pump can be transferred to the frame and the rest of the system plant When no dampener is installed below the electric motor vibrations from the motor and pump may be transferred to the frame and the rest of the system plant Instruction Trouble shooting guide for APP and APP S 674 pumps 6 Typical signs of wear 6 1 Valve plate Picture 1 A normally worn valve plate has no marks scratches but only a slightly polished surface No scratches or marks should be felt The surface must be flat and level Picture 2 A worn valve plate has scratches and or a polished surface Even small scratches will give a loss of flow Scratches Picture 3 A good way to identify a worn valve plate is to hold a straight knife edge over the valve plate When holding it up to the light it will be possible to see any space between the knife edge and the valve plate See picture 3 If any light can be seen between the two arrows on the picture the valve plate is worn If any scratches or marks can be felt by running a fingernail over the surface the valve plate is worn The valve plate on picture 3 is highly damaged 180R9267 IOM APP 1 5 3
40. e is abnormal at operation speed check internal parts see above 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Small air bubbles will accumulate and create large bubbles causing internal cavitation and thus making the pump very noisy WARNING The pump can only run few minutes with air in the fluid without being damaged The pump and the inlet line must be com pletely bled before start up otherwise the pump will cavitate and make high noise WARNING The pump can only run few minutes with air in the fluid without being damaged Too high inlet pressure causes too high pressure inside the pump damaging the pistons and eventually the pump Inlet pressure below min limit causes cavitation and insufficient internal lubrication resulting in wear on internal pump parts Mount a low pressure switch in front of the pump and check its set point function The low pressure switch will ensure that the pump does not start until the min inlet pressure has been reached If pump rotates in wrong direction it will take in water from the high pressure outlet line Pressure will be built up inside the pump and it will eventually be damaged Higher rom than specified in the pump data sheet results in wear of the pistons i e pistons may be damaged High rpm will also increase pressure pulsations from the pump and the noise level will increase If rom is changed noise frequency will also change At too low outle
41. e motor rotor winding is not damaged 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 43 Instruction 3 High torque on electric motor 3 1 Too high outlet pressure from pump 3 2 Pump starts against pressure 3 3 Constant torque 3 4 Water pump damage 3 1 1 Check fluid salinity 3 1 2 Check temperature 3 1 3 Check pressure drop across RO membrane 3 2 1 Check that electric motor is correctly sized 3 2 2 Check internal parts see item 2 1 3 2 3 Systems with more than one electric motor installed Start motors simultaneously 3 3 1 Please contact Danfoss High Pressure Pumps sales office 3 4 1 Dismantle pump and check for wear 44 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Trouble shooting guide for APP and APP S 674 pumps Pump conditions may change more salt lower water temperature or scaling of RO membrane causing higher pressure resulting in higher motor torque Pumps run in parallel with cascade start may switch off the motor relay due to too high torque caused by high outlet pressure If the electric motor is too small for the APP or APP S 674 pump it cannot provide sufficient torque Too heavy damage in the pump will increase friction causing a high torque see item 6 Typical signs of wear Instruction 4 Noise from pump Trouble shooting guide for APP and APP 5674 pumps 4 1 Air in fluid 4 2 Bleeding conditions of pump 4 3 Min max nominal inlet
42. e of Contents APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 2 1 2 2 z 2 4 2 5 Identification System design Open ended systems with water supply from a tank Open ended systems with direct water supply Problems with reversing pumps General guidelines for calculation of pressure losses General comments on Building up the pump unit Mounting Direction of rotation Orientation Protection from too high pressures Connections Initial start up Operation Temperature Pressure Dry running Disconnection Storage Open ended systems with water supply from tank Open ended systems with direct water supply Service Periodic maintenance Repair 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Instruction 1 2 Identification System design Danfoti APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 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 In order to avoid this it is recommended to install a pre stressed check valve or a pressure switch in the pump inlet The opening pressure of the check valve must be bigger or equal to the inlet pressure 2 1 Open ended systems with water supply from a tank The numbers 1 3 refer to the drawing below In order t
