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APP 21-43 - Depco Pump Company

1. NaCl vs temperature 80 C 70 Super Duplex 60 50 40 30 20 a 100 1000 10000 100 000 ppm NaCl 160 1600 16000 160000 ppm 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 23 nstruction APP pump instruction APP 21 43 5 2 Pressure 5 5 Storage The inlet pressure for APP 21 43 must be min 2 bar 30 psi and max 5 bar 72 5 psi At lovver Storage temperature pressures the pump vvill cavitate resulting in Min 40 C to max 70 C damage of the pump Min 40 F to max 158 F Max inlet pressure peak e g in case the pump When preparing the pump for long term storage stops momentarily up to 10 bar 145 psi are or for temperatures below the freezing point acceptable flush the pump with an anti freeze medium type monopropylene glycol to prevent internal Max pressure on the pump s outlet line should corrosion or frost in the pump be limited at 80 bar 1 160 psi continuously 70 bar for APP 43 For further information on anti freeze media please contact Danfoss High Pressure Pumps Note The pump unit should include a pressure sales organization gauge on the high pressure side Recommended procedure 5 3 Dryrunning 1 Disconnect the water supply to the pump When running the pump must always be 2 Through the lower bleeding plug empty connected to the water supply in order to avoid the p
2. 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 13 Data sheet APP 21 43 13 3 RO system vvith APP pump pressure relief valve 9 in order to avoid 1 Dimension the inlet line to obtain mini high pressure peaks in case the pump stops mum pressure loss large flovv minimum momentarilly or spinning backvvards pipe length minimum number of bends 6 For easy system bleeding and flushing a connections and fittings vvith small bypass non return valve 6 is integrated in pressure losses the APP pump 2 Place an inlet filter 1 in front of the APP 7 A non return valve 7 in outlet can be pump 2 Please consult section 10 installed in order to avoid backspin of the Filtration for guidance on hovv to select pump The volume of vvater in the mem the right filter Thoroughly clean pipes and brane vessel vvorks as an accumulator and flush system prior to start up vvill send flovv backvvards in case of the 3 Place a monitoring pressure svvitch 3 set pump stops momentarily at min inlet pressure betvveen filter and 8 A safety valve or a pressure relief valve 8 pump inlet The monitoring switch must can be installed in order to avoid system stop the pump at pressures lower than damage as the Danfoss APP pump creates minimum pressure pressure and flow immediately after 4 Use flexible hoses 4 to minimize vibrations start up regardless of any counterpressure and noise 5 n o
3. 6 7 8 16 ROUTER cr aes CE s i 10 15 Rotation vot re des 8 13 S Safety iss ls ess 6 7 8 9 12 13 14 16 Safety valve esos ERR 7 Scrapping criteria 16 Serial number 4 Servicingu c her ERE ket 6 8 14 Shut dowtk sz sla dos vass malen dd 14 15 Space requirement 8 Sparepart sse re 14 Startups ce Segre ed ARR X AY e kaka 8 Storage v ed PEE 9 10 12 15 SVimbols s sod a RS sr 6 System 6 7 8 9 11 12 13 14 Systems nd aoe oe La a seks 7 8 T Table of Contents 2 Technical data 8 Temperature 7 10 11 12 13 14 16 Transportation 6 9 12 15 Troubleshooting 14 16 V Valve 7 11 12 13 14 16 Ww Warming A got RR 6 9 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 18 180R9266 IOM APP Pumps v03 06 2013 MAKING MODERN LIVING POSSIBLE User manu
4. E 16 8 4 Electrical 5507500007 16 8 5 Responsibility Rm 16 8 6 Scrapping criterl vs sissi ness seven EN EET raskere e ri 16 SUBJECT Ae deg 000 18 Appendices for Installation Operation and Maintenance Manual 1 2 Data sheet for APP 21 43 pumps 521B0852 3 APP pump instruction APP 21 43 180 9133 17 IOM Electricimotors 180R9230 esed s dux pe ehe AN tare B RO Re dee m l URS 27 Recommended service intervals for APP pumps 180R9199 33 APP parts list 52180941 eet gien ix E DUE rk ERR C HERR EE EE dead eR Wen 37 Trouble shooting TERE DRE Y UR E wr e 45 Right and wrong 180R9042 iii te n ph i ao ur es TIS ER Ere ES 55 180R9266 IOM APP Pumps v03 06 2013 3 x User manual Installation Operation and Maintenance APP Pumps APP 21 43 Validity This manual is valid for APP pumps with the following code numbers serial numbers APP 21 1200 Code no 180B3051 Serial no 05 APP 21 1500 Code no 180B3052 Serial no 03 APP 24 1200 Code no 180B3054 Serial no 05 APP 24 1500 Code no 180B3055 Serial no 02 APP 26 1200 Code no 180B3056 Serial no 05 APP 26 1500 Code no 180B3057 Serial no 05 APP 30 1200 Code no 180B3060 Serial no 03 APP 30 1500 Code no 180B3062 Seri
5. APP 43 1700 M S NY Furthermore these diagrams shows that the flow can be changed by changing the rotation speed of the pump The flow rpm ratio is constant and the required flow can be obtained by changing the rotation speed to a corresponding value Thus the required rpm can be determined as Required flow x Rated rpm Required rpm Rated flow 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Data sheet APP 21 43 6 Flushing valve Pressure drop Flushing valve characteristic bar 3 2 5 2 1 5 1 0 5 Flow 3 0 T T T T m h o KS x ES Be o 7 Power requirements Pump model Flow Pressure rpm Calc 60 bar 70 bar 80 bar factor l min m h gpm 870 psi 1015 psi 1160 psi APP 21 1200 352 21 1 929 41 kW 48 kW 55 kW 1200 516 APP 21 1500 365 21 9 96 4 44 kW 52 kW 59 kW 1500 498 APP 24 1200 412 24 7 109 48 kW 56 kW 64 kW 1200 516 APP 24 1500 402 24 1 106 1 49 kW 57 kW 65 kW 1500 496 APP 26 1200 443 26 6 117 2 52 kW 61 kW 70 kW 1200 510 APP 26 1500 443 26 6 117 2 53 kW 62 kW 71kW 1500 504 APP 30 1200 512 30 7 135 1 61 kW 71kW 81 kW 1200 504 APP 30 1500 522 31 3 137 7 62 kW 73 kW 83 kW 1500 504 APP 38 1500 640 38 4 168 9 76 kW 88 kW 101 kW 1500 505 APP 43 1700 743 44 6 196 4 91 kW 106 kW 1700 503 The power requirement
6. 11101 BEL ug ETT WNZ WNOL eee WNL UNZ 0 01122 br Ys ET ZZ UNE WNOE zz d _ uq TZ ZF 449 S Ys TZZ 11141 8 UNE F UJ Ys ET ZZ WNZ F WNOL NE WNOE Ii 41 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 i Parts list APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 22 Parts list Note 7 APP 30 43 The parts listed are not sold E separately only in various kits E SB E SE Exploded view see next page 2 5 8 en 00 TS ES E 9 jz amp ga g S a H018 Z 2512 v 2 n gt z 3 a 32 13 9g as S2 2 9 EIEE EE S E 5212 o So Zb Z E Sie Sole Rae Pos Qnt Designation Material di E E G a n a lt o d E d m d a Bi 21 51 BE 52 313 5151 1 1 Housing Duplex PEEK 2 2 Pin 6x10 AISI 316 x 3 2 Bleeding plug Super Duplex x 4 4 O ring 11x2 NBR x 5 17 Screw M8x30 AISI 316 x 9 1 O ring 228x4 NBR x 10 2 O ring 9 19x2 62 NBR x 11 1 End flange Duplex 12 1 Lifting eye AISI 3169 13 1 Screw M8x16 AISI 316 x 31 1 Swash plate Super Duplex 34 2 Pin 10 5x20 Duplex x 61 1 Cylinder barrel Super Duplex PEEK x 62 4 Spring Duplex x x x 63 1 Spring guide PP x x x 64 1 Retainer ball Super Duplex DLC x x x 65 1 Retainer plate Super Duplex x x x 66 9 Piston Su
7. Media filter Permeate m Brine Y 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 19 nstruction APP pump instruction APP 21 43 2 3 Reversible pumps If exposed to high pressure in the outlet while the electric motor is not energized the pumps vvill start spinning backvvards This vvill not harm the pumps as long as the pressure in the inlet does not exceed the max pressure peak of 10 bar 145 psi If a non return valve is mounted in the inlet line a low pressure relief valve is also required as protection against high pressure pulses and high pressure in general Alternatively a high pressure check valve can be mounted in the pump discharge line to prevent the pump from reversing The dotted setup ensures that the inlet pressure does not exceed 10 bar 145 psi when a non return valve is mounted in the inlet In order to avoid the risk of cavitation the inlet pressure for APP 21 38 must be min 2 bar 29 psi And 3 bar 43 5 psi for APP 43 The inlet line connection must be properly tightened as possible entrance of air will cause cavitation 2 4 General comments Filtration A good filtration is vital to ensure a long and trouble free life of the pump As water has very low viscosity the APP pumps have been designed with very narrow clearance in order to control internal leakage rates and improve component performance The
8. A from top of bell housing to the button of coupling claw 4 Mount the coupling on motor shaft Ensure the coupling and motor flange are not in contact with each other 5 Measure from motor flange to the top of the coupling That measurement B shall be 3 5 mm 0 12 0 2 inch shorter than the measurement A A and B can be found on the next page 20 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 nstruction APP pump instruction APP 21 43 6 Adjust respectively verify the measure ment and secure both couplings vvith the right torques on the locking screvvs see coupling operation amp mounting instruction 7 Mount the elastic gear ring and mount the bell housing pump on the motor After mounting it must be possible to move the elastic gear ring 3 5 mm 0 12 0 2 inch axial C The check can be done through the inspection hole of bell housing Secure flange bolts with the right torque If alternative mounting is desired please contact Danfoss High Pressure Pumps sales organization Choose proper tolerances to ensure an easy mounting of the elastic coupling without use of tools Please take care to observe the recommended length tolerances of the chosen coupling as an axial force on the pump will damage the pump C can be found on the drawing below 1 Bolts and nuts torque 75 Nm 5 Nm Bolts and nuts torque 40 Nm 4 Nm 3 Torque see table
9. 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 44 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 MAKING MODERN LIVING POSSIBLE Guideline Trouble shooting guide for APP and APP S 674 pumps ro solutions com nstruction Trouble shooting guide for APP and APP S 674 pumps Table of Contents Trouble shooting guide for Trouble shooting fish bone chart il No flovv no pressure APP and APP S 674 pumps 2 Reduced flovv reduced pressure 3 High torque on electric motor 4 Noise from pump 5 Noise from installation 6 Typical signs of vvear 6 1 Valve plate 6 2 Port plate 6 3 Swash plate 46 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Trouble shooting guide for APP and APP S 674 pumps nstruction uonelle3sul LOA ISION S 40 0W 214239 D dy Japun Jadwep uoneJqiA e y awey uo p sunoul s did s soH be ss uuns soH Ee suoisuauip u16ue1 Z S L suon
10. 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 electrical 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 ring is part of the ATEX certification It is important that the ring is always intact The shaft sealing must be regularly checked and if dry it must be lubricated It is recommended that the seal is 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 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 29 HOYER MOTORS Connection diagram AnschluBdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexi n
