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APP 21-38

1. 2 01 ddV 195 1514 61 78081 Ce 44 195 1e d ysems 62179081 6 9 195 exejd ysems 0179081 ZL 195 eleld ysems 15158081 2 8 195 eleld ysems 2178081 2 01 ddV 195 eleld ysems 58159081 EE CTT e ey sse res E Leser fe Ne ed E e A X X 43 Parts list APP 0 6 38 0 8 2 9 APPW 5 1 10 2 11 APPW 5 1 10 2 Note The parts listed are not sold separately only in various kits Exploded view see next page C OL L S 195 295 19174081 2 01 1 5 peq 09179081 2 8 1 5 ddV 19 aleld 85179081 1 39 eleld 65179081 2 8 1 6 MddV 195 98078081 01 MddV 195 laulelad 18079081 C 8 L S 195 003519 75179081 2 01 ddV 195 003514 66179081 Ce 44 195 1e d ysems 62179081 6 9 195 exejd ysems 06178081 CZ 195 eleld ysems 15159081 2 8 195 eleld ysems 179081 2 01 ddV 195 eleld usews 58159081 Designation Housing Pin 06 10 Bleeding plug O ring 4 5 1 5 Swash plate Duplex PEEK AISI 316 Duplex NBR Super Duplex Swash plate Super Duplex Swash plate Super Duplex Swash plate Super Duple
2. ase saw ms ET hm i sorng isxaasoxsa7 owes __ _ hw 1 _ ps _ var mao 48 18089266 IOM APP APP 21 38 Appendices v01 09 2012 ech N LA ech ech ech N ii APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Parts list 16 Exploded view APP 16 19 WNE WNOE WNL UN WNL 49 18089266 IOM APP APP 21 38 Appendices 01 09 2012 Parts list APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 17 APP 22 Note The parts listed are not sold separately only in various kits Exploded view see next page 195 295 90579081 001 ZZ OOSL ZZ 4 ysems 81279081 195 uolsid 00579081 ysems 0579081 195 Jepur A 60274081 195 eleld 70208081 195 4 10079081 195 Buiusnj4 60774081 Designation em superbu O gt 10 Lo 5 Retainer ball Supe
3. 4 18089266 IOM APP APP 21 38 Appendices v01 09 2012 Data sheet APP 21 38 All parts included in the pumps are designed to The pumps are fxed 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 No oil lubricant required 3 Technical data Code number Standard APP Pumps Geometric displacement Rated flow at m h max speed Outlet min pressure 2 Outlet max pressure continuous 3 Inlet min pressure Inlet max pressure continuous Inlet max pressure peak Max speed continuous Min speed continuous Power requirement at max speed and 80 bar 1160 psi Torque at 80 bar kg Integrated flushing valve the market Can be powered by a combustion engine provided that a special coupling is used Long service life No preventive mainte nance required in the warranty period Generates insignificant pulsations in the pressure line Integrated flushing valve All parts of the pump are made of non corrosive materials e g Duplex EN1 4462 UNS 531803 532205 and Super Duplex EN1 4410 UNS 532750 stainless steel and carbon reinforced PEEK High efficiency in rpm APP 21 APP 21 APP 24 APP 24 A
4. Ee e 13 5 15 Bleed and remove air from the pump 13 5 16 Verify direction of rotation V Ur quis Tuque wa usq ERR Rd adi EE 13 5 17 COMMISSIONING Gu 13 5 18 Check the filter 13 5 19 Instruct operator and maintenance 13 6 Operation of motor pump unit 14 6 1 Ge eral safety informati sua esr uuu 14 6 2 What to listen and look fof 14 18089266 APP Pumps v01 09 2012 User manual Installation Operation and Maintenance APP Pumps APP 21 38 7 Maintenance and service of the pump unit 15 7 1 General safety information 15 7 2 Service and inspection intervalforthepump 15 7 3 Shut GOWN OF ING eet v eu 15 74 Disassembling assembling the pump unit 15 7 5 Assembling the pump unit 16 7 6 Procedure for mounting pump back onto electric motor 16 7 7 Getting the pump unit back into 16 7 8 Storage
5. 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 weight more than 20 kilos see specific weight for the pump in the Data sheet which is found in appendix 1 Do not run the pump if itis completely dry and not bleeded 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 2 5 Incase of doubt Please contact Danfoss A S in case of doubt Contact information are listed in section 1 3 Manufacturer and customer service address User manual 3 Technical data Installation Operation and Maintenance APP Pumps APP 21 38 3 1 Approved applications and operational limits for the pumps The pump and the pump units are designed for the use in a Sea Water Reverse Osmosis SWRO or Brackish Water Reverse Osmosis BWRO systems The APP pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor Use of the pump in other applications not suitable for the pump unit can cause damages to the pump unit with risk of personal injury For system integration of the pumps please see Data sheet and Instruction which are found in appendix 1 Data sheet and 2 APP pump instruction 3 2 Application range See Data sheet in appendi
6. Recommended service intervals for APP pumps Pistons In case of doubt the pistons must be replaced The pistons are the heart of the pump regarding service The pictures below is ment as a guideline for evaluating the wear of the sliding surface If the pistons break down the pump will suffer a breakdown Cavitation of the piston shoes Cavitation of the piston shoes New inspection is required in 3 000 4 000 hours All pistons must be replaced within the next 500 1 000 hours Cavitation of the piston shoes Cavitation of the piston shoes All pistons must be replaced within the next All pistons must be replaced immediately 100 200 hours Abrasive wear of the piston shoes All pistons must be replaced immediately 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 31 Instruction 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 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 32 18089266 IOM APP APP 21
7. 8 3 10 mie 8 4 Arrival inspection transportation handling lifting and 9 4 1 Bua Ts DOE TOR aa pda Ra REDE EE 9 4 2 Pr 9 4 3 General safety informati M cese Ere Ra eR pe decease 9 4 4 Transport and tree b 9 4 5 RETIN to scu ats exe X ra Ex aa ex ada we aa RE CE Rs 10 4 6 Storage 10 5 Installation and COMMISSIONING 11 5 1 Important CIMENSIONS J quo Id EX OR bers 11 5 2 11 5 3 PII temperatur as ____ _ _ 11 5 4 Electrical data mmm 11 5 5 Local 11 5 6 Pre mounting checklist based on Danfoss preferred system design 12 5 7 Lifting pas TT 12 5 8 Mount the different equipment 12 5 9 dia C eer ee ee 12 5 10 12 511 6 2 12 5 12 ees 13 5 13 Verify setting of safety relief valves 13 5 14 FIGS the pump suc e dea RR EU Ra OR
8. ysems 91579081 002 91 ysems 8127808 ysems 61579081 0051 91 ysems 127808 Exploded view see next IE O ring 211 0 x 2 0 NBR L Screw M8 x 30 O ring 0182 x 4 0 NBR x O ring 0919 x 2 62 NBR De _ est Superbuplex EK swashplate Superbuplex PEk swashplate SuperDupier swashplate SuperDupier m 1 sempe super Duplex reex m ccce E Jumm oases ree a Duplex PEEK sme _ cR UN seecee Se 6 oo Lanser x _ 6 Paton EES x amp p Jaen fase m s mgao x _ m p me swere m 11 vene sp 7 maan ___ o x 7 _ x _ hm mne p e x E p ooa mm x pm 1 x _ us 1 coverforsateseat sp __ m 2 mesa pw gt x 4 eme Jo m pe sewecs eme Jo Ds p ums em O be h ponsa L
9. Japul AD 98179081 Pedwo 01 90 195 28 17808 Pedwo 071 970 ddV 195 Jeute3ay 28178081 12edui05 011 920 195 uoisid 18179081 Pedwo 970 195 e1e d 78178081 Pedwo 0 1 ddV 195 e1e d usews 68179081 Screw M6x12 AISI 316 Super Duplex PEEK 3 LA 6 2 4 5 6 Key 3x3x12 51 316 91 92 i B 1 5 10 1 1 1 1 1 1 1 5 1 1 1 5 5 1 1 1 1 1 1 1 1 1 1 1 1 94 121 O ring 053x1 5 NBR 124 Shaft seal AISI 316 NBR 126 Pin 4x9 PEEK Washer for shaft seal 14 142 151 Plug guide Duplex 156 Locking ring AISI 316 x x Instruction 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 35 APP 0 6 38 0 8 2 9 5 1 10 2 Exploded view APP 0 6 1 0 Compact Parts list 3 7 d pe ZZ X M ANS 77 T 18089266 IOM APP APP 21 38 Appendices v01 09 2012 36 Parts 1154 4 0 6 1 0 0 8 1 2 0 6 38 0 8 2 9 5 1 10 2 The parts listed are not sold separately only in various kits Parts for APM 0 8 1 2 are equivalent to the parts for APP
10. _ m p ws x _ omweg nar _ Da esos _ _ __ _ us mensa mee x x _ hw lt screw asians lasse _ Dw soos ep x _ _ 4 asins _ _ lt asians _ _ asians sees x ps mn tes _ Ds omeeemes wor Joe mwa 195 eleld ysems 917808 gt gt i LA N n gt gt gt i gt ii gt gt gt gt gt gt gt gt gt gt 52 18089266 IOM APP APP 21 38 Appendices 01 09 2012 APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Parts 1154 Exploded view APP 21 26 20 UNE WNOE WS 7 22204 lt GS 42 gt Ee
11. housing pump on the motor After mounting it must be possible to move the elastic gear ring 3 5mm 0 12 0 2 in axial 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 the Danfoss Sales Organization Bolts and nuts torque 75 Nm 5 Nm Choose tolerances to 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 3 2 Direction of rotation Is indicated by an arrow on the pump label NESSIE E 3 3 The pump be mounted orientated 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 pre
12. 2 1 Wear on pump Large internal leakage due to Pre treatment Main filtration Fluid type High fluid temperature 2 2 Low inlet pressure 2 3 Rotation speed RPM 2 1 1 Dismantle the pump 2 1 2 Check valve plate Valve plate has marks scratches on the surface facing the port plate Minor wear on valve plate can cause large internal leakage See Index 6 1 Check port plate Port plate has marks scratches on the surface facing the valve plate Minor wear on port plate can cause large internal leakage See Index 6 2 Check cylinder barrel Liners in cylinder barrel may be scratched or worn Insert a piston in the liner and check the fit If there is any space clearance between liner and piston liner or piston is worn 2 1 5 Analyse fluid for content of particles 2 1 6 Check that filters are OK and working correctly 2 1 7 Install correct pre filter nom string wound filter 2 1 8 Check that the correct filter type is used particles in fluidmust not exceed 10 um Danfoss RO Solutions supply filters Please contact Danfoss sales office 2 1 9 The APP pump is designed for seawater operation for any other fluid please contact Danfoss sales office for further help 2 1 10 If fluid temperature is above 50 stop the pump immediately 2 1 11 Check internal parts see above 2 2 1 Check that booster pump supplies the right pressure flow 2 2 2 Check if filters require replacement 2
13. Leisungen 5 gt L O ring 029 3 FPM 75 x Ces Spring 0 9 025 337 Duplex Pugude L pepuge ILL ILL LI EES jJ x x x J x J x x x J x jJ gt gt gt gt l i gt 46 18089266 IOM APP 21 38 Appendices 01 09 2012 APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 Parts list Exploded view APP 11 13 14 WNE WNOE WNZ WNOL UINL WNE WNOE lt DI u NE lt iz EN lt e ING A ANNUI SN NN BN ALLP 47 18089266 IOM APP APP 21 38 Appendices v01 09 2012 Parts list APP 0 6 38 0 8 2 9 5 1 10 2 15 APP 16 19 61 91 ddV 195 5 90578081 61 91 ddV 195 Jepur A 08 61 91 ddV 195 aleld 7059081 61 91 ddV 195 3 4 10579081 61 91 ddV 195 403514 LCCV808L 61 91 ddV 195 4081 Note The parts listed are not sold separately only in various kits 0051 61 002 61 ysems 1278081 0051 ZL ddV ysems 05279081 uda 0081 ZL