43. e vessel works as an accumulator Filtration for guidance on how to select and will send flow backwards in case of the the right filter Thoroughly clean pipes and pump stops momentarily flush system prior to start up 8 A safety valve 8 can be installed in order 3 Place a monitoring pressure switch 3 set to avoid system damage as the Danfoss at min inlet pressure between filter and APP pump creates pressure and flow pump inlet The monitoring switch must immediately after start up regardless of stop the pump at pressures lower than any counter pressure minimum pressure 4 Use flexible hoses 4 to minimize vibrations and noise 5 n 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 Media filter 9 3 1 1 p e er Y Y 4 i Permeate T 5 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 11 Data sheet 12 Service Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark APP pumps APP 1 5 3 5 12 1 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 produc tion If Danfoss recommendations concerning system design are not followed i
44. e with IEC 60352 2 Tightening torques for terminal board screws a EE ey 12 35 55 18 Ensure that the terminal box is clean and dry Unused glands must be closed Check the terminal box gasket before it is remounted 5 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 connections must be checked and tightened if necessary 22 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 HOYER MOTORS Bearing size and type are specified on the rating plate Motor types HMA2 and HMC2 is as standard with lifetime greased bearing with motor size lt 225 Motor types MS and Y2E is as standard with lifetime greased bearing with motor size lt 160 Typical duty hours for lifetime lubricated bearings 56 160 VEE 40 000h 180 2 35 000h 200 2 27 000h 225 2 23 000h 160925 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 Grease 2 pole 4 pole 6 pole 8 pole size 8 h h h h 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 2000 6000 7000 7000 280
45. ems 000000000 000000000 299999998 No water supply e Is the water supply ok e s water supplied to the pump Lower inlet e Is the water in the tank very hot le above 50 Is the electric motor of the pump unit rotating e s water coming Yes temperature or out of the tap P provide better cooling Are all taps open Is the control light for low pump suction pressure on e Is the power supply ok Are control lights on The filter is clogging s the filter clogged s the filter control light on e s water coming through the filter A blown fuse or short circuit Check power supply and fuses and contact Replace filter element electrician Replace filter element Contact serviceman Turn on the tap for water supply Trouble shooting Closed water systems The system does not work e Is there sufficient water in the tank e Is the electric motor of the pump unit rotating Is the water in the tank BG very hot le above 50 At temperatures higher than 50 the e Is the power supply ok pump drive cuts out Consequently the cooler must be checked cleaned Are control lights on A blown fuse or short Circuit s the filter clogged Check power supply and fuses and contact electrician Fill w
46. enerates more noise than flexible mounting 9 Pipe mounting direct to the pump increases the noise level compared to a flexible hose the filter 50 000 particles pass through it compared to only 20 particles in a filter vvith an efficiency of 99 98 For more information on the importance of proper filtration please consult our publication Filtration code number 521B1009 which also will provide you with an explanation of filtration definitions and a guidance on how to select the right filter Data sheet 10 Dimensions APP pumps APP 1 5 3 5 10 1 Pump 36 1 42 119 8 4 72 l 6 0 23 106 4 4 19 28 1 10 gt 1 0 04 10 7 0 42 20 0 79 eo EE L H a Parallel key DIN 6885 EI Pump mounting flange SAEA 2 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 9 Data sheet 11 Installation 10 APP pumps APP 1 5 3 5 10 2 Complete unit IEC Electric motor a m sasi Ls a m 166 3 0 3 0 kW IEC 10012 7 IEC 100L 2 808 wes se ms lm ne we ms vea we 11 1 Mounting The figure below illustrates how to mount the pump and connect it to electric motor combus tion engine A Flexible coupling B Bell housing C Motor shaft If alternative mounting is required please contact Danfoss Sales Organization for further information Min 5 mm