11. 14 3 Repair In case of irregular function of the APP please contact Danfoss High Pressure Pumps 14 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Data sheet APP 21 43 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 15 Data sheet APP 21 43 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 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 16 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 MAKING MODERN LIVING POSSIBLE ION tructi APP pump ins APP 21 43 Instruction ro solutions com nstruction APP pump instruction APP 21 43 Table of Contents 1 Identification Instruction APP 21 43 2 System design 180R9133 2 1 Open ended systems with direct water supply 22 Preferred RO system design and P amp ID 2 3 Reversible pumps 2 4 General comments 3 Building up the pump unit 3 1 Mounting 3 2 Direction of rotation 3 3 Orientation 34 Protection from too high pressures 3 5 Connections 4 Initial start up
12. 5 Operation 5 1 Temperature 5 2 Pressure 5 3 Dry running 5 4 Disconnection 5 5 Storage 6 Service 6 1 Warranty 6 2 Maintenance 6 3 Repair 7 EC Declaration of Conformity 1 ldentification NESSIE Pump Type APP Serie no Code no MADE IN DENMARK 18 180R9266 APP APP 21 43 Appendices v07 11 2013 nstruction APP pump instruction APP 21 43 2 System design The design of the system must ensure that self emptying of the pump during standstill is avoided The inlet pressure of the pump must never exceed the outlet pressure This may typically occur in boosted or open ended systems vvith direct water supply 2 1 Open ended systems with direct water supply The pump is supplied with water directly from a feed pump The inlet pressure for APP 21 38 must be at least 2 bar 29 psi and 3 bar 43 5 psi for the APP 43 It must not exceed 5 bar 72 5 psi continuous To protect the pump from being damaged by peaks of high pressure in case the pump stops momentarily it is required to mount a low pressure relief valve on the inlet line Preferred RO system design and P amp ID Dimension the inlet line to obtain mini mum pressure loss large flow minimum pipe length minimum number of bends connections and fittings with small pressure losses Place an inlet filter 1 in front of the APP pump 2 Please consult Danfoss filter datasheet f
13. H r i 5 c E i E N N ii 2 1 M12x1 75 13 depth 3 M12x1 75 13 depth a i 10 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Zones available on website APP 21 43 OD 73 mm Data sheet APP 21 43 Description APP 21 APP 43 Accessories Type Code no E Parallel key mm 12x8x70 3 inlet hose kit 3 Victaulic 18020144 2 00 m 79 DIN SES in 0 47 x 0 31 x 2 76 2 outlet hose kit 2Vz Victaulic 18020263 1 78 m 70 21 38 18020280 1 00 m 39 4 F Bleeding G Y Hexagon AF 6 mm 272 outlet hose kit 2 Victaulic 18020618 1 00 m139 4 1 APP 43 18020619 1 78 m 70 I Inlet port M60 x 1 5 depth 24 mm 27 inlet connector 272 Victaulic 180B3206 APP 21 24 O Outlet port M60 x 1 5 depth 24 mm 3 inlet connector 3 Victaulic 180B3208 APP 21 43 R Non return valve outlet Duplex 2 Victaulic 180H0050 Mounting flange ISO 3019 2 180B4TW APP 21 38 OD 73 1 mm For more details on the accessories please Non return valve outlet Super Duplex 272 Victaulic 180H0052 contact Danfoss High Pressure Pumps pamm Or check Data Sheets 521B1303 521B0909 Non return valve outlet Super Duplex 27 Victaulic 180H0055 12 Dimensions complete unit APP 21 38 IEC 250 280 265 10 433 APP 30 38 357 14 069 APP 21 26 351 13 833 APP 30 38 310 12 207 APP 21 26 3
14. Prior to installation burrs and chips and Chips or other impurities in the system other impurities must be removed from may cause damage pipes and hoses eg with a felt plug Sealing Fittings in screvved components to be Using teflon tape or packing yarn in sealed with O rings or bonded seals joints may cause damage 10 Correctly limited quantities of grease Too much grease may develop prevent seizing 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 Ensure always to have 3 mm distance Insufficient distance and or misalign between coupling flanges ment between the coupling flanges will damage the pump Water supply Fill system with water before starting Starting without water will cause to ensure lubrication and cooling damage Starting procedure Cleaning procedure ifevellindicator 1 Fill cold water into the system via the return filter and bleed the pump Power Packs PPH A 6 3 10 and 12 5 are self bleeding 2 Start and bleed the system vvithout pressure by opening the bypass valve 3 Add the cleaning agent to give 396 agent water solution 4 Runthe system for 60 min and activate all components as often as possible to ensure effective flushing with the Cleaning agent Level and temperature indicators Missin
15. 196 4 Outlet min bar 30 30 30 30 30 30 30 30 30 30 2 435 435 435 435 435 435 435 435 435 435 Outlet max bar 80 80 80 80 80 80 80 80 80 70 15775 i 1160 1160 1160 1160 1160 1160 1160 1160 1160 1015 continuous psi Inlet min bar 2 2 2 2 2 2 2 2 2 sl 5 psi 29 29 29 29 29 29 29 29 29 43 Inlet max bar 5 5 5 5 5 5 5 5 5 5 pressure A En psi 72 5 72 5 72 5 72 5 72 5 72 5 72 5 72 5 72 5 72 5 Inlet max bar 10 10 10 10 10 10 10 10 10 10 575 m 145 145 145 145 145 145 145 145 145 145 Max speed rpm 1200 1500 1200 1500 1200 1500 1200 1500 1500 1700 continuous Min speed rpm 700 700 700 700 700 700 700 700 700 700 continuous Power kW 55 59 64 65 70 71 81 83 101 105 requirement 1001 BP 73 6 78 9 86 3 86 9 93 8 95 1 108 3 111 6 135 3 141 4 and 80 bar 1160 psi Torqueat 80 Nm 431 371 510 410 556 451 639 530 643 5939 bar Ibf ft 318 273 6 376 302 410 332 6 471 3 391 4743 43719 Weight kg 105 105 105 105 105 105 105 105 105 105 Ib 231 5 231 5 231 5 231 5 231 5 231 5 231 5 231 5 231 5 231 5 Integrated Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes flushing valve 9 Typical average flow at 60 bar 870 psi 2 For lower pressure please contact Danfoss High Pressure Pumps 9 For higher pressure please contact Danfoss High Pressure Pumps 9 Torque at 70 bar The pump is designed according to EN809 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Denis Da
16. APP W 5 1 10 2 1 General This parts list provides an overvievv of the content of the various service sets for the APP 0 6 1 0 Compact APP 0 6 1 0 APM 0 8 2 9 APP 1 5 2 5 APP 3 0 3 5 APP 5 1 10 2 APP W 5 1 10 2 APP 11 13 APP 16 22 APP 21 43 as well as exploded views of the pumps 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 39 i Parts list APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 20 Parts list APP 21 26 E Note S The parts listed are not sold separately m only in various kits 9 ig Be 9 v 9 2 e Exploded view see next page y 5 5 EIER BEE EE 2 g 58 59 3565 2535 25 Bale S s B PD PBA 2S 5 35 320 30 20 3 Pos Qnt Designation Material d Te ie Ta ma mir 78 DE RE x 78 Ta TE EE EE EEE PEER Er ES Peo 2 lt 8 lt 8 lt 2 lt 8 sz 32 33 9x92 929295 1 1 Housing Duplex PEEK 2 2 Pin 6x10 AISI 316 x 3 2 Bleeding plug Super Duplex x 4 4 O ring 11x2 NBR x 5 17 Screvv M8x30 AISI 316 x x x x 9 1 O ring 228x4 NBR x x x x 10 2 O ring 9 19x2 62 NBR x X x x x x 11 1 End flange Duplex 12 1 Lifting eye AISI 316 13 2 Screvv M8x16 AISI 316 x 31 1 Swash plate Super Duplex x x x x x 34 2 Pin 10 5x20 Duplex x x x x x x 61 1 Cylinder barrel Su
17. Repair In case of irregular function of the APP please contact Danfoss High Pressure Pumps sales 6 2 Maintenance organisation 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 24 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 nstruction APP pump instruction APP 21 43 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 25 nstruction APP pump instruction APP 21 43 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 26 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Electric Motors Motor Manual hoyermotors com HOYER MOTORS 1 General This manual concerns the follovring types of standard induction motors from Hoyer HMA2 HMC2 HMD HMT MS Y2E1 Y2E2 YDT These motors are manufactured in accordance with IEC EN 60034 4 and TEC EN 60072 Motors are rated for the ambient temper
18. below M size Thread M4 M5 M6 MIO M12 M16 Torque 1 5 2 4 8 10 17 40 80 Nm 3 2 Direction of rotation Is indicated by an arrow on the pump label NESSIE Pump Type APP Serie no Code no MADE IN DENMARK ia 3 3 Orientation The pump can be mounted orientated in any horizontal direction with the inlet and the outlet pointing upwards downwards or to either side 3 4 Protection from too high pressures The pump should be protected against too high pressure by means of a safety valve or a pressure relief valve The valve should be placed as close to the pump as possible The opening characteristics of the valve must not result in peak pressures higher than 100 bar 1 450 psi Both the inlet and outlet lines must be flexible soft hoses 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 21 nstruction APP pump instruction APP 21 43 The valve outlet must not be connected directly to the pump suction line t must be connected directly to the drain Outlet B AN NS
19. better cooling s the water in the tank very hot le above 50 Is the electric motor of the pump unit rotating s water coming No out of the tap Are all taps open Is the control light for low pump suction pressure on Is the power supply ok Are control lights on The filter is clogging s the filter clogged s the filter control light on s water coming through the filter A blown fuse or short circuit Check power supply Replace filter element and fuses and contact electrician Replace filter element Contact serviceman Turn on the tap for water supply Trouble shooting Closed vvater systems The system does not vvork s there sufficient water in the tank Yes s the electric motor of s the water in the tank o RG the pump unit rotating very hot le above 50 At temperatures higher than 50 the e Is the power supply ok pump drive cuts out Consequently the Are control lights on cooler must be checked cleaned A blovvn fuse or short circuit Check power supply Is the filter logged Fill water into the system and fuses and contact Is the filter control Yes Replace filter element electrician light on Contact serviceman Trace leakage if any Danfoss can accept no responsibility for possible errors
20. 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 of the pump If the pump has to be shut down for a longer period instructions can be found in appendix 2 Instruction 180R9266 IOM APP Pumps v03 06 2013 15 User manual Installation Operation and Maintenance APP Pumps APP 21 43 8 Troubleshooting and A scrapping criteria 8 1 General safety information If water is leaking into the electric motor it can Before inspecting the pump unit it is necessary cause electric shock fire short circuit or even to read and understand this user manual death VVhen mounting the pump vertically especially the Safety chapter 2 alvvays mount the motor above the pump to avoid vvater leaking into the electric motor Remember to vvear suitable safety equipment according to Safety chapter 2 EN 8 2 Operational conditions which can cause 8 4 Electrical failure pump failures If the wiring of the electric motor is incorrect or The following conditions can cause a pump the ground connection is missing it can cause failure electric shock burn damages fire or even death The pump is running dry If a VFD is use