14. Maintenance APP Pumps APP 21 38 2 1 General information Dangers that can arise from not following the instructions When the pump or pump system is managed by untrained personal there is a danger of e Death or fatal injuries Costly damages and claims AN tes All electrical installation work must only be carried out by authorized personnel in accordance with EN60204 1 and or local regulations Install a lockable circuit breaker to avoid inadvertent starting Protect the motor and other electrical equip ment from overloads with suitable equipment Protective garments must be worn It is recommended to place a local safety switch near by the pump enabling service personal to cut power for the electric motor This prevents unintentionally starting the unit during servicing 0000 Always wear suitable safety clothing when handling the pump When working near the pump system safety proof boot shoes safety glasses ear protection and safety helmet must always be worn ASS 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 VFD VFD operation may increase the temperature inside the el
15. 195 15179081 6 2 0 2 195 05179081 6 2 0 2 195 uoisid 67179081 0 6 195 eleld usews VELy9081 S E ddV 195 ee d ysems 179081 6 6 195 aeAleAPulysnlj 919081 a NN a on 2 J y MUN SALE s J y 7 7 1 Valve plate Super Duplex 7 Back up ring 4 7 0 2 3 To ln s li ln sp Io E 1 92 93 bemus s Jm 5 ae e Ge bases ma 12 12 12 12 12 12 12 12 12 13 15 15 15 15 geepsssmessspssespesspesspseeprp 18089266 IOM APP APP 21 38 Appendices v01 09 2012 41 APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Parts list Exploded view APP 3 0 3 5 9 41995 2 5 lt S EXE ks HESS 18089266 IOM APP APP 21 38 Appendices 01 09 2012 42 Parts list APP 0 6 38 0 8 2 9 APPW 5 1 10 2 10 APP 5 1 10 2 Note The parts listed are not sold separately only in various kits Exploded view see next page C OL L S 195 e s 19179081 C OL L S dd V peq 09173081 Designation Duplex PEEK AISI 316 Duplex NBR Super Duplex Housing Pin
16. 6 2 5 2 WdV S Z Z Z 195 7179081 SZ S L ddV 195 uolsid 7179081 66 61 195 5 4 9217808 Duplex PEEK Super Duplex PEEK Super Duplex Super Duplex Super Duplex PEEK Super Duplex PEEK Super Duplex Duplex ASI316 NBR Dry port ASI 316 62 3 4 67 9 Ww N 2 22 23 124 m4 125 126 127 128 129 130 152 153 154 155 L IL ITE 18089266 IOM APP APP 21 38 Appendices v01 09 2012 39 APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Parts 1154 n Hi gt 00 of 5 oe Ga x A LLI lt lt S10p S10D 2 10 10p ON 5 A gt E 22 1 22222 e WUT NN p S li N 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 40 Parts 1154 8 APP 3 0 3 5 APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Note The parts listed are not sold separately only in various kits Exploded view see next page 6 2 0 2 195 295 5SLy9081 0 ddV 195 Jepur A 2517808 S 0
17. NNN _____ Prior to installation burrs and chipsand 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 screwed components to be Using teflon tape or packing yarn in sealed with O rings or bonded seals joints may cause damage 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 mt 1 Fill cold water into the system via the return filter and bleed the pump Power Packs PPH 4 63 10 and 12 5 are self bleeding 2 Start and bleed the system without pressure by opening the bypass valve 3 Add the cleaning agent to give 3 agent water solution 4 Run the system for 60 min and activate all components as often as possible to ensure effective flushing with the cleaning agent Level and temperature indicators Missing or incorrectly con
18. Serial number 4 0 6 7 14 15 Shutdown 15 16 Space 8 u 15 Statu uns sonet Rr uera 7 17 StOFdge ish Ged 9 10 12 15 16 6 System 6 7 8 11 12 13 14 15 Systems 7 8 T Table 2 Technical data 8 Temperature 7 10 11 12 13 14 15 17 Transportation 6 9 12 15 16 Trouble shooting 14 17 V Valve 7 11 12 13 14 15 17 W 6 9 Danfoss accept no responsibility for possible errors 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 18089266 IOM APP Pumps v01 09 2012 MAKING MODERN LIVING POSSIBLE User manual Appendices for Installation Operation and Maintenance Manual APP pumps APP 21 38 2138 S ro solutions com User manual Table of Contents Appendices for IOM Manu
19. definitions and a guidance on how to select the right filter APP30 38 14 07 APP 21 26 351 13 82 Bleeding plug 70 2 76 0 39 99 sun 1 57 Data sheet APP 21 38 3 inlet hose kit 3 18070277 2 79 Victaulic 29 inlet 2 Victaulic 180B3206 Vic Duplex ET REIR AN 4 Hexagon AF 6 mm negen p A 3 inlet 3 Victaulic 180B3208 outietport M oxis depth24mm Wie Duplex 7775 Non return valve 215 Victaulic 180H0050 Pump mounting flange 18084 outlet Duplex OD 73 1 mm For more details on the accessories please contact the Danfoss RO Solutions Sales Organisation 12 Dimensions complete unit APP30 38 357mm IEC 250 280 265mm APP 21 26 Section APP 30 38 APP 21 26 Accessories keete 211 25 8 3 Accessories 10 18089266 IOM APP APP 21 38 Appendices 01 09 2012 Data sheet APP 21 38 APP 21 24 Examples of different pump motor sizes Check required power 13 Installation 13 1 Mounting further information To ensure easy mounting of The figure below illustrates how to mount the the flexible coupling without using tools the pump and connect it to the electric motor tolerances must be dimensioned accordingly combustion engine Note Any axial and radial loads on the pump If alternative mounting is required please shaft must be avoided contact Danfoss RO Sales Organization for Ensure 3 5mm 0 12 0 2in air ga
20. flush system prior to start up 3 Place monitoring pressure switch 3 set at min inlet pressure between filter and pump inlet The monitoring switch must stop the pump at pressures lower than minimum pressure 4 Use flexible hoses 4 to minimize vibrations and noise 5 norderto 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 Recommend to install safety valve or a Media filter 9 3 O ORS 4 5 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 12 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 pressure relief valve 9 in order to avoid high pressure peaks in cas
21. 0 6 1 0 except for valve plate sets Exploded view see next page 90 dd V 195 OpLESOSL 01 90 dd V 195 e1e d 65179081 1 8 0 WdV 195 aleld 00174081 0 1 9 0 195 8179081 0 1 9 0 195 03514 15179081 Designation 0 1 9 0 ddV 195 295 17179081 122 O ring 68x2 NBR 123 O ring 240 2 NBR exem m mw 130 O ring 4 5x1 5 NBR LA N 155 O ring 27 0x1 5 NBR jedem 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 37 APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 Parts list Zod o 599 x D 2 w lt lt 5 NS v01 09 2012 18089266 IOM APP APP 21 38 Appendices Parts 1154 0 6 38 0 8 2 9 APPW 5 1 10 2 6 1 5 2 5 1 8 2 9 Note The parts listed are not sold separately only in various kits Parts for APM 1 8 2 9 are equivalent to the parts for APP 1 5 2 5 except for valve plate sets Exploded view see next page 67 671 ddV 195 295 7 78081 62 671 195 971598081 S Z S L ddV 195 eleld 08 6 Z 8 1 WdV 195 aleld 10054081 0 2 8 1 WdV 8 1 5 1 195 2117808
22. 06 10 Bleeding plug O ring 24 5x1 5 Swash plate Swash plate Super Duplex Swash plate Super Duplex Swash plate Super Duplex Super Duplex AISI 316 Swash plate Pin 06 10 O ring 0117 2 5 LA A Super Duplex PEEK Super Duplex Cylinder barrel Q A Retainer ball Ui Retainer plate Super Duplex Retainer plate Super Duplex 2 8 1 5 195 eleld 85179081 801 39 eleld 65179081 2 8 1 5 ddV 195 95159081 COL 195 15179081 C 8 L S 195 uoisid 75179081 Piston Piston Key 10x8x45 Port plate NO OV lt J Port plate N Valve plate ring O ring 018 3 2 4 Port flange O ring 0135 3 Guide pin Pin 26x10 Pin 26x10 Screw M8x20 Mounting flange O ring 0135 3 8 Co N 3 Un 8 86 2 N N i Instruction 18089266 IOM APP APP 21 38 Appendices v01 09 2012 Super Duplex PEEK Super Duplex PEEK AISI 316 Super Duplex PEEK Super Duplex PEEK Super Duplex PTFE Super Duplex NBR Super Duplex AISI 316 PEEK AISI 316 AISI 316 PEHD Z Z 2 2 UJ 00 UJ Hastelloy NBR PEEK Super Duplex AISI 316 AISI 316 PITT A ee
23. 3 1 If VFD operated check frequency 2 3 2 Check that rotation speed of the electric motor is as stated on name plate on electric motor Check that the motor rotor winding is not damaged 180R9266 IOM APP APP 21 38 Appendices 01 09 2012 See instruction on replacement criteria 521B0925 Are available on www ro solutions com Typical signs of wear Polished surface all over the swash plate Normally only half of the swash plate the pressure side is polished See index 6 3 If the ring is missing the piston is very worn The filters can be bypassed even if they are correctly mounted Some filters can create channelling where particles can pass trough the filter in tunnels String wound filters are typically channelling filters A string wound filter may have a filtration efficiency of only 5096 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 9896 Beta 5000 at 10 hmto 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 If the pressure drop across the filters is too high the booster pump does not deliver
24. APP APP 21 38 Appendices 01 09 2012 MAKING MODERN LIVING POSSIBLE Right and wrong Trouble shooting guide for water hydraulic systems w mm BHEE i E d danfoss high pressurepumps com 180R9042 Choice of material 655550555 Plastic Stainless steel Always use system components made of corrosion proof materials Non corrosion proof materials may cause damage Choice of filter Install a 10 micron absolute filter with pressure switch Return filter with bypass valve and poorer filterability than 10 H will damage the system Filter location Locate the return filter in the return line immediately before the tank Placing the return filter upstream of the 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 outlet 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
25. aleld ysems 079081 0051 92 920051 92 001 LZ 195 001519 9179081 0021 9 1 195 001519 9179081 195 001514 66179081 0051 2 12 Exploded view see next page mem esee LLL ES bbb gt wa x _ ec ii TP T T T T h war De 2 ooo wn _ m _ __ _ 2 unes ens _ _ o Em sense l gt gt moos our x i onder barra ____ __ CE so e _ nevera sl _ __ __ __ e Ise n i x _ m meme sewer x wwe x _ m s saan ree e _ ws x x
26. appendix 7 Right and Wrong which gives good advises in design installation wiring and troubleshooting User manual Subject index Address 6 7 15 Air bubbles 8 Appendix 7 8 9 10 11 12 14 15 16 17 Application 8 Apptreval s dies x ase ae x AU 6 Arrival 9 12 15 16 Assembling 12 15 16 7 8 13 15 Checklist i e 11 Check 12 8 Cleanliness 11 Commissioning 6 7 11 12 13 16 17 Connections 7 9 10 11 12 15 COUBING 625 0 4448424 7 12 13 16 17 D Dangers exe ERR 5 7 18 17 Datasheet 7 8 9 10 11 12 14 15 16 Declaration of Conformity 5 6 Design 7 8 9 11 12 14 17 Distributor 6 8 5 8 11 Disassembling 15 16 Electric motor 6 7 8 9 10 11 12 13 16 17 Electrical failure 17 6 6 25 iene ware RIT 12 EU Declaration of Conformity 5 ii 8 17 Filter 13 Filtration onau aeaa 8 12 17 02252 E AEN S 7 8 13 14 El sue Res beam
27. for guidelines in how to troubleshoot internal pump parts 1 5 1 Ensure that the air gap between the two coupling parts is min 5 mm It should always be possible to move the plastic part on the coupling at least 3 mm 1 6 1 Contact Danfoss sales office for guidelines in how to troubleshoot internal pump parts 60 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 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 minimuminlet pressure see Data sheet Rotation direction for the APP pump is shown by an arrow on the sticker on the side of the pump If motor type relay or the electrical fuse is blown check that electric motor is sized correctly To ensure easymounting 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 A Flexible coupling B Bellhousing C Motor shaft 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 38 are available on www ro solutions com Instruction 2 Reduced flow reduced pressure Trouble shooting guide for APP pumps