47. equipment CP8 Check the factory settings of the safety relief valves or See Data sheets for the used pressure relief valves 8 amp 9 valves CP9 Check the settings of the pressure transmitter switch 3 set See Data sheet or Instruction at min inlet pressure appendices 1 and 2 CP10 Check that all pressure indicators PI are selected to be able 1 Scaling should at least be 1 Bar to measure the system pressure range or more precise P11 Check coupling distance air gab movement of the spider i P12 Check correct connections on the pump in amp outlet 57 75 CP13 Check piping for possible air gaps gt 5 7 Lifting and positioning 5 9 Electrics Lift the pump unit onto base Remember All electrical installation work must be carried vibration dampeners if needed Fasten the out by authorized personnel in accordance with motor to the base EN60204 1 and or local regulations see also Safety chapter 2 See also chapter 4 Arrival inspection transporta tion handling lifting and storage Turn off the safety circuit breaker and lock it Mount the power cable on the electric motor 5 8 Mount the different equipment connections pipes tubes check and safety relief If a VFD is used adjust the protective motor valves etc switch VFD to the current limits found on the name plate of the electric motor e The hard piping and flexible hoses used must be of proper design and must be installed in acc
48. es can cause cavitation A 3 10 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 4 Transport and handling Small pumps which have a weight below 20 kilos weight can be found in appendix 1 Data sheet 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 User manual Installation Operation and Maintenance APP Pumps APP 1 5 3 5 Pumps which have a weight above 20 kilos see appendix 1 Data sheet must be handled by using lifting eyes and slings Never use only one sling and make sure the slings does not slip off the pump When the pump is mounted together with an electric motor the pump unit always weigh more than 20 kilos and must be handled by using slings around the pump unit See below examples of where to not to attach the lifting slings on the pump unit Correct lifting with 2 separate slings 180R9267 IOM APP Pumps v02 09 2013 Wrong lifting When lifting the pump unit one sling must be attached to the electric motor and one sling around the pump 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 p
49. essure B Stop the high pressure pump 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 User manual Installation Operation and Maintenance APP Pumps APP 1 5 3 5 A F 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 Forthe 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 Carefully pull the pump out of the bell housing by using lifting equipment if necessary 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 assembl
50. hen preparing the pump for long term storage or for 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 the Danfoss Sales Organization Recommended procedure 5 5 1 Open ended systems with water supply from tank 1 Emptythe tank of water and empty the pump housing through the lower bleeding plug When the pump is empty retighten the plug 2 Through the upper bleeding plug fill the pump housing with anti freeze medium Pour anti freeze medium into the tank Connect a hose to the outlet of the pump and lead the other end of the hose back to tank 3 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 19 Danfoti Instruction APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 5 5 2Open ended systems with direct water hose to the inlet port of the pump and via supply another hose return the flow from the 1 Disconnect the water supply to the pump outlet port to the tank with anti freeze 2 Through the lower bleeding plug empty additives the pump housing of water and close it 4 Quickly start and stop the pump Make sure again that the pump does not run dry The pump 3 Connect the pump to a tank of e g 25 litre is now protected against internal corrosion 6 ga
51. ing 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 User manual Installation Operation and Maintenance APP Pumps APP 1 5 3 5 180R9267 IOM APP Pumps v02 09 2013 17 Danfoti User manual Installation Operation and Maintenance APP Pumps APP 1 5 3 5 Subject index A G S Address 7 8 15 General information 7 SE s ers Sk ea ec 6 7 8 9 12 13 14 16 Air bubbles 9 Guideline vas vU e la daa ns 16 Safety kran 7 Appendix 7 8 9 10 11 14 15 16 Scrapping Entera sio beeen eG oe os 16 Application range 8 H Serial number 4 Approval a vx x x R k 6 Handling x2 o hm mms 7 9 12 15 Servicing NEI EE 6 8 14 Arrival Mur 912 15 COW Ms xy ono aid Hee dake ew a en 14 15 Assemblmg anaa 12 15 Space requirement 8 Inspection aoo me Eoo b eS e545 13 14 Spare DAM s d s ek wa om