21. fluids under high pressure e g in seawater reverse osmosis filtration applications and for high pressure salt water pumping The pumps are based on the axial piston principle enabling a very light and compact design and they are designed so that the lubrication of the moving parts in the pumps is provided by the fluid itself No oil lubrication is thus required 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 9 9 0 9 2 5 5 02 O R i NG A ar T D GML MMA LL Ll A NN WN YD Nu i 4572 Wis BIN 1 Shaft sealing VZ IN SIN 2 Mountingandportfange H 1 li m Bleeding plugs ES INTA NS 4 Retainer plate i A 1 e 00 plate nn SS PI KE 4 SS 7775555 m Cylinder barre Y ES WI DTT NG NN Spri E TFT et i Fara Hee ll Bolts for bell housing F ZZZ 14 Drain plug NS ZAZ A SS TEE ALI AN Us 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Dorf Data sheet APP 21 43 All parts i
22. in Denmark for evaluation If there is any leakage at start up or during For other observations or troubles please see operation a high pressure jet can cause eye or appendix 7 Right and Wrong which gives good skin damage advises regarding design installation wiring and troubleshooting Leakage can result in flooding which can cause slipping tripping or falling In case the pump needs to be scrapped please follow your local environmental rules 16 180R9266 IOM APP Pumps v03 06 2013 Ionen User manual Installation Operation and Maintenance APP Pumps APP 21 43 180R9266 IOM APP Pumps v03 06 2013 17 Dorf User manual Installation Operation and Maintenance APP Pumps APP 21 43 Subject index A Address oo 7 8 15 Ait b bbles s sepes xe dE nesi 9 Appendix 7 8 9 10 11 14 15 16 Application range 8 Approval de odes Rer da 6 AVAL ale eos eee ME Es 9 12 15 Assembling ccc enn 12 15 B Bleed oz ERR 8 9 13 15 C Checklist pda aa eec 11 Check points om eae a xm 12 Cliemlcals rs ot a 9 Cleanliness 11 14 Commissioning 6 8 11 12 13 15 16 Connections 7 9 10 11 12 15 COUPIINGS e deed d 8 12 13 15 16 D Danger re e 6 7 13 16 Data sheet 7 8 9 10 11 12 14 Declaration of Conformity 5 7 Design 7 8 9 11 12 13 14 16 Distributor s s run 6 7 8 9 Dimens
23. low pressure switch will ensure that the pump does not start until the min inlet pressure has been reached 4 4 Pump reversing 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 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 4 5 High rotation speed rpm 4 5 1 If electric motor rpm is too high dismantle pump and check for damage 4 5 2 If the rpm is within the specified range of the pump data sheet and abnormal noise remains dismantle pump and check for damage Higher rpm than specified in the pump data sheet results in wear of the pistons i e pistons may be damaged High rpm will also increase pressure pulsations from the pump and the noise level will increase If rpm is changed noise frequency will also change 4 6 Outlet pressure 4 6 1 If outlet pressure is too low check set point of outlet pressure valve 4 6 2 If outlet pressure is lower than mentioned in the pump data sheet please contact Danfoss High Pressure Pumps technical support 4 6 3 If outlet pressure has exceeded its maximum check set point of outlet pressure val
24. min by means of the internal flushing valve to remove possible impurities from pipes hoses etc 3 Loosentop bleeding plug C see item 3 3 using an allen key only plugs with internal hexagan sockets Retighten the plug when water appears from the bleeding plug 4 Make sure that the direction of rotation of the electric motor corresponds to the direc tion of rotation of the pump see label on pump 5 Now the pump is ready for start up WARNING Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump see label on pump Otherwise the pump will be damaged if a check valve is placed between pump and feed pump Internal flushing valve 5 Operation 5 1 Temperature Fluid temperature Min 2 C to max 50 C Min 35 6 F to max 122 F Ambient temperature Min 2 C to max 50 C Min 35 6 F to max 122 F In case of lower operating temperatures please contact Danfoss High Pressure Pumps sales organization The chart below illustrates the corrosive resistance of different types of stainless steel related to NaCl concentration and temperature The APP water pump is made of Duplex and Super Duplex If the water pump is operated above the Super Duplex line always flush water pump with fresh water at operation stop in order to minimize the risk of crevice corrosion
25. motor Check that the motor rotor winding is not damaged Speeds below min limit see User manual result in insufficient internal lubrication causing wear on the internal pump parts 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 49 Dear Instruction Trouble shooting guide for APP and APP S 674 pumps 3 High torque on electric motor Cause Remedy Comments 3 1 Too high outlet pressure from pump 3 1 1 Check fluid salinity 3 1 2 Check temperature 3 1 3 Check pressure drop across RO membrane Pump conditions may change more salt lower water temperature or scaling of RO membrane causing higher pressure resulting in higher motor torque 3 2 Pump starts against pressure 3 3 Constant torque 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 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 3 4 Water pump damage 3 4 1 Dismantle pump and check for wear Too heavy damage in the pump will increase friction causing a high torque see item 6 Typical signs of wear 5
26. uuo 3 hno lul L S e BIER UL Ot WdH ez aanssasd lul MO ZZ duind w014 asion y e Wdy p ds uone1o1 E 40 0W l uo anb10 YBIH e do3s 14e1s os p P aInssasd nno 9 p Bulsa A l dung tt abewep dund 131eM 56 aunssaid lul jeunuou XEW UIN E y nbuo 3ue3suo es e duind jo suonipuo Bulpas g cp aunssad sule5e syje3s dund Z E o di duind uo AA T a4nssasd anno YBIY ool ve piny uf 8 12 d pin LT abewep dung 9L yeys dund uo 3240 jeixy st duind jo uone3o4 ON b 10 0W 21329 9 JO UONEJOI ON 50 uoneny urew 30 G z jueunee eJd E ve eunsse1d mop p np q 7 Trouble shooting fish bone chart Bulsi l dung CL buluuni Aug m aunssaid Moy ON L 47 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 nstruction Trouble shooting guide for APP and APP S 674 pumps 1 Noflow no pressure Cause Remedy Comments 1 1 Dry running no water supply to the pump If no water comes out of the pump 1 1 1 Check that inlet valve is open 1 1 2 Check that booster pump is running 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 inl
27. working with high pressures it is important to have the right space available around the pump A as stated in the safety requirements 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 8 180R9266 IOM APP Pumps v03 06 2013 Zonen User manual Installation Operation and Maintenance APP Pumps APP 21 43 A 3 7 Filtration 10um absolute B 50001 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 TDS without consulting your local Danfoss pump distributor A 3 9 Airbubbles Large bubbles in a pressurised RO system can result in damage to piping equipment and the pump AII air must be bleeded from both the low pressure and high pressure side be
28. 0 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Dorf Instruction Trouble shooting guide for APP and APP S 674 pumps 4 Noise from pump Cause Remedy Comments 4 1 Air in fluid 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 Small air bubbles will accumulate and create large bubbles causing internal cavitation and thus making the pump very noisy line WARNING The pump can only run few minutes with air in the fluid without being damaged 4 2 Bleeding conditions of pump 4 2 1 Follow the instructions Initial start up The pump and the inlet line must be com supplied vvith the nevv pump 4 2 2 Ensure that the pump is completely bled before start up pletely bled before start up othervvise the pump will cavitate and make high noise VVARNING The pump can only run fevv minutes vvith air in the fluid vvithout being damaged 4 3 Min max nominal inlet pressure 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 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
29. 04 11 97 97 3 819 Pump A mm B mm C mm D mm E mm F mm IEC Electric motor APP 21 24 550 635 250 406 349 770 55 kW IEC 250 M 4 APP 24 26 550 693 280 457 368 845 75 kW IEC 280 S 4 APP 26 38 550 693 280 457 419 895 90 kVV IEC 280 M 4 Examples of different pump motor sizes Check required power 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Data sheet APP 21 43 APP 43 EC 315 265 10 433 413 16 26 zi E so 2 362 310 12 205 sp DA E F A eo Y Pump A mm B mm C mm D mm E mm F mm IEC Electric motor APP 43 660 861 315 508 406 1038 110 kW IEC 315 S 4 Above examples of different pump motor sizes and dravving dimensions are only for IEC motors and couplings Please make sure to check required motor povver and dimensions vvhen selecting size of pump and motor Due to the design and dimensions of an APP 43 pump bell housing and IEC motor a dampening flange on the bell housing is standard when an IEC 315 motor is selected If this dampening flange for some reason is deselected an extension for the non return valve may be needed in order to mount the pipe or hose with Victaulic clamps 12 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Dorf Data sheet APP 21 43 13 Installation 13 1 Mounting The
30. 5 5 Local regulations Commissioning must alvvays be done in accordance with valid regulations and local standards Media filter TO ES S Permeate gt gt Bine Y 180R9266 IOM APP Pumps v03 06 2013 Dent User manual Installation Operation and Maintenance APP Pumps APP 21 43 5 6 Pre mounting checklist based on Danfoss preferred system design Table 1 Check points when assembling and commissioning system Check points Comment OK 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 CP3 Filtration condition 10 um absolute B gt 5000 See Danfoss requirements in Data sheet and Instruction appendices 1 and 2 CP4 Power supply for electric motor and VFD See Data sheet for the used motor and VFD CP5 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 CP7 Instrumentation pressure switch should be designed to See Data sheet for the used conform to the environment corrosion and humidity equipment CP8 Che
31. 6 Duplex or PEEK No wear part 152 1 Valve cone flushing valve Duplex or PEEK 40 000 hours 3 129 2 Bleeding screw Duplex No wear part 67 1 Key AISI 316 40 000 hours depends on pump size 34 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 nstruction Recommended service intervals for APP pumps 3 Appendix1 Pistons n 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 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 35 nstruction Recommended service intervals for APP pumps 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 pr
32. Collegamento Cxema Schemat polaczen 0005 OL L r Motor Manual 30 180R9266 IOM APP APP 21 43 Appendices v07 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 CEo Signed by anaging Director Date December 2010 Page 1 1 Svend Hoyer A S Over Hadstenvej 42 DK 8370 Hadsten VAT no DK 21 96 23 09 Bank Danske Bank SWIFT DABADKKK IBAN EUR 2X6630003617176718 7 USD DK8330003785071190 T 45 86 98 21 11 F 445 86 98 17 79 svendhoyer svendhoyer com svendhoyer com M y a SI s 5 a E ER 2 3 m 8 o E 8 3 E a m g a n Tif 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 V rnamo Tel 46 37 04 77 13 Fax 46 37 01 00 46 E mail svendhoyer svendhoyer se http www svendhoyer se N