28. motors should be stored indoors in dry vibration and dust free conditions Lifting eyebolts must be tightened before use Damaged eyebolts must not be used check before use Lifting eyes at motor must not be used to lift the motor when it is attached to other equipment Before commissioning measure the insulation impedance If values are lt 10M at 25 C the winding must be oven dried The insulation resistance reference is halved for each 20 rise in motor temperature It is recommended that shafts are rotated periodically by hand to prevent grease migration 3 Installation The motor must be fixed on a stable clear and flat founda tion It must be sufficiently rigid to withstand possible short circuit forces It is important to ensure that the mounting conditions do not cause resonance with the rotational frequency and the doubled supply frequency Only mount or remove drive components pulley 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 ou
29. operational limits and hardware e Changes to the delivered pump or motor pump system may only be done with a written approval from Danfoss RO Solutions e Operation outside the Danfoss specifications requires a written approval from Danfoss RO Solutions Ifany changes are made without written approval the warranty will automatically become void 18089266 IOM APP Pumps 01 09 2012 Ensure that these instructions are always readily available to all personnel concerned 1 2 Symbols Indicates something to be noted by the reader Indicates a situation which will or could result in damage to the pump and its function Indicates a situation which will or could result in personal injury and or damage to the pump Electrical hazard Indicates a high voltage warning Safety glasses required Hearing protection required Safety shoes required Safety helmet required O p 1 3 Manufacturer and customer service address Danfoss A S 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 CE Declaration of Conformity can be found on page 5 User manual 2 Safety Installation
30. provide better cooling Is the water in the tank very hot le above 50 5 the electric motor of the pump unit rotating s water coming out of the tap Are all taps open s the control light 5 the power supply ok for low pump suction pressure on Are control lights on The filter is clogging s the filter clogged Is the filter control light on e water coming through the filter A blown fuse or short circuit e Check power supply and fuses and contact Replace filter element i electrician Replace filter element Contact serviceman Turn on the tap for water supply Trouble shooting Closed water systems No in the tank Fill water into the system race leakage if any s there sufficient water s the electric motor of the pump unit rotating The system does not work s the water in the tank very hot le above 50 At temperatures higher than 50 the pump drive cuts out Consequently the cooler must be checked cleaned s the power supply ok Are control lights on blown fuse or short circuit s the e Check power supply filter clogged and fuses and contact e Is the filter control Replace filter element electrician light on Contact serviceman Danfoss can accept no responsibi
31. request User manual 6 14 Operation of motor pump unit Installation Operation and Maintenance APP Pumps APP 21 38 6 1 General safety information Before inspecting the pump unit read the Safety chapter 2 in this user manual 6 2 What to listen and look for If the following is observed please act as indicated A Re checkall bolts and if necessary contact the maintenance department in order to have all bolts tighten to the specified levels B Leakage if a small leak dripping from the bell housing is observed contact the maintenance department C Leakage if there is a large leak the unit should be stopped as soon as possible Contact the maintenance department D High frequency tones safety relief valves are either damaged or running very close to their cracking pressure stop the unit immediately Contact the maintenance department Non standard noise or vibration from the pump requires the unit to be stopped immediately Contact the maintenance department F Very high temperatures can indicate one or more damaged parts inside the pump The pump then needs to be stopped immediately and inspected before running again Contact the maintenance depart ment G Drop flow and or pressure can indicate wear on one or more parts inside the pump The pump needs to be stopped immediately and inspected before running again Contact the maintenance depart ment H Oth
32. 2 EG 2006 42 2006 42 Hiermit erkl ren wir dass die Maschinegema We hereby declare that the machine is Par la pr sente nous d clarons que la machine 2006 42 EG entwickelt designedaccording to the directive 2006 42 EC est concue conform ment la Directive 2006 42 Maschinentyp Machine designation Type de machine APP 0 6 1 0 APP 1 5 3 5 APP 0 6 1 0 APP 1 5 3 5 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 5 1 10 2 APP 11 13 APP 16 22 APP 21 38 APP 16 22 APP 21 38 APP 16 22 APP 21 38 Seriennummer Serial number Num ro de s rie N A Technisches Dossier Technical dossier Personne de contact pour le Kontaktperson Contact person dossler technique Leiter Qualitatsabtellung Manager Quality Department Manager d partement qualit Angewandte harmonisierte Normen Used harmonised standards Normes harmonis es appliqu es DS EN ISO 12100 2011 DS EN ISO 12100 2011 DS EN 150 12100 2011 Hersteller Unterschrift Titel Manufac signature Title Signature du fabricant Titre d F z 4 z 2012 08 30 2012 08 30 2012 08 30 Datum Date Date Welm Friedrichsen Welm Friedrichsen Welm Friedrichsen Leiter F amp E Director R amp D Directeur R amp D 180R9266 IOM APP Pumps v01 09 2012 5 User manual 1 Introduction Installation Operation and Maintenance APP Pumps APP 21 38 11 General The APP pumps and
33. 20 127 AISI 316 128 Screw M8x90 AISI 316 142 Stop for shaft seal p 6607 144 Tailstock screw M12x60 AISI 316 145 Check nut M12 AISI 316 146 Lifting eye AISI 316 147 Screw M8x16 AISI 316 x 151 O ring 2353 FPM 75 x 152 Super Duplex 154 Plug guide Super Duplex instruction 54 180R9266 IOM APP APP 21 38 Appendices 01 09 2012 x APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Parts 1154 Exploded view APP 30 38 22 UN UNOL WNG WNE Ni ly WNg UJ NOL SS gt SS SSS SS XX SS WS 517752 WN H 2022 N 55 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 Parts list APP 0 6 38 0 8 2 9 APPW 5 1 10 2 23 Tool sets Note The parts listed are not sold e separately only in various kits gt gt 79 79 071 970 ddV 195 00 7178 081 67 671 195 001 87178081 01 1 6 195 00 9174081 EL LL ddV 195 00 08579081 lt 91 ddV 195 00 72278081 88 1 195 00 2117808 e 3 5 Designation A Shaft bush Press bush Drif 30 Shaft bush 218 x x Press Bush 018 Allen Key 4mm Allen Key 5mm Allen Key 6mm Shaft bush 035 Shaft seal extractor 035 Press bush 035 Adjustable pin wrench Combinatio
34. 38 Appendices 01 09 2012 MAKING MODERN LIVING POSSIBLE 22 Parts list APP Pumps APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 ro solutions com Parts list APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 APP parts list 521B0941 1 General Table of Contents 2 APP 0 6 1 0 Compact 3 Exploded view APP 0 6 1 0 Compact 4 APP 0 6 1 0 and 0 8 1 2 5 Exploded view APP 0 6 1 0 APM 0 8 1 2 6 APP 1 5 2 5 and 1 8 2 9 7 Exploded view APP 1 5 2 5 1 8 2 9 8 APP 3 0 3 5 9 Exploded view APP 3 0 3 5 10 APP 5 1 10 2 11 APPW 5 1 10 2 12 Exploded view APP 54 10 2 APPW 5 1 10 2 13 APP 11 13 14 Exploded view APP 11 13 15 APP 16 19 16 Exploded view APP 16 19 17 22 18 Exploded view 22 19 21 26 20 Exploded view APP 21 26 21 APP 30 38 22 Exploded view APP 30 38 23 Tool sets 1 General This parts list provides an overview of the content of the various service sets for the as we APP 0 6 1 0 Compact APP 0 6 1 0 0 8 2 9 1 5 2 5 3 0 3 5 5 1 10 2 APPW 5 1 10 2 11 13 16 22 21 38 as exploded views of the pumps motors 34 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 Parts list APP 0 6 38 0 8 2 9 APPW 5 1 10 2 2 APPO 6 1 0 Compact Note The parts listed are not sold separately Exploded view see next page Pedwo 071 970 195
35. 99 98 For more information on the importance of proper filtration please consult our publication Filtration code number 521B1009 which also will provide you with an explanation of filtration definitions and a guidance on how to select the right filter Monitoring It is recommended to continuously monitor the following conditions Filter clogging Pressure inlet and outlet side of the pump max 0 25 mm max 0 01 inch Elastic coupling Bell housing Motor shaft Pump flange 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 Mountthe bell housing on pump Secure nuts with the right torque 3 Measure the longest distance A from top of bell housing to the button of coupling claw 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 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 in shorter than the measurement Instruction APP pump instruction APP 21 38 6 Adjust respectively verify the measure ment and secure both couplings with the right torques on the locking screws see coupling operation amp mounting instruc tion 7 Mountthe elastic gear ringand mount the
36. MAKING MODERN LIVING POSSIBLE 22 User manual Installation Operation and Maintenance Manual APP pumps APP 21 38 2138 S ro solutions com User manual Table of Contents Installation Operation and Maintenance APP Pumps APP 21 38 Validiy 4 EC Declaration GF COMMOMMILY 5 1 ug e e GER 6 1 1 General T TE 6 1 2 6 1 3 Manufacturer and customer service 4 6 2 Sale EE 7 2 1 ie SEIN ee 7 2 2 Preferred system __ __ 08 Sl 7 2 3 Commissioning and servicing the unit 7 2 4 Adhere to the following important points 7 2 5 qa c ol TEE Sasa sauna su E 7 3 Technical _____________ RENETTE RE 8 31 Approved applications and operational limits for the 8 3 2 Application ranges a sex 8 3 3 Electilc motor Cata _ _______ 8 3 4 Noise ang esate cette een Rn EU AU La 8 3 5 General 8 3 6 Space requirement 8 3 7 su 8 3 8 8 3 9
37. P 26 1500 APP 24 1500 APP 21 1500 800 900 1000 1100 1200 1300 1400 1500 rpm 6 18089266 IOM APP APP 21 38 Appendices 01 09 2012 Data sheet 6 7 Flushing valve Power requirements APP 21 38 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 Flushing valve characteristic Pressure drop bar 300 Flow l min Pump model m factor Fr CNET RET RR ET RM c eran m xe Ian we se The power requirements 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 or 7 kW Calc factor Calc factor Calc factor hp 075kW 1 kW 1 34 hp 1 gpm 3 79 l min 1 l min 0 26 gpm 440gpm 1gpm 0 23 m h 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 7 Data sheet 8 Temperature corrosion 9 Noise level APP 21 38 Fluid temperature 2 C to 50 C 35 6 F to 122 F dependent onthe concentration Ambient temperature 2 C to 450 C 735 6 F to 122 F 8 1 Ope
38. PM 0 8 2 9 APPW 5 1 10 2 13 APP 11 13 Note The parts listed are not sold separately only in various kits 1 LL 195 295 677748081 1 LL 195 o41eq 85579081 EL LL ddV 195 eleld r0Zr808L L LL ddV 195 JIeulelad 102774081 EL LL 195 uoisid 15579081 EL LL ddV 195 1 2774081 Exploded view see next 0051 LL ysems 95579081 ysems zzrg08L 001 EL ddV ysems 91279081 Designation 0051 EL OOZL LL as 252112 2 22 1 O ring 0182 4 NBR 2 O ring 29 19 x 2 62 NBR js O o ho sess er s AN Duplex oie eee m 7 mera sera D s 2 2 o pe UN Do peee e 7 exem me i N 5 PP 123 O ring 0182 4 NBR Shaft seal 035 s 4 1 1 4 J J i _ faa