52. ing the pump unit A Remove all connections from the pump B Disassemble the pump according to the Disassembling and Assembling Instruction available at www ro solutions 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 3 Parts list D Ifthe 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 180R9267 IOM APP Pumps v02 09 2013 Productinformation see label on product Only 1 product on each report Code number Serial number Operational conditions Application Inlet pressure Rpm pump motor only Hours of operation Outlet pressure Number of duty cycles valves only Filtration qi absolute nominal OW Water temperature Pumps in parallel yes no Returns without a return number will be rejected 11 7 5 Assembling the pump unit Assemble the pump according to the Dis assembling and Assembling Instruction available at www ro solutions danfoss com 7 6 Procedure for mounting the p
53. isk of cavitation the inlet pressure at the pump must be in accordance with the specifications mentioned in Data sheet 521B0850 bar m psi ft The inlet line connection must be properly tightened as possible entrance of air will cause cavitation The suction conditions can be optimized according to below guidelines In smooth pipes and hoses 40 gpm US 150 L minl bar psi In 90 bends 2 5 General comments on Filtration A good filtration is vital to ensure a long and trouble free life of the pump When selecting a filter or strainer please note that filter materials should be compatible with water i e should neither corrode or dissolve Also be aware of the electrochemical series of the applied materials Main filter must have a fineness of 10 um abs 8 10 25000 The pressure loss across the filter should be monitored 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Water tank Must be made of corrosion proof material such as Stainless steel or plastic and must be sealed to prevent entrance of impurities from the environ ment Instruction APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 Automatic pressure equalization between tank and surroundings must be ensured Inlet from the water supply and inlet to the pump should be placed in opposite ends of the tank to calm and deaerate the water and to ensure optimum opport
54. ks scratches on the Normally only half of the swash plate the surface facing the port plate Minor wear pressure side is polished See index 6 3 on valve plate can cause large internal leakage See Index 6 1 If the ring is missing the piston is very worn Check port plate Port plate has marks scratches on the surface facing the valve plate Minor wear on port plate can cause large internal leakage See Index 6 2 Check cylinder barrel Liners in cylinder barrel may be scratched or worn Insert a piston in the liner and check the fit If there is any space clearance between liner and piston liner or piston is worn Pre treatment Analyse fluid for content of particles Check that filters are OK and working correctly Main filtration Check that the correct filter type is used The filters can be bypassed even if they are particles in fluid must not exceed 10 um correctly mounted Some filters can create Danfoss High Pressure Pumps supplies channelling where particles can pass through filters please contact the sales office the filter in tunnels String wounded filters are typically channelling filters A string wounded filter may have a filtration efficiency of only 50 which will cause internal wear and must always be followed by a main filter Fluid type The APP and APP S 674 pumps are designed Insufficient filtration means that too many or for seawater operation for any other fluid too large hard p
55. l of anti freeze additive Connect a and frost 6 Service 6 1 Periodic maintenance 6 2 Repair The APP pump is designed so that lubrication In case of irregular function in the pump please follows from the water itself and there is thusno contact the Danfoss Sales Organisation oil in the pump The pump requires no periodic replacements of seals and valve parts Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 20 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Electric Motors Motor Manual HOYER MOTORS 1 General This manual concerns the following types of standard induction motors from Hoyer HMA2 HMC2 HMD HMT MS Y2E1 Y2E2 YDT These motors are manufactured in accordance with IEG EN 60034 4 and IEG EN 60072 Motors are rated for the ambient temperature range 20 C to 40 C and site altitudes lt 1000 m above sea level Low voltage motors are components for installation in machinery They are CE m