33. D DIOS mE 9 3 10 Chemicals P 9 4 Arrival inspection transportation handling lifting and storage 9 4 1 Arrival inspectioni cassia nce te ia 9 4 2 WARMING iue et 00 0 oe PUR AR CR 9 4 3 General safety Trdotrgalon 2 geed d vh REF A VOR P ETE YN 9 4 4 Ttarisport and handlilgi es adan an RUE S ntn eS Xa ON radix ee ie IURE E T IE 9 4 5 Return to supplier ee Ree rrr E EC A Ra R UOCE e eene et 10 4 6 Ern f AAA A ad 10 5 Installation and COMMISSIONING eeii E E EE E TE 11 5 1 ImportantidimensiONS e seee e EE TE eR EAE eran 11 5 2 ere 11 5 3 Fluid temperate isse n 11 54 Electrical data TET ETT 11 5 5 L calr gul tions dar tuoi vied cn 11 5 6 Pre mounting checklist based on Danfoss preferred system design 11 5 7 Lifting NA positioning eere oct RIT E E Rr e PE VY EC Pe aker Gs 12 5 8 Mount the different equipment eee hehehe 12 5 9 3 Ea c P 7 ena 12 5 10 af ge TEE 12 5 11 CONNECtHONS canna k l m y nese 12 5 12 Erisure free lov ee Ee b ies 13 5 13 Verify setting of safety relief valves 13 5 14 Flush the PUMP ic BR daaa da YN V bz KEYS 13 5 15 Bleed and remove air from the pump 9 98 eene 13 5 16 Verify direction of rotation le dekade 13 5 17 COMMISSIONING resta ia 13 5 18 Check the filter c
34. G Outlet lt D 3 5 Connections l Inlet O Outlet C Bleeding D Parallel key Description APP 21 APP 43 Accessories Type Code no E Parallel key mm 12x8x70 3 inlet hose kit 3 Victaulic 18020144 2 00 m Lo DIN 6885 z in 0 47 x0 31 x 2 76 2 outlet hose kit 2 Victaulic 18020263 1 78 m 70 APP 21 38 18020280 1 00 m 39 4 F Bleeding G 4 Hexagon AF 6 mm 2 outlet hose kit 2v Victaulic 180Z0618 1 00 m 39 4 APP 43 18020619 1 78 m 70 Inlet port M60 x 1 5 depth 24 mm 2 inlet connector 272 Victaulic 180B3206 APP 21 24 O Outlet port M60 x 1 5 depth 24 mm 3 inlet connector 3 Victaulic 180B3208 APP 21 43 R Non return valve outlet Duplex 21 Victaulic 180H0050 Mounting flange ISO 3019 2 180B4TVV APP 21 38 OD 73 1 mm Non return valve outlet Super Duplex 27 Victaulic 180H0052 APP 21 38 OD 73 mm For more details on the accessories please contact Danfoss High Pressure Pumps Non return valve outlet Super Duplex 27 Victaulic 180H0055 Possible extension see next page APP 21 43 OD 73 mm 22 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 nstruction APP pump instruction APP 21 43 4 Initial start up 1 Hlush inlet line before connecting the pump to remove possible impurities from pipes hoses etc 2 Connect pump inlet to inlet line and flush the pump for 5
35. MAKING MODERN LIVING POSSIBLE User manual Installation Operation and Maintenance Manual APP pumps APP 21 43 APP 21 43 ro solutions com User manual Installation Operation and Maintenance APP Pumps APP 21 43 Table of Contents Validity Ce m Ee 4 EU Declaration of Conformity avion cosas a E 5 1 EE 6 1 1 General ererig Ert ee EE jaan de er ane 6 1 2 2200000000 0020002000 IO 6 1 3 Manufacturer and customer service address 7 2 Eri 2 A 7 2 1 General information s i sisi rire ili ERRE A RR 7 2 2 Preferred system designes sese ee Epp RR Ra 7 2 3 Commissioning and servicing E AEE aE E EEEE E EAG 8 2 4 Adhere to the following important points 8 2 5 Inrc se of doubt ua vr are es 8 3 Technical data 6 seer i eee NTE ES 8 3 1 Approved applications and operational limits for the pumps 8 3 2 Application range scooter RR 8 3 3 Electrice motor datas esci o eoe o eee Ee PUER ies 8 34 Noiseandivibratioh eo yr rr ARES baa ERR E es 8 3 5 Dimension R PERRA RE UP E PETER 8 3 6 Space reete UR RR ERI ORE E REPAS d y EE HORE ENEE AE 8 3 7 PiltratiOM MP EE 9 3 8 Properties of Water Nie op 7 EA 9 3 9 Air DU
36. OE WA LYT UJq TZ 7 WNE F WNOE 622 u3d t1 1 YABE DIA 127s b un F UNDE LUNZ WNL WIG ET ZZ Dua 1227 Y Jal ET ZZ UNE F WNOE vg SS ble HA YA a m Bi d NS S NE JR 2222222222022222240 43 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Parts list APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 24 Tool sets Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Note The parts listed are not sold separately only in various kits Designation 180B4188 Tool set APP 0 6 1 0 Compact 180B4142 Tool set APP 0 6 1 0 180B4148 Tool set APP 1 5 3 5 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 Shaft bush Press bush x Drift Torx T30 Shaft bush 218 Press bush 218 Allen key 4 mm Allen key 5 mm Allen key 6 mm x x x x Shaft bush 35 x Shaft seal extractor 035 IX Press bush 235 x Adjustable pin wrench x x x x Combination wrench 10 mm x x fx x Combination wrench 13 mm x x x Nut M8x6 5x13 x x x Guide bolt M8x140 x x Shaft seal extractor 245 x x Press bush 245 x ix Eye bolt M8 x x Press bush for valve plate x x Stop for retainer plate x Screw M8x20 x x x Screw M8x70 x x
37. a situation vvhich vvill or could not suitable for the pump unit can cause result in personal injury and or damage damages to the pump unit vvith risk of personal to the pump injury A Electrical hazard Indicates a high A voltage warning All personnel being responsible for operation and maintenance of the pump unit must read o Safety glasses required and fully understand these instructions especially the section Safety before Transportation of the pump unit 9 Hearing protection required Lifting the unit Installing the pump unit 2 Connecting the pump unit to the water system Safety shoes required e Connecting the electric motor and instru mentation e Commissioning the unit Servicing the pump unit mechanical and e Safety helmet required electrical parts Decommissioning the pump unit The pump must always be installed and used in Q Protective garments accordance vvith existing national local ur must be worn sanitary safety regulations and lavvs It is the responsibility of the safety officer or the chief operator to assure compliance with all A me Danger HOT local regulations that are not taken into Do not touch account in this manual A A EA Electrical hazard Changing the pumps or pump units opera tional limits and hardware Changes to the delivered pump or motor pump unit may only be done with a written approval from Danfoss High Pressure Pumps e Operation outside the Danfoss specifications requ
38. afe electrical connection is maintained both for the main supply and the earth connection We recommend that crimped connections are made in accordance with IEC 60352 2 Tightening torques for terminal board screws T Nm 35 7 12 55 2 5 18 35 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 mspect the motor at regular intervals keep it clean and ensure free ventilation air flovr check the condition of shaft seals and replace if necessary Both electrical and mechanical connections must be checked and tightened if necessary 28 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 HOYER MOTORS Bearing size and type are specifted 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 2 6 40 000h 180 2 35 000h 200 2 27 000h 225 2 23 000h 180 225 4 8 40 000h Motors with a re greasing system must be lubricated with high quality lithium complex grease NLGI grade 2 or 3 with a temperature range of between 40 C to 150 C Motors are normal fitted with a data plate with greasing information if it is missing use the following re greasing intervals Frame Grease 2 pole 4 pole 6 pole 8 pol
39. al Appendices for nstallation Operation and Maintenance Manual APP pumps APP 21 43 APP 21 43 ro solutions com User manual Appendices for IOM Manual for APP Pumps APP 21 43 Table of Contents 1 Data sheet for APP 21 43 pumps 521B0852 2 APP pump instruction 21 43 180R9133 09 3 IOM Electric motors 180R9230 4 Recommended service intervals 180R9199 5 APP partslist 521B0941 is eorr ccert T RP RO E EE SE sued yaaa EE OFTEN 6 Troubleshootingguide daa OE EFE 7 Righit and wrong 180R9042 ee dE a dE E KE 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 MAKING MODERN LIVING POSSIBLE Data sheet Data sheet APP 21 43 ro solutions com Data sheet APP 21 43 Table of Contents 1 General information 13 13 1 13 2 13 3 14 14 1 14 2 14 3 General information Benefits Technical data Variants Flow at different rpm Flushing valve Power requirements Temperature and corrosion Operation Storage Noise level Filtration Dimensions Dimensions complete unit Installation Mounting Open ended system with direct water supply RO system with APP pump Service Warranty Maintenance Repair APP 21 43 pumps are designed to supply low viscosity and corrosive
40. al no 02 APP 38 1500 Code no 180B3071 Serial no 02 APP 43 1700 Code no 180B3072 Serial no 02 4 180R9266 IOM APP Pumps v03 06 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 f 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 Qualitatsabteilung Angewandte harmonisierte Normen DS EN ISO 12100 2011 Hersteller Unterschrift Titel 2013 05 27 Datum D claration de conformit CE conform ment la Directive 2006 42 CE EC Declaration of Conformity according to Directive 2006 42 EC Par la pr sente nous d clarons que la machine est concue conform ment a la Directive 2006 42 CE Machine description Description de la machine High pressure pump Pompe haute pression Type de machine APP 0 6 1 0 APP 1 5 3 5 We hereby declare that the machine is designedaccording to the directive 2006 42 EC Machine designation APP 0 6 1 0 APP 1 5 3 5 APP 5 1 10 2 APP 11 13 APP 5 1 10 2 APP 11 13 APP 16 22 APP 21 43 APP 16 22 APP 21 43 Serial number Num ro de s rie N A N A Personne de contact pour le Contact person dossier techniqu
41. and stored FROST from DOW Chemical Company or Chilsafe plugged mono propylene glycol from Arco Chemical Company 9 Noiselevel The sound pressure levels L PA 1m db A for It is therefore very important that the motor APP 21 38 pumps are typically 85 dB A at 80 bar 1500 rpm For APP 43 the sound pressure level L PA 1m db A is 85 3 at 70 bar 1700 rpm The sound pressure level for the APP 43 is including a rubber damper 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 Measurements according to EN ISO 3744 2010 dB A LPA 1m values is calculated according to EN ISO 20361 section 6 2 pump unit is mounted correctly on a frame with anti vibration isolation to minimize vibrations and noise The noise level is influenced by The speed of the pump high rpm create more noise than low rpm Rigid mounting of the pump generates more noise than flexible mounting Pipe mounting direct to the pump increases the noise level compared to a flexible hose If using a VFD the motors can produce higher noise values depending on the operation point 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 21 43 As water has very low viscosity the APP pumps have been designed wit
42. ature 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 marked 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 It is also important that transport locking is used when motors are transported mounted on equipment All motors should be stored indoors in dry vibration and dust free conditions Lifting eyebolts must be tightened before use Damaged eyebolts must not be used check before use Lifting eyes at motor must not be used to lift the motor vrhen itis attached to other equipment Before commissioning measure the insulation impedance If values are x 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 mount