39. PP 26 APP 26 APP 30 APP 30 APP 38 1200 1500 1200 1500 1200 1500 1200 1500 1500 180B3051 18083052 18083054 18083055 18083056 18083057 18083060 18083062 180B3071 256 362 282 389 308 444 362 444 145 145 145 145 145 145 145 145 1200 1500 1200 1500 1200 1500 1200 1500 700 700 700 700 700 700 700 700 z s e m m Je 431 371 556 451 639 530 105 105 105 105 105 Yes Yes Yes Yes Yes Yes Yes D Typical average flow at 60 bar 870 psi 2 For lower pressure please contact Danfoss RO Sales Organization 3 For higher pressure please contact Danfoss RO Sales Organization The pump is constructed according to EN809 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 5 Data sheet APP 21 38 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 RO Solutions Sales Organisation Available with pressure parts Super Duplex according to NORSOK Available with material certificates wetted parts Available with API674 design verification 5 Flow at different 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 APP 30 1200 APP 26 1200 APP 24 1200 APP 21 1200 APP 1500 rpm version APP 38 1500 APP 30 1500 AP
40. alfor APP Pumps APP 21 38 Data sheet for APP 21 38 pumps 521B0852 3 APP pump instruction APP 21 38 1I80R9133 15 JOM Electric motors 180R9230 z 25 Recommended service intervals for APP pumps 18089199 29 APP parts list O21BOSAT 33 Troubleshooting guide a 2er e beu deo PS ERE RIA 57 Right and wrong 180R9042 67 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 MAKING MODERN LIVING POSSIBLE Data sheet Data sheet APP 21 38 ro solutions com Data sheet APP 21 38 Data sheet for 1 General information APP 21 38 pumps 521B0852 2 Benefits Table of Contents 3 Technical data 4 Variants 5 Flow at different rpm 6 Flushing valve 7 Power requirements 8 Temperature and corrosion 8 1 Operation 8 2 Storage 9 Noise level 10 Filtration 11 Dimensions 12 Dimensions complete unit 13 Installation 13 1 Mounting 13 2 Open ended system with direct water supply 13 3 RO system with APP pump 14 Service 14 1 Warranty 14 2 Maintenance 14 3 Repair 1 General information APP 21 38 pumps are designed to supply low lubrication of the moving parts in the pumps is viscosity and corrosive fluids under high provided by the fluid itself No oil lubrication is pressure
41. and warranty in the Data sheet appendix 1 APP pump instruction and Instruction for recommended service intervals in appendix 2 and 4 For spare parts and service tools please see Parts list appendix 5 Danfoss offers service of the pump at the system manufacturer s location and training in servicing the pump Quotes are offered upon request 7 3 Shutdown of the system A Open the pressure valves at the brine site to release the pressure B SH Stop the high pressure pump C Stop the feed pump D on the motor safety circuit breaker for both the high pressure pump the feed pump and the VDF if used and lock them Only the employees servicing the pump unit should be able to unlock activate the switch again Open bleeding and drain plugs Wait until the pump and system are emptied for water F Slowly unscrew and remove the bolts and gaskets from the in out hoses or pipes be careful about jets of water Be aware that there still can be pressure in the system which will be released when unscrewing and removing the bolts and gaskets G Attach the lifting equipment to the pump unit For instructions on lifting the complete pump unit see chapter 4 Arrival inspection transportation handling lifting and storage H Forthe small pumps unscrew the bolts holding the pump to the bell housing and for the bigger pumps unscrew the bolts holding the pump and bell housing to the 18089266 APP Pum
42. are specified on the rating plate Motor types HMA2 and HMC2 is as standard with lifetime greased bearing with motor size 225 Motor types MS and Y2E is as standard with lifetime greased bearing with motor size 160 Typical duty hours for lifetime lubricated bearings 56 160 2 99 40 000h 180 2 35 000h 200 2 27 0008 225 2 23 000h 150 225 4 8 40 0001 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 to 150 Motors are normal fitted with a data plate with greasing information if it is missing use the following re greasing intervals Frame 2 pole 4 pole 6 pole 8 pole size 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 35 2000 6000 7000 7000 515 50 1500 5500 6500 6500 255 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 tempera
43. ctory settings of the safety relief valves pressure relief valves 8 amp 9 5 Safety circuit breaker must be sized for the motor and 7 Instrumentation pressure switch should be designed to conform to the environment corrosion and humidity See Danfoss requirements in Data sheet and Instruction appendices 1 and 2 See Data sheet for the used motor and VFD appendix 1 See Data sheet for the used safety circuit appendix 1 See Data sheet for the used equipment appendix 1 See Data sheets for the used valves appendix 1 9 Check the settings of the pressure transmitter switch 3 set See Data sheet or Instruction appendices 1 and 2 at min inlet pressure CP10 Check that all pressure indicators are selected to be able Scaling should at least be 1 Bar to measure the system pressure range 79 Bolts and screws must conform to environmental conditions or more precise Check coupling distance air gab movement of the spider CP12 Check correct connections on the pump in amp outlet MEE CP13 Check piping for possible air gaps gt 5 7 Lifting and positioning Lift the pump unit onto base Remember vibration dampers 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 Theha
44. cts 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 24 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 Electric Motors Motor Manual i d k A4 e 180R9230 HOVER MOTORS 1 General This manual concerns the following types of standard induction motors from Hoyer 2 HMC2 HMD HMT MS Y2E1 Y2E2 YDT These motors are manufactured in accordance with IEC EN 60034 4 and IEC EN 60072 Motors are rated for the ambient temperature range 20 to 40 C and site altitudes 1000 m above sea level Low voltage motors are components for installation in machinery They are CE marked according to the Low Voltage Directive 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
45. decreased service life of the pumps 3 8 Properties of water is recommended NOT to use the pumps in feed water concentrations higher than 50 000 ppm TDS without consulting your local Danfoss pump distributor 3 9 Airbubbles Large bubbles pressurised RO system result in damage to piping equipment and the pumps All air must be bleeded from both the low pressure and high pressure side before the RO system is pressurised Special consideration should also be given to air bubbles in feed flow and continuously feed into the pumps as it else can give cavitation 3 10 Chemicals Thepumps should not be exposed to chemicals that can result in damage to piping equipment and internal parts of the pumps User manual 4 Arrival inspection transportation handling lifting and storage Installation Operation and Maintenance APP Pumps APP 21 38 41 Arrival inspection Pumps which have a weight above 20 kilos see The pump is packed in a cardboard or wood box Data sheet appendix 1 must be handled by with plugs in the port connections to protectthe using lifting eyes and slings pumps from damage during transportation Immediately check the shipment for damage on arrival and make sure that the name plate type designation is in accordance with the packing slip and your order Remove all packing materials immediately after delivery In case of damage and or missing parts a report shou
46. e ZAR SS 53 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 Parts list APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 21 APP 30 38 Note The parts listed are not sold separately only in various kits 195 5 LZLv 8081 leJJeqepull 2 99179081 195 eleld 08179081 8 0 195 403514 66173081 39 Buiusn 4 01179081 Exploded view see next page 195 3 4 6 1 8081 0091 05 ddV 195 99179081 0051 05 ddV 195 aleld ysems 89179081 195 eleld ysems 87178081 0051 pue 021 8 ddV Designation 0051 85 pue 0021 05 ddV Duplex PEEK Pin 06 10 AISI 316 Bleeding plug Super Duplex 62 x ri Screw M8x30 AISI 316 O ring 2228x4 NBR ri 10 11 12 13 NR fasses x 5 swash plate superou m mensey we Jl III s 1 Oinderberr x L e a sms me e D soos m hr X e Retainerpiate x x ss o Piston Superbupler PEK x X X X X x O ring 30 2x3 NBR x O ring 06802 r 7 91 92 9 94 9 121 1 124 Shaft seal Hastelloy NBR X 125 Cover for shaft seal Super Duplex 126 Pin 010 5
47. e see item 6 Typical signs of wear 62 180R9266 IOM APP APP 21 38 Appendices 01 09 2012 Instruction 4 Noise from pump Trouble shooting guide for APP pumps 4 1 Air in fluid 4 2 Bleeding conditions of pump 4 3 Min max nominal inlet pressure 4 4 Pump reversing 4 5 High rotation speed RPM 4 6 Outlet pressure 4 7 Soft start stop 4 1 1 Ensure that the entire inlet line is bled before starting up the system 4 1 2 Ensure that air cannot enter into the inlet line 4 2 1 Follow the instructions Initial start up supplied with the new pump 4 2 2 Ensure that the pump is completely bled before start up 4 3 1 Ensure that inlet pressure is between 1 and 5 bar 4 3 2 Check the pump for internal damage 4 4 1 Dismantle pump and check if anything is broken or worn See 1 No flow item 1 2 Pump reversing WARNING The pump must not run without water for more than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure and will eventually be damaged 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 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 A S RO Solut
48. e connectionsmounted directly on the frame will cause even small pressure pulsations from pump and create vibrations in the system plant Too small pipes or too many bends may create too fast flow turbulence through the pipes and thus increase the noise level Too stiff hoses cannot damp the small pressure pulsations from the pump and subsequently vibrations occur in the system plant If the hoses are mounted directly on the frame the small pressure pulsations from the pump can be transferred to the frame and the rest of the system plant When no damper is installed below the electric motor vibrations from the motor and pump may be transferred to the frame r est of the system plant Instruction Trouble shooting guide for APP pumps 6 Typical signs of wear 6 1 Valve plate Picture 1 A normally worn valve plate has no marks scratches but only a slightly polished surface No scratches or marks should be felt The surface must be flat and level Picture 2 A worn valve plate has scratches and or a polished surface Even small scratches will give a loss of flow Scratches Picture 3 A good way to identify a worn valve plate is to hold a straight knife edge over the valve plate When holding it up to the light it will be possible to see any space between the knife edge and the valve plate See picture 3 If any light can be seen between the two arrows on the picture the valve plate is worn If any scratches or marks ca