56. o eliminate the risk of cavitation observe the following guidelines 1 Place the tank above the pump water level in the tank should always be above the pump 2 Place the inlet filter before the tank 3 Dimension the inlet line to obtain mini mum pressure loss large flow area minimum pipe length minimum number of bends connections fittings with small pressure losses 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 2 2 Open ended systems with direct water supply The pump is supplied with water direct from a booster pump The water pressure must not exceed 5 bar abs 72 5 psi 2 3 Problems with reversing pumps If exposed to high pressure in the outlet while the electric motor is not energized the pumps will start spinning backwards This will not harm the pumps as long as the pressure in the inlet does not exceed the max pressure of 5 bar If a non return valve is mounted in the inlet line a low pressure relief valve will also be required Alternatively a high pressure check valve could be mounted in the pump discharge line to prevent the pump from reversing The dotted setup ensures that the inlet pressure does not exceed the 5 bar abs when a non return valve is mounted in the inlet 15 Instruction APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 2 4 General guidelines for calculation of pressure losses In order to avoid the r
57. onitor 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 A 5 18 Check the filter condition Evaluate contamination found in filter replace filter elements if necessary A 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 13 User manual 6 7 Operation of pump unit Maintenance and service of the pump unit Danfotk Installation Operation and Maintenance APP Pumps APP 1 5 3 5 A 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 de
58. ordance with the manufactur 5 10 Instrumentation er s recommendations see also Data sheet The pressure switch sensor should be mounted for Hose and hose fittings and Instruction for as close to the pump as possible It is recom Assembling Hose kit both available on mended to test the pressure sensor switch via an www ro solutions danfoss com instrumentation manifold Misalignment of the hard pipes may give unintended stress on the pump port Mount the pressure switch sensors according to connections and may damage the pump the manufacturer s instructions e Prevent excessive external pipe load e Do not connect piping by applying external force use of wrenches crane etc Piping 5 11 Connections must be aligned without residual stress Mount and tighten connections and check e Do not mount expansion joints so that their valve s as specified force applies internal pressure on the pump connections 180R9267 IOM APP Pumps v02 09 2013 User manual Danfoti Installation Operation and Maintenance APP Pumps APP 1 5 3 5 5 12 Ensure free flow Ensure free flow from the safety relief valves 8 and 9 figure 1 item 5 6 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
59. oss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 30 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 MAKING MODERN LIVING POSSIBLE Parts list APP Pumps APP 1 5 3 5 APM 1 8 2 9 APP 1 5 3 5 ro solutions com Parts list Table of Contents Parts list APP 21 43 521B0941 32 APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 1 General p Parts list APP 0 6 1 0 Compact S Exploded view APP 0 6 1 0 Compact 4 Parts list APP 0 6 1 0 and APM O 8 1 2 5i Exploded view APP 0 6 1 0 and APM 0 8 1 2 6 Parts list APP 1 5 2 5 and APM 1 8 2 9 7 Exploded view APP 1 5 2 5 and APM 1 8 2 9 8 Parts list APP 3 0 3 5 9 Exploded view APP 3 0 3 5 10 Parts list APP 5 1 10 2 11 Exploded view APP 5 1 10 2 12 Parts list APP W 5 1 10 2 13 Exploded view APP W 5 1 10 2 14 Parts list APP 11 13 15 Exploded view APP 11 13 16 Parts list APP 16 19 17 Exploded view APP 16 19 18 Parts list APP 22 19 Exploded view APP 22 20 Parts list APP 21 26
60. otection is required at temperatures below 2 C Danfoss recommends to use DOW FROST from DOW Chemical Company or Chilsafe mono propylene glycol from Arco Chemical Company 60 bar 870 psi 1500 rpm 60 bar 870 psi 3000 rpm Generally noise will be reduced if speed is reduced and vice versa Use flexible hoses in order to minimize vibrations and noise Since the pump is typically mounted on a bell housing or frame the noise level must be determined for the complete unit system It is therefore very important that the motor pump unit is mounted correctly on a frame with antivibration isolation to minimize vibrations and noise 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 um We recommend to use precision depth filter cartridges rated 10um abs 810 gt 5000 equivalent to a filtration efficiency of 99 98 Bag filters and string wound filter cartridges typically have only 50 filtration efficiency This means that for each 100 000 particles reaching 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 The noise level is influenced by The speed of the pump high rpm create more noise than low rpm o Rigid mounting of the pump g