43. ave a vveight belovv 20 kilos weight can be found in appendix 1 Data sheet can be handled by hand if they are not mounted together vvith an electric motor The vveight ofa small pump with a motor will be above 20 kilos 180R9266 IOM APP Pumps v03 06 2013 User manual Installation Operation and Maintenance APP Pumps APP 21 43 Pumps vvhich have a vveight 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 VVhen the pump is mounted together vvith an electric motor the pump unit alvvays vveigh 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 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 pump unit Hovv to mount the pump and the electric motor correctly see appendix 1 Data sheet or appendix 2 Instruction A Incorrect lifting can r
44. ck 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 Scaling should at least be 1 Bar to measure the system pressure range or more precise CP11 Check coupling distance air gab movement ofthe spider 3 5mm CP12 Check correct connections on the pump in amp outlet CP13 Check piping for possible air gaps A 5 7 Lifting and positioning Lift the pump unit onto base Remember vibration dampeners if needed Fasten the motor to the base See also chapter 4 Arrival inspection transporta tion handling lifting and storage 5 8 Mountthe different equipment connections pipes tubes check and safety relief valves etc hard piping and flexible hoses used must be of proper design and must be installed in accordance with the manufactur er s recommendations see also Data sheet for Hose and hose fittings and Instruction for Assembling Hose kit both available on www ro solutions danfoss com Misalignment of the hard pipes may give unintended stress on the pump port connections and may damage the pump Prevent excessive external pipe load Do not connect piping by applying external force use of wrenche
45. ction for recom servicing the pump unit should be able to mended service intervals unlock activate the switch again For spare parts and service tools please see E Open bleeding and drain plugs Wait until appendix 3 Parts list the pump and system are emptied for water 14 180R9266 IOM APP Pumps v03 06 2013 Denis User manual Installation Operation and Maintenance APP Pumps APP 21 43 A 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 n G Attach the lifting equipment to the pump unit For instructions on lifting the complete pump unit see chapter 4 Arrival inspection transportation handling lifting and storage H For the small pumps unscrew the bolts holding the pump to the bell housing For the bigger pumps unscrevv the bolts nuts from the pump and bell housing to the motor Aftervvards unscrevv 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 vvater trapped in the pump to drain Clean and dry the pump surface and plug the bleeding and draining plugs K Move the pump to a clean and safe location where the pump can be inspected serviced 7 4 Disassembling and assembling the pump unit A Remo
46. d 54 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 MAKING MODERN LIVING POSSIBLE Danfett Right and wrong Trouble shooting guide for water hydraulic systems danfoss high pressurepumps com 180R9042 Choice of material Rubber Plastic Stainless steel Always use system components made Non corrosion proof materials of corrosion proof materials may cause damage Choice of filter Install a 10 micron absolute filter with Return filter with bypass valve and pressure switch poorer filterability than 10 u 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 Pump always to be placed below water Pump location above water surface surface level level will cause damage Suction conditions System to be dimensioned to provide Poor suction conditions will cause a suction pressure of the pump inlet of malfunction and damage the pump max 0 1 bar vacuum Pressure Relief valve Pressure relief valve to be mounted Coupling the pressure relief valve outle vertically or with vertical outlet and directly to the pump inlet may damage connected to return hose or tank the pump Water supply Filling system with unfiltered water causes damage System to be filled via filter Installation Impurities
47. d thus increase the noise level 5 3 Hose stiffness 5 3 1 Use a more flexible hose Danfoss can provide flexible hoses Please contact Danfoss High Pressure Pumps sales office for further information Too stiff hoses cannot dampen the small pressure pulsations from the pump and subsequently vibrations occur in the system plant 5 4 Hoses pipes mounted directly on frame 5 4 1 Mount the connections to the frame by a vibration dampener mounting plate 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 5 5 Vibration dampener under the electric motor 5 5 1 Mount a vibration dampener below the motor pump 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 52 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 nstruction Trouble shooting guide for APP and APP S 674 pumps 6 Typical signs of vvear 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 vvorn 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 ide
48. d and wrongly programmed it can The inlet pressure is too high damage the pump and lead to high tempera The inlet pressure is too low tures or other dangers The temperature of the fluid is too high The ambient temperature is too high All electrical installation must be carried out by The pump is running against a blocked authorized personnel in accordance with port closed manual valve EN60204 1 and or local regulations The pump is operating at a pressure out of specification The pump is running with a non specified 8 5 Responsibility approved fluid Danfoss takes no responsibility for any abnormal The pump is running in the wrong injuries risks or damages that could arise caused direction by abnormal conditions vibrations corrosion The filtration is insufficient abrasives foreign objects or excessive tempera The pump is not being serviced according tures and shall not be liable for any consequen to Danfoss specifications end of life tial or incidental damages There is excessive mechanical load on the shaft coupling and piping 8 6 Scrapping criteria Whether the pump can be repaired or need to be N ONE scrapped depends on in which conditions the internal parts are or how damaged the whole 8 3 Mechanical failure unit is Please use appendix 6 Trouble shooting If the pump is running dry the temperature will guide as guideline or send the pump to Danfoss quickly increase which can cause burns headquarter
49. e Manager Quality Department Manager d partement qualit Used harmonised standards Normes harmonis es appliqu es DS EN ISO 12100 2011 DS EN ISO 12100 2011 Technical dossier Signature du fabricant Titre wot ai gnatur 2013 05 27 Date 2013 05 27 Date 180R9266 IOM APP Pumps v03 06 2013 5 User manual Installation Operation and Maintenance APP Pumps APP 21 43 1 Introduction 11 General The APP pumps and pump units are manufac changes are made without written tured by Danfoss A S and are sold and marketed approval the warranty will automatically by a net of authorized distributors world wide become void This manual contains the necessary instructions It is important that these instructions are for the installation operation and service of the always available to the personnel concerned pumps used in a Sea Water Reverse Osmosis SWRO system or Brackish Water Reverse Osmosis BWRO system 1 2 Symbols In case the pump delivered is ATEX certified the additional ATEX instruction must also be read Indicates something to be noted by the The APP pumps must not be used for other reader purposes than those recommended and specified without first consulting your local pump distributor Indicates a situation which will or could result in damage to the pump and its function Use of the pump in other applications that are A ndicates
50. e size 2 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 35 2000 6000 7000 7000 280 85 2000 6000 7000 7000 315 50 1500 5500 6500 6500 855 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 C The values must be halved for every 15K increase in bearing temperature Higher speed operations e g frequency converter drive will require shorter greasing intervals Typically doubling the speed will reduce the values by 50 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
51. esult 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 10 180R9266 IOM APP Pumps v03 06 2013 Denis User manual Installation Operation and Maintenance APP Pumps APP 21 43 5 Installation and commissioning 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 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
52. et pressure has reached minimum inlet pressure see User manual 1 2 Pump reversing electric motor is running the wrong direction i e counter clockwise 1 2 1 Change the phase on the electric motor to make it run clockwise WARNING The pump must not run without water for more than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure in pump housing and will eventually break down Rotation direction for the APP or APP S 674 pump is shown by an arrow on the label on the pump 1 3 No rotation of electric motor 1 3 1 Check that main switch is switched on 1 3 2 Check the electricity at the facility 1 3 3 Ensure that motor relay is switched on 1 3 4 Ensure that fuse is not blown 1 3 5 Ensure that booster pump is started 1 3 6 Check that the monitor switches are working correctly 1 3 7 Disconnect pump from electric motor and check that the motor is capable of running with no load If motor type relay or the electrical fuse is blown check that electric motor is sized correctly 1 4 No rotation of pump 1 4 1 Ensure that coupling between electric motor and pump is connected 1 4 2 Check if coupling is damaged 1 4 3 Check that electric motor is sized correctly 1 4 4 Check that the electrical installation is correctly sized 1 4 5 Contact Danfoss Sales office for guidelines in how to troubleshoot internal pump parts 1 5 Axial load on
53. figure below illustrates how to mount the pump and connect it to the electric motor combustion engine If alternative mounting is required please contact Danfoss High Pressure Pumps for further information To ensure easy mounting of the flexible coupling without using tools the tolerances must be dimensioned accordingly Note Any axial and radial loads on the pump shaft must be avoided Ensure 3 5 mm 0 12 0 2 inch air gap between coupling parts A Flexible coupling B Bell housing C Motor shaft Scale 15 13 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 section 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 svvitch 2 set at min inlet pressure betvveen filter and pump inlet The monitoring svvitch must stop the pump at pressures lovver than min inlet pressure Please see technical data section 3 for specific pressure values 3 Install a low pressure safety valve or a pressure relief valve 3 in order to avoid system or pump damage in case the pump stops momentarilly or spinning backwards Note If a non return valve is mounted in the inlet line a low pressure relief valve is also required between non return valve and pump as protection against high pressure peaks