49. e g in seawater reverse osmosis thus required filtration applications and for high pressure salt water pumping The pumps are supplied with an integrated flushing valve that allows the salt water to flow The pumps are based on the axial piston from inlet to the outlet when the pump is not principle enabling a very light and compact running design and they are designed so that the 969009090990 SS CZ H 777747 Z SSS SS Z T 2 3 4 5 6 7 8 9 2 Z Yi Mounting and port flange JN Bleedi eeding plugs Piston shoe AN SN 5 SS WI Tt y SSS Valve thrust plate NS N Y Cylinder barrel E ylinder barre m a D Ac CY Springs WW SS NS gt Flushing valve HS WZ 222 MW NG 2222 Housing with bearing E _ Drain plug S gt x Shaft seali N Ne EEN sealing SS ES _ gt a W Retaining plate Age SS AL SSS WN 555 GQ QD Z Swash plate 5 NS _ A gt Port plate sS S Bolts for bell housing E S RX sss Z 2
50. e 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 at the pump must be min 2 bar 30 psi The inlet line connection must be properly tightened as possible entrance of air will cause cavitation 2 4 General comments on 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 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 9896 at 10 um We recommend to use precision depth filter cartridges rated 10um abs 31025000 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
51. e the pump stops momentarilly or spinning backwards 6 For easy system bleeding and flushing bypass non return valve 6 is integrated in the APP pump 7 A non return valve 7 in outlet can 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 A safety valve or a pressure relief valve 8 can be installed in order to avoid system damage as the Danfoss APP pump creates pressure and flow immediately after start up regardless of any counterpressure 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 Fermeate 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 14 3 Repair In case of irregular function of the APP please contact the Danfoss RO Solutions Sales Organisation Data sheet APP 21 38 18089266 IOM APP APP 21 38 Appendices v01 09 2012 Data sheet APP 21 38 Danfoss 5 High Pressure Pumps DK 6430 Nordborg Denmark Danfoss accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products withou
52. eR xe 11 12 15 17 Flush 11 13 Danfoss 5 High Pressure Pumps DK 6430 Nordborg Denmark G Generalinformation 7 Guideline 17 H DEE 7 9 12 15 16 5 9 12 14 15 16 Installation 6 7 11 12 14 16 17 Instruction 6 7 8 10 12 14 15 16 6 12 Introduction 6 M Maintenance 6 7 10 13 14 15 17 Mounting 16 N plate 9 11 12 13 14 L kus a y XA 17 6 9 10 12 15 16 Localregulations 6 7 11 12 17 O Operation 6 7 8 9 13 14 16 17 Operational conditions 7 17 PIPING E 8 11 12 17 0 12 Preferred system design 7 11 Pre mounting 11 6 7 10 R Relief valve 12 13 14 Responsibility 6 7 17 sea 10 15 445 E od 13 Installation Operation and Maintenance APP Pumps APP 21 38 S 6 7 8 9 12 13 14 15 17 7 Scrapping 17
53. ectric motor if the motor is not designed for VFD operation Before start up the settings for all protective devices for example sensors switches and safety valves must be verified and free flow from safety valves must be ensured 18089266 APP Pumps v01 09 2012 A All pipe and hose connections must be stress free mounted securely fastened to the pumps well supported Improper installation will or could 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 normal good judgment in the operation and care of the pump and its components 2 2 Preferred system design Danfoss recommends building systems with a high degree of safety See Danfoss preferred system design and PI amp D in Data sheet and Instruction which are found in appendix 1 Data sheet and 2 APP pump instruction 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 care of start up and shut down devices and over 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 Adhereto the following important points Before using the
54. eet 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 At too low outlet pressure the pump will create higher pressure pulsations and thus make noise Too low pressure also causes insufficient internal lubrication and wear on internal parts Pump may eventually be damaged Too high outlet pressure may damage the pump Noise frequency changes during soft start up stop 63 Instruction 5 Noise from installation Trouble shooting guide for APP pumps 5 1 Inlet outlet connections hoses pipes 5 2 Length dimension of inlet outlet line 5 3 Hose stiffness 5 4 Hoses pipes mounted directly on frame 5 5 Vibration damper under the electric motor 5 1 1 Use flexible hoses at inlet outlet connec tions Danfoss A S can provide flexible hoses Please contact Danfoss sales office for further information Mount the connections to the frame by a vibration damper mounting plate Increase pipe diameter and or reduce the number of bends Use amore flexible hose Danfoss A S can provide flexible hoses Please contact Danfoss sales office for further informa tion Mount the connections to the frame by a vibration damper mounting plate Mount a vibration damper below the motor pump 64 180R9266 IOM APP APP 21 38 Appendices 01 09 2012 Non flexibl
55. er observations or troubles please see appendix 7 Right and Wrong or the Trouble shooting guide appendix 6 Both appendices give good advises on design installation wiring and trouble shooting If the pump is not stopped for inspection it can lead to damage of the pump See also service and warranty section in the Data sheet appendix 1 APP pump instruction or Instruction for recommended service intervals in appendix 2 and 4 Danfoss offers service of the pump at the system manufacturer s location as well as training in servicing the pump Quotes are offered upon request 18089266 IOM APP Pumps 01 09 2012 Danfoss recommends at the same time also to check the filter and membrane condition and evaluate dirt found replace filter and membrane elements if necessary User manual 7 service of the pump unit Installation Operation and Maintenance APP Pumps APP 21 38 71 General safety information Before servicing the pump unit it is necessary to read and understand this user manual especially the Safety chapter 2 Remember to wear suitable safety equipment according to Safety chapter 2 7 2 Service and inspection interval for the pump Maintenance and service intervals are depending on the cleanness level of the water hydraulic load and temperature of the pump unit The most important parameter is the cleanness of the water See the section Service
56. ervals The recommen dation is based upon good engineering practice and on experience gained from operation even under extreme conditions Danfoss APP pumps are designed for long 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 recommended to inspect the pump and replace The recommendation is for guidance only If the Danfoss recommendations concerning system design see our data sheet are not followed the service life of the APP pumps might be affected The recommended service intervals on the different parts in the APP pumps appear from the table below worn parts if any 211 end flange Dry part AISI 316L I 5 7 9 Piston Super Duplex and PEEK Recommended inspection basis and evaluated acc to app 1 T 62 1 4 63 Spring guiede Duplex or PP 40 000 hours 124 215 1 Shaft seal Hasteloy and NBR It is good practice to change the seal after each disassembly of the pump 1 Cover flange for Super Duplex No wear part shaft seal 579 Backup ring 24 000 hours O ring overall NBR 24 000 hours KES Pin overall AISI 316 Duplex or PEEK Valve cone flushing valve Duplex or PEEK 40 000 hours 67 Parallel key AISI 302 40 000 hours depends on pump size 30 18089266 IOM APP APP 21 38 Appendices 01 09 2012 Instruction 3 Appendix 1
57. es in the connection box of the motor or reprogram the direction in VFD 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 ramp up time of minimum 10 second is required to avoid damage of internal pump parts Monitor the inlet pressure and outlet pressure of the high pressure pump and look for leakages Check the pressure indicatorfunction by slowly closing the valves The pump unit should stop when the minimum inlet pressure and maximum outlet pressure has been reached 18089266 IOM APP Pumps 01 09 2012 Adjust the pressures to the specifed inlet and outlet pressure forthe system and let the pump unit run until the electric motor and pump temperature is stable If the system is running within the system design limits the system is released for operation 5 18 Check the filter condition Evaluate dirt found in filter replace filter elements if necessary 5 19 Instruct operator and maintenance personnel Before using the pump pump unit the personnel must be instructed in using the pump pump unit its function components documentation and safety Danfoss offers commissioning and service at system manufacturer s location Rate quotes are offered upon
58. ewandte harmonisierte Normen DS EN ISO 12100 2011 Hersteller Unterschrift Titel 2012 08 30 Welm Friedrichsen Leiter F amp E 2006 42 EC D claration de conformit CE conform ment la Directive 2006 42 EC Declaration of Conformity according to Directive We hereby declare that the machine is designedaccording to the directive 2006 42 Par la pr sente nous d clarons que la machine est concue conform ment la Directive 2006 42 CE Type de machine APP 0 6 1 0 APP 1 5 3 5 4 APP 5 1 10 2 APP 11 13 APP 16 22 APP 21 38 Machine designation APP 0 6 1 0 APP 1 5 3 5 APP 5 1 10 2 APP 11 13 APP 16 22 APP 21 38 Serial number Nume ra de s rie N A Personne de contact pour le dossier technique Manager d partement qualit Technical dossier Contact person Manager Quality Department Normes harmonis es appliqu es DS EN 150 12100 2011 Used harmonised standards DS EN 150 12100 2011 Signature du fabricant Titre 2012 08 30 2012 08 30 Date Date Welm Friedrichsen Welm Friedrichsen Director R amp D Directeur R amp D 180R9266 IOM APP APP 21 38 Appendices 01 09 2012 23 Instruction APP pump instruction APP 21 38 Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danfoss can accept no responsibility for possible errors in catalogues brochures other printed material Danfoss reserves the right to alter its produ
59. for APP pumps 1 1 Dry running no water supply to the pump 1 2 Pump reversing electric motor is running the wrong direction i e counter clockwise 1 3 No rotation of electric motor 1 4 No rotation of pump 1 5 Axial load on pump shaft may cause high internal leakage Only applying to APP 0 6 to APP 3 5 and APP 21 to APP 26 only 1 6 Pump damage the internal parts may be damaged If no water comes out of the pump 1 1 1 Check that inlet valve is open 1 1 2 Check that booster pump is running 1 2 1 Change the phase on the electric motor to make it run clockwise WARNING The pumpmust not run withoutwater formore than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure in pump housing and will eventually break down 1 3 1 Check that main switch is switched on 1 3 2 Check the electricity at the facility 1 3 3 Ensure that motor relay is switched on 1 3 4 Ensure that fuse is not blown 1 3 5 Ensure that booster pump is started 1 3 6 Check that the monitor switches are working correctly 1 3 7 Disconnect pump from electric motor and check that the motor is capable of running with no load 1 4 1 Ensure that coupling between electric motor and pump is connected 1 4 2 Check if coupling is damaged 1 4 3 Check that electric motor is sized correctly 1 4 4 Check that the electrical installation is correctly sized 1 4 5 Contact Danfoss Sales office