61. p is not being serviced according to Danfoss specifications end of life o 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 180R9267 IOM APP Pumps v02 09 2013 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 ANS 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 tempera tures 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 tempera tures and shall not be liable for any consequen tial or incidental damages 8 6 Scrapp
62. partment 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 mainte nance 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 A 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 Instruc tion and appendix 4 Instruction for recom mended service intervals For
63. r svendhoyer com svendhoyer com MAKING MODERN LIVING POSSIBLE Instruction Recommended service intervals for APP pumps ro solutions com Instruction Table of Contents Recommended service intervals for APP pumps 180R9199 1 General information 2 Design features 28 Recommended service intervals for APP pumps 1 General information 2 Design features 3 Appendix 1 This guideline provides information on the The recommendation is for guidance only recommended service intervals The recommen dation is based upon good engineering practice and on experience gained from operation even under extreme conditions Danfoss APP pumps are designed for long If the Danfoss recommendations concerning operation and low maintenance and life cycle system design see our data sheet are not costs followed the service life of the APP pumps might be affected Danfoss guarantees 8 000 hours service free operation however max 18 months from date of The recommended service intervals on the production After 8 000 operation hours it is different parts in the APP pumps appear from the recommended to inspect the pump and replace table below worn parts if any ms q Description maera servicemen 211 end flange Dry part AISI 316L 5 7 9 Piston Super Duplex and PEEK Recommended inspection on a yearly basis and evaluated acc to app 1 s Lars s 1 renerne sumDute
64. r water hydraulic systems FI Leger TITTET E JET sets SSH ST danfoss high pressurepumps com 180R9042 Choice of material Rubber Plastic Stainless steel Always use system components made of corrosion proof materials Non corrosion proof materials may cause damage Choice of filter 000000000 000000000 000009999 Install a 10 micron absolute filter with pressure switch Return filter with bypass valve and poorer filterability than 10 H will damage the system Filter location Locate the return filter in the return line Placing the return filter upstream of the immediately before the tank final load may damage the pump Pump location looooooooo 000000000 233999399 Pump always to be placed below water surface level Pump location above water surface level will cause damage Suction conditions System to be dimensioned to provide a suction pressure of the pump inlet of max 0 1 bar vacuum Poor suction conditions will cause malfunction and damage the pump Pressure Relief valve Pressure relief valve to be mounted vertically or with vertical outlet and connected to return hose or tank Coupling the pressure relief valve outlet directly to the pump inlet may damage the pump Water supply 000000000 000000000 009999909 System to be filled via filter Filling system with unfiltered water causes damage Installation Impurities Prior to installation burrs and chips
65. re made of high corrosion resistant materials e g Duplex EN1 4462 UNS 531803 532205 and Super Duplex EN1 4410 UNS 532750 stainless steel and carbon reinforced PEEK High efficiency APP 3 5 APP pumps 1 5 APP 1 8 APP 2 2 APP 2 5 APP3 0 18083043 18083044 180B3045 18083046 18083030 180B3032 20 5 Rated flow 3000 rpm m h de gpm 7 5 Outlet min pressure bar psi 290 290 oe ls s N N il Outlet max pressure continuous Outlet max pressure intermittent Inlet min pressure bar b 5 5 10 10 Inlet max pressure ar Si bar continuous Inlet max pressure peak Max speed continuous 3450 3450 pm Power requirement at kW 80 bar and 3000 rpm g D Torque at 80 bar Nm 14 2 lbf ft 10 5 Weight 17 Integrated flushing valve YES YES 1 Typical average flow at 80 bar 1160 psi 2 For lower pressure please contact 10 Danfoss RO Sales Organization 5 Fo 3 For higher pressure please contact Danfoss RO Sales Organzation N A UT Ww CO A 180R9267 APP 1 5 3 5 Appendices v04 11 2013 2 1 26 3 0 N o N w o UT 9 2 11 4 13 2 N N O 290 N N 1160 1160 1160 100 10 1 1450 1450 1450 057 0 5 0 5 7 3 7 3 7 3 5 5 10 10 UT 72 5 ul N n x e 4 4 4 UT 1 Ls 3450 3000 3450 3000 700 70