54. fore the RO system is pressurised Special consideration should be given in order to minimize air bubbles in the feed flow Air bubbles can cause cavitation 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 Arrival inspection transportation handling lifting and storage 4 1 Arrival inspection The pump is packed in a cardboard or wood box with plugs in the port connections to protect the pumps from damage during transportation When the shipment has arrived it is important to check the pump for any damages The name plate type designation must be in accordance with the delivery note and your order In case of damage and or missing parts a report should be documented and presented to the carrier at once A 4 2 Warning Before any lifting operation is performed environmental conditions must be taken into consideration Ex rated areas vvind speed vvet 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 vveigh more than 20 kilos vvhich requires lifting slings and suitable lifting devices e g an overhead crane or industrial truck to be used as minimum 4 4 Transport and handling Small pumps vvhich h
55. g or incorrectly connected level 5 Empty the system of the cleaning agent solution must be fitted Follow installation and temperature indicators cause instructions damage Flushing procedure 6 Fill cold water through the return filter and bleed the Rotation direction pump Power Packs PPH 4 6 3 10 and 12 5 are self bleeding 7 Runthe 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 Check pump drive motor rotation Incorrect rotation direction will direction matches that of the pump damage the pump 10 Change the return filter element fill cold water through 21 17 the return filter and bleed the pump during start up 11 The system is now ready for operation Bleeding Starting procedure Bleeding the pump will ensure correct Insufficient bleeding may cause dam Observing the starting procedure wi If the system is not cleaned before cooling and lubrication age not applicable to Power Packs ensure problem free operation starting the filter will clog Trouble shooting Open ended vvater systems No water supply Is the water supply ok Is water supplied to the pump Lower inlet Yes temperature or provide
56. h 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 B10 x 5000 equivalent to a filtration efficiency of 99 98 Bag filters and string wound filter cartridges typically have only 5096 filtration efficiency This means that for each 100 000 particles reaching the filter 50 000 particles pass through it compared to only 20 particles in a filter with an efficiency of 99 9896 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 Filtration 11 Dimensions APP 30 43 357 14 07 pa APP 21 26 351 13 82 d 47 3 1 862 Bleeding plug i m 1 3 gt 83 5 3 29 l si 2 m J Sl Ei B LI VE 5 n H E 1 Mo CE 45 bd rg e 4 T 12x1 75 13 depth 2 47 a L iz i 2 M12x1 75 13 depth 5 eo e
57. 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 60 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 User manual Appendices for IOM Manual for APP Pumps APP 21 43 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 61 User manual Appendices for IOM Manual for APP Pumps APP 21 43 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 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 62 180R9266 IOM APP APP 21 43 Appendices v07 11 2013
58. ing conditions do not cause resonance with the rotational frequency and the doubled supply frequency Only mount or remove drive components pulley coupling 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 x 5 voltage and x 2 frequency according to IEC60034 1 Connection diagrams for main supply and accessory as PTC or heater are located inside the terminal box Connections must be made in such a way as to ensure that a permanently s
59. 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 180R9266 IOM APP Pumps v03 06 2013 13 User manual Installation Operation and Maintenance APP Pumps APP 21 43 6 Operation of pump A unit 6 1 General safety information G Drop in flow and or pressure may indicate Before inspecting the pump unit read the Safety wear on one or more parts inside the chapter 2 in this user manual pump The pump must be stopped immediately and inspected before it is restarted Contact the maintenance 6 2 What t
60. ions tra a 8 11 Disassembling 15 E EC Declaration of Conformity 5 7 Electric motor 6 7 8 9 10 11 12 13 15 16 Electrical failure 16 Electrical hazard 6 7 Electiies scada SE m d bd 12 F AA SEES 8 16 Filter condition 13 Filtratlonu sisse os eee ee 9 12 14 16 m 7 9 13 14 Fluid ard Tanner 11 12 15 16 A oe l n 8 11 13 Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark G General information 7 Guideline s ok 16 H Handling ss sora 7 9 12 15 I Inspection csse m s sl 13 14 Installation 6 7 8 11 12 14 15 16 nstruction 6 7 8 9 10 12 14 15 nstrumentation 6 12 Introduction 6668 9s 6 M Maintenance 6 7 10 13 14 Mechanical failure 16 Mounting sed 8 11 13 15 N Nameplate 9 11 12 13 N S 8 14 L Leaking d RR 16 liftindi ata 6 9 10 12 15 Local regulations 6 7 8 11 12 16 o Operation 6 7 8 9 13 14 15 16 Operational conditions 7 16 P Piping 9 11 12 16 Positioning rg RR 12 Preferred system design 7 41 Premountings 2 d z sto use des 11 Protection 6 7 8 10 R Reliefvalve 12 13 14 Responsibility
61. ires a written approval from Danfoss High Pressure Pumps 6 180R9266 IOM APP Pumps v03 06 2013 Denis User manual Installation Operation and Maintenance APP Pumps APP 21 43 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 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 2 Safety A 2 1 General information Dangers that can arise from not follovving the instructions When the pump or pump unit is managed by untrained personnel there is a danger of Death or fatal injuries Costly damages and claims 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 eq
62. n 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 Technical data 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 2010 see appendix 1 Data sheet Possibilities to reduce noise and vibration are described in the same Data sheet 3 1 Approved applications and operational limits for the pumps 3 5 Dimension drawings The pump and the pump units are designed for Dimensions of the different pumps can be found the use in a Sea Water Reverse Osmosis SWRO in appendix 1 Data sheet or Brackish Water Reverse Osmosis BWRO systems and Brackish Water Reverse Osmosis BWRO system 3 6 Spacerequirement When doing service or replacing the complete The APP pumps must not be used for other pump unit it is recommended to have sufficient purposes than those recommended and space available around the pump in order to specified without first consulting your local ensure easy access Sufficient space means at pump distributor least 1 meter 40 inches around the pump When
63. name plates 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 5 17 Commissioning Close all the bleeding and draining plugs Open the pressure valve at the brine site Switch the safety circuit breaker on for both motor s and VFD s Start the feed pump Start the high pressure pump If a VFD or a soft starter is used a ramp up time of minimum 10 seconds is required to avoid damage of the pump Monitor the
64. ncluded in the pumps are designed to The pumps are fixed displacement pumps in provide long service life i e long service life with which the flow is proportional to the number of a constantly high efficiency and minimum revolutions of the input shaft and the pump service required displacement 2 Benefits One of the smallest and lightest pumps on No oil lubricant required the market Integrated flushing valve Can be powered by a combustion engine All parts of the pump are made of non provided that a special coupling is used corrosive materials e g Duplex EN1 4462 Long service life No preventive mainte UNS 531803 532205 and Super Duplex nance required in the warranty period EN1 4410 UNS S32750 stainless steel and Generates insignificant pulsations in the carbon reinforced PEEK pressure line High efficiency 3 Technical data APP Pumps APP21 APP21 APP24 APP24 APP26 APP26 APP30 APP30 APP38 APP43 1200 1500 1200 1500 1200 1500 1200 1500 1500 1700 Code number Standard 18083051 180B3052 18083054 18083055 18083056 18083057 18083060 18083062 18083071 18083072 Geometric cm rpm 308 256 362 282 389 308 444 362 444 444 m 18 8 15 6 221 172 237 18 8 27 1 224 271 271 Ratedflowat m3 h 21 1 21 9 24 8 24 1 26 6 26 6 30 7 31 3 38 4 44 6 1 maxspeed gpm 92 9 96 4 109 106 2 117 1 117 4 135 1 137 7 168 9
65. ntact Danfoss recommends simultaneously to check the maintenance department the filter and membrane condition and to evaluate contamination filter and membrane F Very high temperatures may indicate that elements must be replaced if necessary 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 7 Maintenance and A service of the pump unit 7 1 General safety information Danfoss offers service of the pump at the system Before servicing the pump unit it is necessary to manufacturer s location and training in how to read and understand this user manual especially service the pump Quotes are offered upon the Safety chapter 2 Remember to vvear suitable request safety equipment according to Safety chapter 2 7 3 Shut down of the system 7 2 Service and inspection interval for the A Open the pressure valves at the brine site pump to release the pressure Maintenance and service intervals are depending on the cleanliness level of the water hydraulic B Stop the high pressure pump load and temperature of the pump unit The most important parameter is the filtration ofthe Stop the feed pump water D Switch off the safety circuit breaker for See the section Service and warranty in the both the high pressure pump feed pump appendix 1 Data sheet in appendix 2 Instruc and VFD and lock them Only personnel tion and appendix 4 Instru
66. ntify a worn valve plate is to hold a straight knife edge over the valve plate VVhen holding it up to the light it vvill be possible to see any space betvveen 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 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 53 Dorf 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 vvorn valve plate has scratches and or a polished surface Even small 3 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 damage