60. ions Technical Support 4 6 3 If outlet pressure has exceeded its maximum check set point of outlet pressure valve 4 6 4 Check internal parts for wear damage 4 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 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 Small air bubbles will accumulate and create large bubbles causing internal cavitation and thus making the pump very noisy WARNING The pump can only run fewminutes with air in the fluidwithout being damaged The pump and the inlet line must be com pletely bled before start up otherwise the pump will cavitate and make high noise WARNING The pump can only run few minutes with air in the fluid without being damaged Too high inlet pressure causes too high pressure inside the pump damaging the pistons and eventually the pump Inlet pressure below 1 bar causes cavitation and insufficient internal lubrication resulting in wear on internal pump parts Mount a low pressure switch before the pump and check its set point function The low pres sure switch will ensure that the pump does not start until the inlet pressure has reached 1 bar If pump rotates in wrong direction it will take in water fromthe high pressure outlet line Pressure will be built up inside the pump and it will eventually be damaged Higher RPM than specified in the pump data sh
61. label on product Only 1 preduct om each report Operational comdition After Danfoss has been informed about the return you will receive a return number and a template to fill out One copy should be attached to the shipment and one copy should be sent to the E mail address on the template Returns without a return number will be rejected User manual Installation Operation and Maintenance APP Pumps APP 21 38 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 pump back onto electric motor Do always follow the procedure delivered with the instructions from the coupling manufacturer Mount the flexible coupling and housing according to the Data sheet appendix 1 and APP pump instruction appendix 2 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 or put on the shelf instructions can be found in Storage chapter in Data Sheet appen dix 1 or APP pump instruction appendix 2 18089266 IOM APP Pumps 01 09 2012 User manual 8 Troubleshooting and scrapping criteria Ins
62. ld be drawn up and presented to the carrier at once 4 2 Warning Before any lifting operation is performed environmental conditions must be taken into consideration Ex rated areas wind speed wet dry conditions lifting height etc 4 3 General safety information Personnel involved in lifting and transporting the equipment see Safety chapter 2 must be trained in handling and safety procedures when lifting heavy loads Many of the pumps and pump units weigh more than 20 kilos which requires lifting slings and suitable lifting devices e g an overhead crane or industrial truck to be used as minimum 4 4 Transport and handling Small pumps which have a weight below 20 kilos weight can be found in the Data sheet in appendix 1 can be handled by hand if they are not mounted together with an electric motor The weight of a small pump with a motor will be _ Never use only one sling and make sure the above 20 kilos slings does not slip off the pump When the pump is mounted together with an electric motor the pump unit always weight more than 20 kilos and must be handled by using slings around the pump unit 18089266 IOM APP Pumps 01 09 2012 9 User manual Installation Operation and Maintenance APP Pumps APP 21 38 See below examples of where to not to attach A the lifting slings on the pump unit Incorrect lifting can result in personally injury Correct lifting with 2 separate slings a
63. lity 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 72 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 User manual Appendices for IOM Manualfor APP Pumps APP 21 38 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 73 User manual Appendices for IOM Manual for APP Pumps APP 21 38 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 74 18089266 IOM APP APP 21 38 Appendices 01 09 2012
64. looding which again can cause a risk of slipping tripping or falling If water is dripping into the electric motor it can lead to electric shock fire short of circuit or even death In order to avoid water dripping into the electric motor see Installation and commission ing chapter 5 and Operation chapter 6 AN o 8 4 Electrical failure If the wiring connection of the electric motor is not correct or the earth connection is missing it can lead to electric shock burn damages fire or even death 180R9266 IOM APP Pumps 01 09 2012 If a VFD is used and wrongly programmed it can damage the pump and lead to high tempera tures or other dangers Therefore all electrical installation work must only be carried out by authorized personnel in accordance with EN60204 1 and or local regulations 8 5 Responsibility Danfoss takes no responsibility for any other abnormal injuries risks or damages that could arise caused by abnormal conditions vibrations corrosion abrasives foreign objects or excessive temperatures and shall not be liable for any consequential or incidental damages 8 6 Scrapping criteria Whether the pump can be repaired or need to be scrapped depends on how damaged the internal parts are or how damaged the whole unit is Please use appendix 6 Trouble shooting guide as guideline or send the pump to Danfoss head quarter in Denmark for evaluation For other observations or troubles please see
65. ly occur in boosted or open ended systems with direct water supply 2 1 Open ended systems with direct water supply The pump is supplied with water direct from a feed pump The inlet pressure for APP 21 38 must be at least 2 bar 30 psi and 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 2 2 Preferred RO system design and P amp ID 1 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 2 Placeaninlet filter 1 in front of the APP pump 2 Please consult Danfoss filter datasheet for guidance on how to select the right filter Thoroughly clean pipes and flush system prior to start up 3 Place monitoring pressure switch 3 set at min inlet pressure between filter and pump inlet The monitoring switch must stop the pump at pressures lower than minimum pressure 4 Use flexible hoses 4 to minimize vibrations and noise 5 norderto 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 Recommend to install safety valve or a pressure relief valve 9 in order to avoid Inlet Outlet TU A high pressure peak
66. n 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 38 Appendices v01 09 2012 65 Instruction Trouble shooting guide for APP pumps 6 2 Port plate Picture 1 i Ifthe port plate has scratches level differences or both between the arrows the port plate must be replaced Even small scratches or wear will cause loss of flow To check See item 6 1 picture 3 6 3 Swash plate Picture 1 _ If the swash plate is polished 360 itis an indication of insufficient filtration The surface of the swash plate must be plane and even at same level all over To check this please see item 6 1 picture 3 If the surface has any marks scratches it is worn damaged and a new one is required Please contact Danfoss sales office for further information 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 66 18089266 IOM
67. n wrench 10mm Nut M8x6 5x13 Guide bolt M8x140mm Shaft seal extractor 45 Press Bush 045 Eye bolt M8 Press bush for valve plate Stop for retainer plate Screw M8x20 Screw M8x70 Screw M8x140 Combination wrench 13mm Lifting eye Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 56 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 MAKING MODERN LIVING POSSIBLE Guideline Trouble shooting guide for APP pumps ro solutions com Instruction Trouble shooting guide for APP pumps Trouble shooting guide Trouble shooting fish bone chart for APP pumps 1 No flow no pressure Table of Contents 2 Reduced flow reduced pressure 3 High torque on electric motor 4 Noise from pump 5 Noise from installation 6 Typical signs of wear 6 1 Valve plate 6 2 Port plate 6 3 Swash plate 58 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 Trouble shooting guide for APP pumps Instruction Trouble
68. nd or damage to the pump unit 4 5 Return to supplier Please see maintenance chapter 7 4 6 Storage Each pump is tested before shipment and therefore holds water so for storage tempera ture and frost protection see Data sheet in appendix 1 or APP pump instruction in appendix 2 The pumps are NOT delivered frost protected from the factory Wrong lifting When lifting the pump unit one sling must be attached to the electric motor and one sling around the pump Only 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 attempting to lift as the centre of the mass is different from pump to pump and pump unit to pump unit How to mount the pump and the electric motor correctly together see Data sheet in appendix 1 or APP pump instruction in appendix 2 10 180R9266 APP Pumps v01 09 2012 User manual 5 Installation commissioning Installation Operation and Maintenance APP Pumps APP 21 38 5 1 Important dimensions Physical dimensions and connections for the pump unit are described in Data sheet appendix 1 5 2 Cleanliness 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
69. nected 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 Run the system for 30 min and activate all components as often as possible 8 Empty the system of the water 9 Alternatively the system may be flushed by running the unit without the return hose while continuously filling up water The flushing should continue until there is no trace of cleaning agent in the return water 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 formel Ban 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 will 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 water systems looooooooo 000000000 899999999 No water supply e Is the water supply ok e 5 water supplied to the pump e Lower inlet temperature or
70. ning the pump must always be connected to the water supply in order to avoid damage if it should run dry 5 4 Disconnection If the inlet line is disconnected from the water supply the pump will be emptied of water through the disconnected inlet line When starting up again follow the bleeding procedure described under section 4 Initial start up 6 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 6 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 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 5 5 Storage Storage temperature Min 40 C to max 70 C Min 40 F to max 158 F When preparing the pump for long term storage or for temperatures below the freezing point flush the pump with an anti freeze medium type monopropylene glycol to prevent internal corrosion or frost in the pump For further information on anti freeze media please contact the Danfoss RO Solutions Sales Organization Recommended procedure 1 Disco