66. roper 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 responsibil ity of applying good judgment when operating and maintaining the pump and its compo nents 2 2 Preferred system design Danfoss recommends to build systems with a high degree of safety Danfoss preferred system design and P amp ID are found in appendix 1 Data sheet and appendix 2 Instruction User manual 3 Technical data Davis Installation Operation and Maintenance APP Pumps APP 1 5 3 5 A It is always the system builders 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 shut down 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 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 and Brackish Water Reverse Osmosis BWRO system
67. spare parts and service tools please see appendix 3 Parts list 180R9267 IOM APP Pumps v02 09 2013 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 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 Open the pressure valves at the brine site to release the pr
68. t pressure the pump will create higher pressure pulsations and thus make noise Too low pressure also causes insufficient internal lubrication and wear on internal parts Pump may eventually be damaged Too high outlet pressure may damage the pump Noise frequency changes during soft start up stop 45 Instruction 5 Noise from installation 5 1 Inlet outlet connections hoses pipes 5 2 Length dimension of inlet outlet line 5 3 Hose stiffness 5 4 Hoses pipes mounted directly on frame 5 5 Vibration dampener under the electric motor 5 1 1 Use flexible hoses at inlet outlet connec tions Danfoss can provide flexible hoses Please contact Danfoss High Pressure Pumps sales office for further information 5 1 2 Mount the connections to the frame by a vibration dampener mounting plate Increase pipe diameter and or reduce the number of bends Use a more flexible hose Danfoss can provide flexible hoses Please contact Danfoss High Pressure Pumps sales office for further information Mount the connections to the frame by a vibration dampener mounting plate Mount a vibration dampener below the motor pump 46 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 Trouble shooting guide for APP and APP S 674 pumps Non flexible connections mounted directly on the frame will cause even small pressure pulsations from pump and create vibrations in the system plant Too small pipes or too many bends may creat
69. t will strongly influence the life of the APP pumps 12 2 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 Standstill 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 Danfoti 12 3 Repair In case of irregular function of the APP please contact the Danfoss RO Solutions Sales Organisa tion Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 12 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 MAKING MODERN LIVING POSSIBLE APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 ro solutions com Instruction APP pump instruction APP 0 6 3 5 180R9065 Tabl
70. th suitable equipment In case the pump delivered is ATEX certified the additional ATEX instruction must also be read Protective garments must be worn 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 180R9267 IOM APP Pumps v02 09 2013 Your local Danfoss pump distributor can be found on our homepage Data sheets and instructions on all accessories are available on www ro solutions danfoss com EC Declaration of Conformity can be found on page 5 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 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 A 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 A All pipe and hose connections must be stress free mounted securely fastened to the pump and well supported Imp