67. o listen and look for department If one or more of the following examples are observed please act as indicated H Other observations or troubles please see appendix 7 Right and Wrong or appendix A Loose bolts check all bolts and if 6 the Trouble shooting guide necessary contact the maintenance Both appendices give good advises department in order to have all bolts regarding design installation wiring and tightened to the specified torque s troubleshooting See also service and warranty section in B Leakage if a small leakage from the bell appendix 1 Data sheet and appendix 2 housing is observed Contact the mainte Instruction nance department If the pump is not stopped for inspection as C Leakage if there is a large leak the unit recommended it can lead to damage of the should be stopped immediately Contact pump or break down See also service and the maintenance department warranty section in the appendix 1 Data sheet in appendix 2 Instruction or appendix 4 D High frequency tones safety relief valves Instruction for recommended service intervals are either damaged or running very close to their design pressure stop the unit Danfoss offers service of the pump at the system immediately Contact the maintenance manufacturer s location as well as we offer department training in how to service the pump Quotes are offered upon request E Increased noise or vibration requires the unit to be stopped immediately Co
68. oducts 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 36 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 MAKING MODERN LIVING POSSIBLE Parts list APP Pumps APP 21 43 APP 21 43 ro solutions com Parts list APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 Table of Contents i General Parts list APP 21 43 DI Parts list APP 0 6 1 0 Compact 521B0941 3 Exploded view APP 0 6 1 0 Compact 4 Parts list APP 0 6 1 0 and APM 0 8 1 2 5 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 V 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 IL 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 vievv APP 16 19 18 Parts list APP 22 19 Exploded vievv APP 22 20 Parts list APP 21 26 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 38 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Parts list APP 0 6 43 APM 0 8 2 9
69. ondition erede etre ette ex Fre IE ria 13 5 19 Instruct operator and maintenance personnel sss 13 6 Operation of pump unit ENEE e cover or QR ETC DOSE URN EXT 14 6 1 General safety Information ee cesses e er s s s y Rad RE E Er a a 14 6 2 What to listen and lookfor hme a 14 180R9266 IOM APP Pumps v03 06 2013 User manual Installation Operation and Maintenance APP Pumps APP 21 43 7 Maintenance and service of the pump unit 14 7 1 General safety information dinar ARABA n n see PA VERA ae eee 14 7 2 Service and inspection interval for the pump 14 7 3 Shut down of the system issues cares nso DER PE IH TENER A R were 14 74 Disassembling and assembling the pumpunit 15 7 5 Assembling the pump unt 15 7 6 Procedure for mounting the pump onto the electric motor 15 7 7 Getting the pump unit back into operation 15 7 8 Storage of the PUMP iii er cad ee RET En 15 8 Troubleshooting and scrapping criteria 16 8 1 General safety information ehe hen 16 8 2 Operational conditions which can cause pump failures 16 8 3 Mechanical failure aa a
70. or guidance on how to select the right filter Thoroughly clean pipes and flush system prior to start up Place a monitoring pressure switch 3 set at min inlet pressure betvveen filter and pump inlet The monitoring switch must stop the pump at pressures lower than minimum pressure Use flexible hoses 4 to minimize vibrations and noise In order to eliminate the risk of damage and cavitation a positive pressure at the inlet 5 is always to be maintained at min inlet pressure and max inlet pressure Inlet Outlet It is recommend to install safety valve or a pressure relief valve 9 in order to avoid high pressure peaks in case the pump stops momentarilly or is spinning backwards 6 For easy system bleeding and flushing a bypass non return valve 6 is integrated in the APP pump 7 A non return valve 7 in outlet can be installed in order to avoid backspin of the pump The volume of water in the mem brane vessel works as an accumulator and will send flow backwards in case of the pump stops momentarily 8 Asafety valve or a pressure relief valve 8 can be installed in order to avoid system damage as the Danfoss APP pump creates pressure and flow immediately after start up regardless of any counter pressure Note If a non return valve is mounted in the inlet line a low pressure relief valve is also required between non return valve and pump as protection against high pressure peaks
71. orge 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 H yer 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 svendhoyer svendhoyer com svendhoyer com 32 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 MAKING MODERN LIVING POSSIBLE Instruction Recommended service intervals for APP pumps ro solutions com nstruction Recommended service intervals for APP pumps Table of Contents Il General information Recommended service 2 Design features intervals for APP pumps 180R9199 3 Appendix 1 1 General information This guideline provides information on the recommended service intervals The recommen dation is based upon good engineering practice and on experience gained from operation even under extreme conditions The recommendation is for guidance only 2 Design features Danfoss APP pumps are designed for long operation and low maintenance and life cycle costs Danfoss guarantees 8 000 hours service free operation however max 18 months from date of production After 8 000 operation hours it is If the Danfoss recommendations concerning system design see o
72. per Duplex PEEK 67 1 Key 12x8x70 AISI 316 x 71 1 Retainer guide Super Duplex PEEK 80 4 Spacer Super Duplex 91 1 Port plate Super Duplex PEEK x 92 Valve plate Super Duplex x 93 9 Back up ring PTFE x 94 9 O ring 30 2x3 NBR x x 121 1 Port flange Duplex PEEK 122 1 O ring 68x2 NBR x 123 1 O ring 228x4 NBR 124 1 Shaft seal Hastelloy NBR x 125 1 Cover for shaft seal Super Duplex 126 2 Pin 10 5x20 Duplex x 127 4 Screvv M6x16 AISI 316 x 128 15 Screw M8x90 AISI 316 x 142 1 Stop for shaft seal PP x 144 4 Tailstock screw M12x60 AISI 316 145 4 Check nut M12 AISI 316 x 146 1 Lifting eye AISI 316 147 1 Screw M8x16 AISI 316 x 151 1 O ring 35x3 FPM 75 x x 152 1 Valve cone Super Duplex x 153 1 Spring 1 9x 25x33 7 Duplex x 154 1 Plug guide Super Duplex x 155 1 O ring 47 22x3 53 NBR x x Instruction x x x 42 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 APP 30 1200 and APP 43 1700 Exploded view Parts list 23 xoq ay Ul dwnd ay 0 1xeu peoeld aq JIM p lunoul 10U IM Gy pU pyL SOd Lu Jal TF R VII 8671 Dua TZ Z WIG ETZZ UNE 5 UNOE 4301 HUE UIQ GE o A WNZ WNOL p AIG Lo TF 11301 gez WNZ WNOL 29 1141 8671 MIA tec z WNZ WNOL vere av E hq TZ 7 W WNL WNZ WA ETZ E PN 001 t0 UNE F WN
73. per Duplex PEEK x 62 4 Spring Duplex x 63 1 Spring guide PP x 64 1 Retainer ball Super Duplex DLC x 65 1 Retainer plate Super Duplex x 66 9 Piston Super Duplex PEEK x x x 67 1 Key 12x8x70 AISI 316 x 71 1 Retainer guide Super Duplex PEEK x 91 1 Port plate Super Duplex PEEK x 92 1 Valve plate Super Duplex x 93 9 Back up ring PEEK x x 94 9 O ring 30 2x3 NBR x x 121 1 Port flange Duplex PEEK 122 1 O ring 268x2 NBR x 123 1 O ring 2228x4 NBR x 124 1 Shaft seal Hastelloy NBR x 125 1 Cover for shaft seal Super Duplex 126 2 Pin 10 5x20 Duplex x 127 4 Screvv M6x16 AISI 316 x 128 15 Screvv M8x90 AISI 316 x 142 1 Stop for shaft seal PP x 144 4 Tailstock screvv M12x60 AISI 316 145 4 Check nut M12 AISI 316 x 146 1 Lifting eye AISI 316 147 1 Screvv M8x16 AISI 316 x 151 1 O ring 35x3 FPM 75 x x 152 1 Valve cone Super Duplex x 153 1 Spring 1 9x 25x33 7 Duplex x 154 1 Plug guide Super Duplex x 155 1 O ring 47 22x3 53 NBR x x nstruction x x x x x x x x x x x x x 40 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 Parts list Exploded view APP 21 26 21 7 Di Io Lr T Ly 44 t2 7 i Xoq y Ul dund ay 0 1xeu peoeld aq JIM 1301 TZZ 5 491 8 peiunou ag JOU JIM Gp PUB 904 WNE UINOE ON WNG WNOL 002 WNOL BA pL OF Di Io p T 14401 Ze 1 1119188271 WNL UNZ ALL TF 31141 8671 WNZ WNOL Di
74. pump shaft may cause high internal leakage Only applying to APP 0 6 to APP 3 5 and APP 21 to APP 26 only Also applying to APP S 674 pumps 1 5 1 Ensure that the air gap between the two coupling parts is min 5 mm It should always be possible to move the plastic part on the coupling at least 3 mm To ensure easy mounting of the flexible coupling without using tools the tolerances must be dimensioned accordingly WARNING Any axial and or radial loads on the shaft must be avoided Any axial or radial load will cause breakdown A Bell housing B Flexible coupling C Motor shaft A B C 1 6 Pump damage the internal parts may be damaged 1 6 1 Contact Danfoss sales office for guidelines in how to troubleshoot internal pump parts Instructions on internal elements 180R9092 180R9085 for APP 0 6 1 0 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 48 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Dorf Instruction Trouble shooting guide for APP and APP S 674 pumps 2 Reduced flow reduced pressure Cause Remedy Comments 2 1 Wear on pump Large internal leakage due to 2 1 1 Dismantle the pump 2 1 2 Check valve pla
75. rder to eliminate the risk of damage Note If a non return valve is mounted in the and cavitation a positive pressure at the inlet line a low pressure relief valve is also inlet 5 is alvvays to be maintained at min required betvveen non return valve and pump inlet pressure and max inlet pressure as protection against high pressure peaks Recommend to install safety valve or a Media filter OMOR Feed gt LS Permeate Lo Aa Brine 14 Service 14 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 it will strongly influence the life of the APP pumps 14 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
76. re particles can pass through the filter in tunnels String wounded filters are typically channelling filters A string wounded filter may have a filtration efficiency of only 50 which will cause internal wear and must always be followed by a main filter Insufficient filtration means that too many or too large hard particles can pass the main filter because it is damaged bypassed or simply too poor Filtration efficiency must be 99 98 Beta 5000 at 10 um to prevent abnormal wear of the pump Temperature gt 50 C will cause wear on internal pump parts Mount a temperature switch and check its set point function The temperature switch will ensure that the pump stops at fluid temperatures gt 50 C 2 2 Low inlet pressure 2 2 1 Check that booster pump supplies the right pressure flow 2 2 2 Check if filters require replacement If the pressure drop across the filters is too high the booster pump does not deliver sufficient flow pressure No pressure or low pressure results in cavitation and insufficient internal lubrication causing wear on internal pump parts Mount a low pressure switch in front of the pump and check its set point function The low pressure switch ensures that the pump does not start until the inlet pressure has reached 1 bar 2 3 Rotation speed rpm 2 3 1 If VFD operated check frequency 2 3 2 Check that rotation speed of the electric motor is as stated on name plate on electric