71. nnect the water supply to the pump 2 Through the lower bleeding plug empty the pump housing of water and close it again 3 Connect the pump to a tank containing anti freeze additive Connect a hose to the inlet port of the pump and via another hose return the flow from the outlet port port to the tank with antifreeze additives 4 Quickly start and stop the pump Make sure that the pump does not run dry The pump is now protected against internal corrosion and frost 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 6 3 Repair In case of irregular function of the APP please contact the Danfoss RO Solutions Sales Organisa tion EC Declaration of Conformity Danfoss A S Danfoss High Pressure Pumps Mordborgve 81 6430 Nordborg Denmark EG Konformit amp tserklarung gem EG Richtlinie 2006 42 EG Hiermit erkl ren wir dass die Maschine gem t 2006 42 EG entwickelt 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 38 Serlennummer N A Technisches Dossier Kontaktperson Leiter Qualit tsabtellung Ang
72. of th DUPID asco siur ii as ds 16 8 Troubleshooting and scrapping criteria 17 8 1 General safety Iiformiatl li ea PP ues p 17 8 2 Operational conditions which can cause pump 17 8 3 Mechanical TEE 17 8 4 leet r u EE ENEE Gre 17 8 5 Responsibilify n z Rad ERES E E E yasa 17 8 6 Scrapping criteria 17 18 18089266 IOM APP Pumps 01 09 2012 3 User Installation Operation and Maintenance APP Pumps APP 21 38 Validity This manual is valid for APP pumps with the following code numbers serial numbers APP 21 1200 18083051 APP 21 1500 180B3052 APP 22 1200 180B3257 APP 22 1500 180B3253 APP 24 1200 180B3054 APP 24 1500 180B3055 APP 26 1200 180B3056 APP 26 1500 180B3057 APP 30 1200 180B3060 APP 30 1500 180B3062 38 1500 18083071 4 18089266 IOM APP Pumps 01 09 2012 EC Declaration of Conformity Danfoss A S Danfoss High Pressure Pumps Mordborgve 81 6430 Nordborg Denmark EG Konformit tserklhrung EC Declaration of Conformity D claration de conformit CE gem EG Richtlinie according to Directive conform ment la Directive 2006 4
73. of the piping must not be corroded If dirt or rust is not removed the pump and the valves can be damaged and in the worst case damaged beyond repair 5 3 Fluid temperature Before start up the fluid and pump housing temperature must be above the minimum start up temperature see Data sheet appendix 1 5 4 Electrical data Check voltage current frequency and rated power on the electric motor and VFD setting name plate on both the motor and the VFD 5 5 Local regulations Commissioning must always be done in accordance with valid regulations and local standards 5 6 Pre mounting checklist based on Danfoss preferred system design Schematic 1 Recommended system design Media filter eren e 180R9266 IOM APP Pumps v01 09 2012 User manual 12 Installation Operation and Maintenance APP Pumps APP 21 38 Table 1 Check points when assembling and commissioning system CP1 Ensure that the environmental conditions are safe See Arrival inspection transportation handling lifting and storage chapter 4 CP2 Minimum and maximum start up temperature for fluid and See Data sheet or Instruction pump appendices 1 and 2 Filtration condition 10um absolute 810 5000 Power supply for electric motor and VFD CP4 CP environment corrosion and humidity CP6 as well as fluid and torque requirements P C CP8 Check the fa
74. p between coupling parts A Flexible coupling B Bell housing C Motor shaft 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 Placethe filter 1 in the water supply line in front of the pump 2 Place a monitoring pressure switch 2 set at min inlet pressure between filter and pump inlet The monitoring switch must stop the pump at pressures lower than min inlet pressure Please see technical data 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 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 11 Data sheet APP 21 38 13 3 system with APP pump 1 Dimension the inlet line to obtain mini pressure loss large flow minimum pipe length minimum number of bends connections and fittings with small pressure losses 2 Placeaninlet filter 1 in front of the APP pump 2 Please consult section 10 Filtration for guidance on how to select the right filter Thoroughly clean pipes and
75. perature Min 2 to max 50 Min 35 6 F to max 122 F Ambient temperature Min 2 to max 50 Min 35 6 F to max 122 In case of lower operating temperatures please contact the Danfoss RO Solutions Sales Organiza tion Internal flushing valve 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 minimise the risk of crevice corrosion NaCl vs temperature Super Duplex 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 100000 Gh 160000 ppm 21 Instruction 6 Service 22 APP pump instruction APP 21 38 5 2 Pressure The inlet pressure for APP 21 38 must be min 2 bar 30 psi and max 5 bar 72 5 psi At lower pressures the pump will cavitate resulting in damage of the pump Max inlet pressure peak e g in case the pump stops momentarily up to 10 bar 145 psi are acceptable Max pressure on the pump s outlet line should be limited at 80 bar 1160 psi continuously Note The pump unit should include a pressure gauge on the high pressure side 5 3 Dry running When run
76. ps 01 09 2012 motor and afterwards unscrew the bolts nuts holding the pump and bell housing together 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 left over water trapped in the pump to drip out Clean and dry the pump surface and plug the bleeding and draining plugs K Move the pump to a clean and safe location where the pump can be inspected serviced 7 4 Disassembling and assembling the pump unit A Remove all connections from the pump Disassemble the pump according to the Disassembling and Assembling Instruction available at www ro solutions danfoss com At the website you can also find the Changing pistons instructions for APP 11 13 and APP 16 22 as well as for APP 21 38 Clean all the parts and surfaces with a fluid compatible with the materials found in the pump Wipe the parts clean and dry with a dry and lint free cloth Inspectallpartsincluding shaft seal and if necessary replace them see Parts list appendix 5 and APP pump instruction appendix 2 or general instruction for Recommended service intervals appendix 4 D Ifthe pump is going to be returned to Danfoss for repair or a warranty claim it is important that Danfoss besides your contact information and reason for returning gets the below information before shipping Product information see
77. pump units are manufac tured by Danfoss A S and are sold and marketed by a net of authorized distributors world wide This manual contains the necessary instructions for the installation operation and service of the pumps used in a Sea Water Reverse Osmosis SWRO or Brackish Water Reverse Osmosis BWRO system The APP pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor Use of the pump in other applications not suitable for the pump unit can cause damages to the pump unit with risk of personal injury A All personnel being responsible for operation and maintenance of the pump unit must read and fully understand these instructions especially the section Safety before e Transportation of the motor pump unit Lifting the unit e Installing the pump unit e Connecting the motor pump unit to the water system Connecting the electric motor and instru mentation e Commissioning the unit Servicing the motor pump unit mechanic and electric parts e Decommissioning the motor pump unit The pump must always be installed and used in accordance with existing national local sanitary safety regulations and laws It is the responsibility of the safety officer or the chief operator to assure compliance with all local regulations that are not taken into account in this manual A Changing the pumps or motor pump units
78. r Duplex Key 12 x 8 x 70 AISI 316 Pin 06 4 x 40 Super Duplex 9 Lo ct 3 3 3 6 6 6 6 6 6 8 9 9 9 9 5 O O 515 Shaft seal Hastelloy NBR Cover for shaft seal Super Duplex Lo Q m S EE Spring 01 9 x 025 0 x 33 7 ET 50 18089266 IOM APP APP 21 38 Appendices v01 09 2012 12 1 1 4 1 2 3 4 5 7 1 1 2 3 4 121 122 123 124 125 126 127 128 129 142 144 145 151 152 153 154 155 APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 Parts list Exploded view APP 22 18 UNC UNOL WNE WNOE K Ka WNL F WNZ WNL UNG WNE WNOE SA 27 TT ES S 2 d EI 2 2 51 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 Parts list APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 19 APP 21 26 97 LZ 92 12 195 Bulusnid 04179081 9 lt 1 lt 195 79179081 92 12 195 aleld 808 95 15 99173081 195 5 1 179081 Note The parts listed are not sold separately only in various kits 1 1 92 0051 2 195 aleld ysems 69198081 udi 001 72 195 eleld ysems 27778081 00 LZ 195 eleld ysems 89179081 195
79. ration The chart on the next page illustrates the corrosive resistance of different types of stainless steel related to NaCl concentration and tempera ture All critical parts of the APP water pump is made of Super Duplex If the water pump is operated at high salinity always flush the water pump with fresh water at operation stop in order to minimize the risk of crevice corrosion NaCl vs temperature Super Duplex 8 2 Storage Storage temperature 40 to 70 40 F to 158 F provided that the pump is drained of fluid and stored plugged The noise from APP 21 38 is typically 84 dB A at 60 bar 1200 rpm and 86 dB A at 60 bar 1500 rpm Generally noise will be reduced if speed is reduced and vice versa Use flexible hoses in order to minimize vibrations and noise Since the pump is typically mounted on a bell housing or frame the noise level must be determined for the complete unit system It is therefore very important that the motor pump unit is mounted correctly on a frame with antivibration isolation to minimize vibrations and noise 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 100000 hin 160000 opm Frost protection is required at temperatures below 2 C Danfoss recommends to use DOW FROST from DOW Chemical Company or Chilsafe mono propylene glycol f
80. rd piping and flexible hoses used must be of proper design and must be installed in accordance with the manufacturer s recom mendations 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 place stress on the pump port connection and may damage the pump Prevent excessive external pipe load Donotconnect piping by applying external force use of wrenches crane etc Piping must be aligned without residual stress Do not mount expansion joints so that their force applies internal pressure on the pump connections 18089266 APP Pumps v01 09 2012 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 Mount the safety circuit breaker turn the circuit off and lock it in the off position 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 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 connections and ma
81. rom Arco Chemical Company The noise level is influenced by The speed ofthe 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 increases the noise level compared to a flexible hose Data sheet 10 Filtration 11 Dimensions M12x1 75 13 depth APP 21 38 As water has very low viscosity the APP pumps have been designed with very narrow clearance in order to control internal leakage rates and improve component performance Therefore it is important that the inlet water is filtered properly to minimize the wear of the pump The main filter must have a filtration efficiency of 99 98 at 10 um We recommend to use precision depth filter cartridges rated 10um abs 31025000 equivalent to a filtration efficiency of 99 98 Bag filters and string wound filter cartridges typically have only 5096 filtration mms Gamme A X 5279 0 98 12 1 75 13 depth 12 1 75 13 depth 18089266 IOM APP APP 21 38 Appendices v01 09 2012 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 98 For more information on the importance of proper filtration please consult our publication Filtration code number 521B1009 which also will provide you with an explanation of filtration