71. tions com User manual Table of Contents Appendices for IOM APP Pumps APP 1 5 3 5 ou ES Data sheet for APP 1 5 3 5 pumps 521B0850 3 APP pump instruction APP 0 6 3 5 180R9065 RR CHER we EE n s 13 IOM Electric motors T EE 21 Recommended service intervals for APP pumps 180R9199 27 APP paris S ii b n aa s 31 Trouble SHOOUNG QUIAS evocar UR Rp Pes 39 Rightand wrong 180R9042 a airis EE EE 49 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 MAKING MODERN LIVING POSSIBLE APP pumps APP 1 5 3 5 ro solutions com Data sheet Data sheet for APP 1 5 3 5 pumps 521B0850 Table of Contents 1 General information APP pumps APP 1 5 3 5 1 General information Benefits 3 Technical data 4 Flushing valve Flow at different rom 6 Power requirements 7 Temperature and corrosion 7 1 Operation 1 2 Storage 8 Noise level 9 Filtration 10 Dimensions 10 1 Pump 10 2 Complete unit 11 Installation 11 1 Mounting 11 2 Open ended system with direct water supply 11 3 RO system with APP pump 12 Service 12 1 Warranty 12 2 Maintenance 12 3 Repair APP 1 5 APP 1 8 APP 2 2 APP 2 5 APP 3 0 and APP 3 5 pumps are designed to supply low viscosity and corrosive fluids under high pressure e g in seawater reverse osmosis filtration applications and for high pressure saltwater pumping
72. trical connection is maintained both for the main supply and earth connection Installations must be in accordance with actual standards for installation in the Zone 22 area It is recommended that EN 50281 2 is followed according 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 ringis 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 re lubricated 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 zone 22 motors must only be carried out by qualified specialists 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 23 24 HOYER MOTORS Motor Manual Connection diagram AnschluBdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexion Collegamento coeHHHEHMH Schemat polaczen u V W C C N V 1 0 L ke 2 L L La 180R9267 IOM APP 1 5 3 5 Appendices v04
73. ump onto the electric motor A 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 inspec tion transportation handling lifting and storage and Installation and commissioning chapter 5 7 8 Storage ofthe pump If the pump has to be shut down for a longer period instructions can be found in appendix 2 Instruction 15 User manual 8 Troubleshooting and scrapping criteria Installation Operation and Maintenance APP Pumps APP 1 5 3 5 A 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 8 2 Operational conditions which can cause pump failures The following conditions can cause a pump failure The pump is running dry o The inlet pressure is too high The inlet pressure is too low The temperature of the fluid is too high o The ambient temperature is too high o 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 9 The filtration is insufficient o The pum
74. ump unit How to mount the pump and the electric motor correctly see appendix 1 Data sheet or appendix 2 Instruction A Incorrect lifting can result in personal injury and or damage to the pump unit see appendix 2 Instruction 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 User manual 5 Installation and commissioning Installation Operation and Maintenance APP Pumps APP 1 5 3 5 A 5 1 Important dimensions Physical dimensions and connections of the pump unit are described in appendix 1 Data sheet A 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 A 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 ETT TR 180R9267 IOM APP Pumps
75. unity for particles to settle Pump suction line should be placed relatively high above the tank bottom in order to prevent settled particles from being led into the pump We recommend a separation wall to separate the inlet from the outlet end of the tank Monitoring It is recommended to continuously monitor the following conditions VVater level in the tank 9 Filter contamination Pressure inlet and outlet side of the pump 3 Building up the pump 3 1 Mounting unit Please also see hints in Right and VVrong If alternative mounting is desired please contact the Danfoss Sales Organization Choose proper tolerances to ensure an easy mounting of the elastic coupling vvithout use of tools A Elastic coupling B Ball housing C Motor shaft Please take care to observe the recommended length tolerances of the chosen coupling as an axial force on the pump will damage the pump max 0 25 mm max 0 01 inch 3 2 Direction of rotation Is indicated by means of an arrow at the inlet side of the pump P Outlet T Inlet 180R9267 IOM APP 1 5 3 5 Appendices v04 11 2013 17 p Instruction APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 3 3 Orientation The valve should be placed as close to the pump The pump can be mounted oriented in any as possible The opening characteristics of the horizontal direction Vertically only with the shaft valve must not result in
76. upling 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 Motor Manual 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 4 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 1EC60034 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 accordanc

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