77. refore 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 9896 at 10 um We recommend to use precision depth filter cartridges rated 10 um abs p10 x 5000 equivalent to a filtration efficiency of 99 98 Bag filters and string wound filter cartridges typically have only 5096 filtration efficiency This means that for each 100 000 parti cles reaching the filter 50 000 particles pass through it compared to only 20 particles in a filter with an efficiency of 99 9896 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 Monitoring It is recommended to continuously monitor the following conditions Filter clogging Pressure inlet and outlet side of the pump 3 Building up the pump unit A Elastic coupling B Bell housing C Motor shaft D Pump flange E O max 0 25 mm max 0 01 inch 3 1 Mounting 1 Mount the coupling flush or maximum 1 mm offset from the pump shaft end Ensure an air gap between coupling and pump flange of min 4 mm 0 16 inch 2 Mount the bell housing on pump Secure nuts with the right torque 3 Measure the longest distance
78. s crane etc Piping must be aligned without residual stress Do not mount expansion joints so that their force applies internal pressure on the pump connections 5 9 Electrics All electrical installation work must be carried out by authorized personnel in accordance with EN60204 1 and or local regulations see also Safety chapter 2 Turn off the safety circuit breaker and lock it Mount the power cable on the electric motor If a VFD is used adjust the protective motor switch VFD to the current limits found on the name plate of the electric motor 5 10 Instrumentation The pressure switch sensor should be mounted as close to the pump as possible It is recom mended to test the pressure sensor switch via an instrumentation manifold Mount the pressure switch sensors according to the manufacturer s instructions 5 11 Connections Mount and tighten connections and check valve s as specified 12 180R9266 IOM APP Pumps v03 06 2013 Denis User manual Installation Operation and Maintenance APP Pumps APP 21 43 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
79. s can be determined using one of the following guiding equations l min x bar 16 7 x m h x bar 0 26 x gpm x psi Required power kW or kW kw Calc factor Calc factor Calc factor Thp 075kW 1kW 134hp 1gpm 3 791 min 1l min 0 26 gpm 1m h 440gpm 1gpm 0 23 m h 8 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Data sheet APP 21 43 8 Temperature and Fluid temperature corrosion 42 C to 50 C 35 6 F to 122 F dependent on the NaCl concentration Ambient temperature 2 C to 450 C 35 6 F to 122 F 8 1 Operation The chart on the next page illustrates the If the water pump is operated at high salinity corrosive resistance of different types of stainless always flush the water pump with fresh water at steel related to NaCl concentration and tempera operation stop in order to minimize the risk of ture crevice corrosion All critical parts of the APP water pump is made of Super Duplex NaCl vs temperature 80 C 70 Super Duplex 60 50 316L 40 30 20 ar 100 1000 10000 100 000 ppm NaCl 160 1600 16000 160000 ppm 8 2 Storage Storage temperature Frost protection is required at temperatures 40 C to 70 C 40 F to 158 F provided below 2 C Danfoss recommends to use DOW that the pump is drained of fluid
80. ta sheet APP 21 43 4 Variants Available as ATEX certified Category 2 For more details on the variants please contact zone 1 and category 3 zone 2 the Danfoss High Pressure Pumps Available with pressure containing parts in Super Duplex according to NORSOK Available vvith material certificates on metallic wetted parts Available with API 674 design verification 5 Flowatdifferent rpm When using the diagrams 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 APP 1200 rpm version m3 h 32 0 30 0 APP 30 1200 28 0 26 0 24 0 22 0 20 0 18 0 16 0 14 0 12 0 4 10 0 8 0 T T APP 26 1200 APP 24 1200 APP 21 1200 rpm APP 1500 rpm version m h 40 0 38 0 APP 38 1500 36 0 34 0 32 0 7 APP 30 1500 28 0 Li APP 26 1500 24 0 APP 24 1500 22 0 APP 21 1500 20 0 18 0 16 0 14 0 12 0 10 0 8 0 T T T T T rpm 6 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 Data sheet APP 21 43 APP 1700 rpm version m3 h 45 0 42 0 39 0 36 0 33 0 30 0 27 0 24 0 21 0 18 0 15 0 Pm SD OD SD O LC D cQ HD DO OC D OC O9 LO 9 cQ O S ai ci cO dq cO DONI 4S X40 WI NI OI DY LY S PAPE PS PSP PP A A AS
81. taining 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 180R9266 IOM APP Pumps v03 06 2013 Zayi User manual Installation Operation and Maintenance APP Pumps APP 21 43 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 Do not try to lift the pump unit manually most of the pumps weigh more than 20 kilos see specific weight for the pump in the appendix 1 Data sheet Always bleed the pump prior to initial start up Do not mount the pump without the bell housing and a flexible coupling Do not try to start the unit before the system components are mounted bleeded and adjusted Flush the system throughly before connecting the pump or pump unit Check rotatio
82. te Valve plate has marks scratches on the surface facing the port plate Minor wear on valve plate can cause large internal leakage See Index 6 1 2 1 3 Check port plate Port plate has marks scratches on the surface facing the valve plate Minor wear on port plate can cause large internal leakage See Index 6 2 2 1 4 Check cylinder barrel Liners in cylinder barrel may be scratched or worn Insert a piston in the liner and check the fit If there is any space clearance between liner and piston liner or piston is worn 2 1 5 Pre treatment Analyse fluid for content of particles Check that filters are OK and working correctly 2 1 6 Main filtration Check that the correct filter type is used particles in fluid must not exceed 10 um Danfoss High Pressure Pumps supplies filters please contact the sales office 2 1 7 Fluid type The APP and APP S 674 pumps are designed for seawater operation for any other fluid please contact Danfoss High Pressure Pumps sales office for further help 2 1 8 High fluid temperature If fluid temperature is above 50 C stop the pump immediately Check internal parts see above Typical signs of wear Polished surface all over the swash plate Normally only half of the swash plate the pressure side is polished See index 6 3 If the ring is missing the piston is very worn The filters can be bypassed even if they are correctly mounted Some filters can create channelling whe
83. uip ment from overloads with suitable equipment In case the pump delivered is ATEX certified the additional ATEX instruction must also be read Protective garments must be worn 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 ALX 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 Improper installation will or can result in personal injury and or damage to the pump Use of this manual does not relieve operation and maintenance personnel of the responsibil ity of applying good judgment when operating and main
84. ump housing of water and close it damage if it should run dry again 3 Connect the pump to a tank containing 5 4 Disconnection anti freeze additive Connect a hose to the If the inlet line is disconnected from the water inlet port of the pump and via another supply the pump will be emptied of water hose return the flow from the outlet port to through the disconnected inlet line the tank with antifreeze additives 4 Quickly start and stop the pump Make When starting up again follow the bleeding sure that the pump does not run dry procedure described under section 4 Initial The pump is now protected against start up internal corrosion and frost 6 Service 6 1 Warranty This is done in order to prevent a potential Danfoss APP pumps are designed for long breakdown of the pump If the parts are not operation low maintenance and reduced replaced more frequent inspection is recom lifecycle costs mended according to our guidelines Provided that the pump has been running Standstill according to the Danfoss specifications Danfoss The APP pumps are made of Duplex Super guarantees 8 000 hours service free operation Duplex materials with excellent corrosion however max 18 months from date of produc properties It is however always recommended tion to flush the pump with freshwater when the system is shut down If Danfoss recommendations concerning system design are not followed it will strongly influence the life of the APP pumps 6 3
85. ur data sheet are not followed the service life of the APP pumps might be affected The recommended service intervals on the different parts in the APP pumps appear from the recommended to inspect the pump and replace table below worn parts if any Pos Oty Description Material Service interval 1 1 Housing main bearing Duplex PEEK No need for service 11 125 1 Mounting flange Wetted part Duplex No wear part 211 end flange Dry part AISI 316L 121 181 1 Port flange Duplex No wear part 31 1 Swash plate Super Duplex 40 000 hours 66 5 7 9 Piston Super Duplex and PEEK Recommended inspection on a yearly basis and evaluated acc to app 1 92 1 Valve plate Super Duplex 24 000 hours 91 1 Port plate Super Duplex PEEK 24 000 hours 61 1 Cylinder barrel Super Duplex 40 000 hours 65 1 Retainer plate Super Duplex 24 000 hours 64 1 Retainer ball Super Duplex 40 000 hours 71 1 Retainer guide Super Duplex 40 000 hours 62 1 4 Spring Duplex 40 000 hours 63 1 Spring guide Duplex or PP 40 000 hours 142 1 Stop for shaft seal PP No wear part 124 215 1 Shaft seal Hastelloy and NBR It is good practice to change the seal after each disassembly of the pump 125 1 Cover flange for shaftseal Super Duplex No wear part 93 5 7 9 Back up ring PTFE 24 000 hours zi O ring overall NBR 24 000 hours Screw overall AISI 316 No wear part Pin overall AISI 31
86. ve 4 6 4 Check internal parts for wear damage At too low outlet pressure the pump will create higher pressure pulsations and thus make noise Too low pressure also causes insufficient internal lubrication and wear on internal parts Pump may eventually be damaged Too high outlet pressure may damage the pump 4 7 Soft start stop 4 71 Check if noise is normal when the pump is running at operation speed 4 7 2 If noise is abnormal at operation speed check internal parts see above Noise frequency changes during soft start up stop 180R9266 IOM APP APP 21 43 Appendices v07 11 2013 51 nstruction Trouble shooting guide for APP and APP S 674 pumps 5 Noise from installation Cause Remedy Comments 5 1 Inlet outlet connections hoses pipes 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 Non flexible connections mounted directly on the frame will cause even small pressure pulsations from pump and create vibrations in the system plant 5 2 Length dimension of inlet outlet line 5 2 ncrease pipe diameter and or the number of bends Too small pipes or too many bends may create too fast flovv turbulence through the pipes an
87. ve 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 Product information see label on product Only 1 product on each report Product type 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 ji absolute nominal Flow Water temperature Water type TDs Pumps in parallel yes no Returns without a return number will be rejected III 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 pump onto the

APP 21-43 - Depco Pump Company

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