82. ry 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 18089266 IOM APP APP 21 38 Appendices 01 09 2012 27 Motor Connection diagram Anschlupdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexi n Collegamento 1 L L La Schemat polaczen 2 L5 L L5 Wi vi u W C Y O CQ 1 1 2 3 2 2 1 3 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 MAKING MODERN LIVING POSSIBLE Instruction Recommended service intervals for APP pumps ro solutions com Instruction Recommended service intervals for APP pumps 180R9199 Table of Contents 1 General information 2 Design features Recommended service intervals for APP pumps 1 General information 2 Design features 3 Appendix 1 This guideline provides information on the recommended service int
83. s in case the stops momentarilly or spinning backwards 6 For easy system bleeding and flushing 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 A safety valve or a pressure relief valve 8 can be installed in order to avoid system damage as the Danfoss APP pump creates pressure and flow immediately after start up regardless of any counter pressure Note If a non return valve is mounted in the inlet line a low pressure relief valve is also required between non return valve and pump as protection against high pressure peaks Media filter OKO ax 4 Feed I Permeate E 4 e 5 Pr S A Brine 18089266 IOM APP APP 21 38 Appendices v01 09 2012 17 Instruction 3 Building up the pump unit 18 APP pump instruction APP 21 38 2 3 Reversible pumps If exposed to high pressure in the outlet while the electric motor is not energized the pumps will start spinning backwards This will not harm the pumps as long as the pressure in the inlet does not exceed the max pressure peak of 10 bar 145 psi If a non return valve is mounted in the inlet line a low pressur
84. shooting fsh bone chart Uonej ei3sur WO1 SION S asion r uo nbio1 UBIH 1030 21432 Jadwep uoneaqiA uo sedid sesoH be 5591 1115 950 Ce allno alul Jo suolsuaulp dl6ua1 Z S C Le sedid sesou Wd ainssaid 3e ui MOT e 4015 11215 1105 Zt anno 9 7 p ds et eut EE duind tt p 5 jo Buip lg e piny ui aly v anssa4d 15 slels ZE nss d anno uBiu 00 Le 2 ainssaid moly Pe2npeyd LL L Z piny Jo 6122 UIEN 8 1 2 jueuneaJ eJd 12 yeys uo 2210 jeixy D C jo oN 2 e 1030 211329 9 JO ON 15 e e Aug a 5 59 18089266 IOM APP APP 21 38 Appendices 01 09 2012 Instruction 1 No flow no pressure Trouble shooting guide
85. ssures higher than 100 bar 1450 psi Both the inlet and outlet lines must be flexible soft hoses 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 Instruction APP pump instruction APP 21 38 The valve outlet must not be connected directly to the pump suction line It must be connected directly to the drain Outlet 3 5 Connections Inlet Outlet Bleeding Parallel key 20 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 Instruction 4 5 Initial start up Operation APP pump instruction APP 21 38 1 Flush inlet line before connecting the pump to remove possible impurities from pipes hoses 2 Connect pump inlet to inlet line and flush the pump for 5 min by means of the internal flushing valve to remove possible impurities from pipes hoses etc 3 Loosen top bleeding plug 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 5 1 Temperature Fluid tem
86. 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 before the pump and check its set point function The low pressure switch ensures that the pump does not start until the inlet pressure has reached 1 bar Speeds below 700 rpm result in insufficient internal lubrication causing wear on the internal pump parts 61 Instruction Trouble shooting guide for APP pumps 3 High torque on electric motor 3 1 Too high outlet pressure from pump 3 1 1 Check fluid salinity Pump conditions may change more salt lower 3 1 2 Check temperature water temperature or scaling of RO membrane 3 1 3 Check pressure drop across RO membrane causing higher pressure resulting in higher motor torque 3 2 Pump starts against pressure 3 2 1 Check that electric motor is correctly sized Pumps run in parallel with cascade start may 3 2 2 Check internal parts see item 2 1 switch off the motor relay due to too high 3 2 3 Systems with more than one electric torque caused by high outlet pressure motor installed Start motors simultaneously 3 3 Constant torque 3 3 1 Please contact Danfoss sales office If the electric motor is too small for the APP 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 torqu
87. t 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 14 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 MAKING MODERN LIVING POSSIBLE truction INS APP pump APP 21 38 Instruction ro solutions com Instruction APP pump instruction APP 21 38 APP pump instruction 1 Identification APP 21 38 180R9133 2 System design Table of Contents 2 1 Open ended systems with direct water supply 2 2 Preferred RO system design and P amp ID 2 3 Reversible pumps 2 4 General comments on Bi Building up the pump unit 3 1 Mounting 3 2 Direction of rotation 3 3 Orientation 3 4 Protection from too high pressures 3 5 Connections 4 Initial start up 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 Identification 16 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 Instruction 2 System design APP pump instruction APP 21 38 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 typical
88. tallation Operation and Maintenance APP Pumps APP 21 38 8 1 General safety information Before inspecting the unit it is necessary to read and understand this user manual especially the Safety chapter 2 Remember to wear suitable safety equipment according to Safety chapter 2 8 2 Operational conditions which can cause pump failures The following conditions can cause a pump failure The pump is running dry inlet pressure is too high inlet pressure is too low The viscosity of the fluid is too high The temperature of the fluid being pumped is too high The ambient temperature is too high pump is running against blocked port closed manual valve pump is operating at pressure above the operational specification The pump is running with non specified approved fluid The pump is running in the wrong direction The filtration is insufficient pump is not being serviced according to Danfoss specifications end of life There is excessive mechanical load on the shaft coupling and piping 8 3 failure If the pump is running dry the temperature will quickly increase which can be dangerous depending on how long time the pump is running dry If there is any leaking at start up or leaking arises during operation the high pressure can lead to eye or skin damage Leaking can result in f
89. tdoors 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 safe electrical connection is maintained both for the main supply and the earth connection We recommend that crimped connections are made accordance with IEC 60352 2 Tightening torques for terminal board screws 125 3557 55 Ensure that the terminal box is clean and dry Unused glands must be closed Check the terminal box gasket before it is remounted 5 Maintenance Inspect the motor at regular intervals keep it clean and ensure free ventilation air flow check the condition of shaft seals and replace if necessary Both electrical and mechanical connections must be checked and tightened if necessary HOVER MOTORS Bearing size and type
90. ture 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 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 d
91. x Swash plate Pin 06 10 AISI 316 O ring 0117x2 5 Cylinder barrel Super Duplex UJ B Super Duplex PEEK Super Duplex DLC Super Duplex DLC Super Duplex DLC Super Duplex PEEK Super Duplex PEEK AISI 316 Super Duplex PEEK Super Duplex PEEK Super Duplex PTFE Retainer ball Retainer plate Retainer plate Piston Piston Key 10 8 45 Port plate plate N Valve plate ring O ring 018 2 4 Port flange O ring 0135 3 NBR Guide pin Super Duplex Pin 06 10 AISI 316 Pin 06 10 PEEK Screw M8x20 AISI 316 Mounting flange AISI 316 O ring 0135 3 Sealing ring O ring 58x2 Shaft seal Stop bush Bush Screw M8x20 Screw 8 Super Duplex N Ww 185 8 2 N N WIN PEHD 4 5 00 UJ 2 Hastelloy NBR PEEK Super Duplex AISI 316 AISI 316 N N 219 Instruction 44 180R9266 IOM APP APP 21 38 Appendices v01 09 2012 APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Exploded view APP 5 1 10 2 APPW 5 1 10 2 Parts list 2 1 UN S WN 09 555552277 5722227 A UUA SS S VV 45 18089266 IOM APP APP 21 38 Appendices v01 09 2012 Parts list APP 0 6 38 A
92. x 1 3 3 Electric motor data See recommended motor in Data sheet appendix 1 or IOM for motors appendix 3 The motors mentioned are the most common used motors by Danfoss High Pressure Pumps 3 4 Noise and vibration Noise level for a motor pump unit with a standard motor measured according to EN ISO 3744 2010 see Data sheet in appendix 1 Possibilities to reduce noise and vibration are described in the same Data sheet 3 5 Generalarrangement Dimensions for the different pumps see Data sheet in appendix 1 18089266 IOM APP Pumps v01 09 2012 3 6 Spacerequirement For service and replacement of the complete motor pump unit it is recommended having sufficient space around the unit For easy access to the unit at least 1 meter 40 inches available space should be kept free around the pump When working with high pressures space demands should reflect the required safety requirements 3 7 Filtration 10um absolute 810 25000 Requirements are specified in Data sheet appendix 1 and APP pump instruction appendix 2 Danfoss recommends not to build a filter bypass function or 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
93. ybe check valve s Mount and tighten as specified User manual Installation Operation and Maintenance APP Pumps 21 38 5 12 Ensure free Ensure that the flow from safety reliefvalves 8 and 9 is completely unhindered A blocked safety relief valve can cause excessive build up of pressure and thereby cause dangerous situations and damage to the whole system 5 13 Verify setting of safety relief valves Make sure the safety relief valves 8 and 9 are placed correctly Check the pressure settings on the name plates of the safety relief valves If they are OK continue Otherwise replace the safety relief valves 5 14 Flush the pump Fully open the pressure valve at the brine site Close all the bleeding and draining plugs on the high pressure pump Start the feed pump and ensure that the flow from the feed pump to the high pressure pump is unhindered 5 15 Bleed and remove air from the pump Open bleeding plugs Keep the plugs open until only water leaves the high pressure pump 5 16 Verify direction of rotation An arrow can be found on the pump or pump unit The direction of rotation must always follow the arrow Unlock the safety circuit breaker Start the motor for 1 second and observe the direction of rotation either looking on the fan of the motor or on the coupling true the hole in the bell housing not available on all bell houses If the motor is turning the wrong direction switch two phas

APP 21-38

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