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APP 0.6-1.0

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1. 08 195 5014 60274081 Designation hosna oeae OO x mex fasse 1 0 omgie n x dme 1 swash plate SuperDuplex PEEK swash plate ________ SuperDuplex PEEK Pin 10 5 x 20 Duplex Cylinder barrel eae Spring Duplex Spinggude PP Retainer ball Super Duplex Retainer plate Super Duplex men spre Key 2x8x70 NASISIG SuperDuplex Port plate SuperDuplex PEEK ox NN Em 56 NN EN EG NN ox X X X X 29 n 5 ong 30230 m 11000000 46 180R9262 APP 0 6 1 0 Appendices 01 09 2012 45 54 APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 Parts list Exploded view APP 22 18 CIN Cra gt WNOL WNE K WNL WNG WNL EX X 1 4 21 221 47 18089262 IOM APP 0 6 1 0 Appendices v01 09 2012 Parts list APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 19 APP 21 26
2. saan pam x m p mese x m mee fx b p we x us O ring 04032 _ NBR wr vs L pee I far pe seems ase e m p pem _ gt ecaro ome e 8 fe e me 11212122 se mosse ome D ws 1 NBR 11111011 a Instruction 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 37 APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Exploded view APP 3 0 3 5 Parts list 9 01 JIVOS 9 U e 2 VMN Al EN 5 M 4 ZW SSY 12222222 S lt A NA 127 my 18089262 APP 0 6 1 0 Appendices v01 09 2012 38 Parts list APP 0 6 38 APM 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 2 01 1 5 ddV 195 19179081 2 01 1 5 09179081 2 8 1 5 e1e d 8517808 195 6579081 28 15 dd
3. gt gt Ug 99 90 92 99 ome 2 01212618 02 01 61 cee 1 0017 0100 20 00 The parts listed not sold separately A lt gt m ivi ki lt EY 2 only In various Kits ES 5 E 2 De A D S S S 3 5 Exploded vi t a m jan xploded view see next page 23 gt D D D lt D co T T S MEE N m 5 m 5 Designation D a 5 3 p pees fers n _ e 15515 E E Lemos pw T E serewmaco fase 3 _ n 0990 6 NBR DLL Ld dfn Duplex fe reser E se f gt n Deptrsetss fe valwecone 2
4. 6 7 10 R Relief valve 12 13 14 Responsibility 6 7 17 usu 10 15 s eae wed 13 Installation Operation and Maintenance APP Pumps APP 0 6 1 0 5 6 7 8 9 12 13 14 15 17 7 Scrapping 17 Serial number 4 6 7 14 15 15 16 Space 8 15 Start Up a cae eR e ence 1 4 7 17 9 10 12 15 16 SYMBOLS a 6 System 6 7 8 11 12 13 14 15 SYSTEMS 2a RR RAE 7 8 Table of 2 Technical data 8 Temperature 7 10 11 12 13 14 15 17 Transportation 6 9 12 15 16 Troubleshooting 14 17 V Valve 7 11 12 13 14 15 17 Warning eap aaa e OR 6 9 Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be mad
5. a fe oweeeco w _______ _ s x LLL _ 9 7 w Hommes LE 7 2 m 1 1 1 1 2 121 15 LL swash ate swashplate spei LL gt sasoe sewer swash ate sewer _ em Em Duplex PEEK sping x 63 1 springguide P 64 1 Retainerbal SuperDuptex 65 1 Retainerplate Swerplx x j j 7 Piston jsweDweutEK j J j _ 67 1 eae j j 3 4 0 SuprDupex x 9 1 Portplate _ SuperDuplx PEK x 92 jVavepbte SuperDuplex x 3 7 eackupring fret x xl j j j j 2 O ring 230230 wR x xe pn _ 2 1 omegex2 wR Jsf j j NR x j j 31 31 31 31 31 31 34 61 62 63 123 O ring 2182 x 4 0 NBR Shaft seal 245 Hastelloy NBR Cover for shaft seal Super Duplex ms gt r
6. 42 18089262 IOM APP 0 6 1 0 Appendices v01 09 2012 APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Parts list Exploded view APP 11 13 14 WNE WNOE WNOL WNZ WNOL WNL WNOE WNL NY BP ANS 20 47 TINY SS VIII NN 752 ps 1 i Vow 3 BS 2 43 18089262 IOM APP 0 6 1 0 Appendices v01 09 2012 Parts list APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 15 APP 16 19 61 91 ddV 195 5 907v 8081 61 91 ddV 195 Jepur A5 4081 61 91 dd V 195 70278081 61 91 ddV 195 Jeul e328H 1027908 61 91 195 001514 1227808 61 91 ddV 195 5014 60274081 Note The parts listed are not sold separately only in various kits 0051 61 ddV OOZL 61 ddV eje d ysems 21278081 0091 ZL ysems 02088081 udi 002 ZL ysems 91279081 002 91 1 4 ysems 81774081 ysems 612774081 0061 91 61708081 Exploded view see next page 2 2 mem x 2 mes un x _ 20 x
7. 1 eJnsse1d woy padnpay ainssaid MOY 55 Trouble shooting guide for APP pumps Instruction Trouble shooting fish bone chart 18089262 APP 0 6 1 0 Appendices v01 09 2012 Instruction 1 No flow no pressure 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 56 Trouble shooting guide for APP pumps If no water comes out of the pump 1 1 1 Check that inlet valve is open 1 3 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 Disconne
8. cl REESE Ls 1 Ds 1 vax p ojemem 5 as Uu ct o 2 N L o o EN NN o de I ee 1 x pp o de __ __ o L p L _ __ 1 p p _ L Lm E A 121 px x x x 48 18089262 IOM APP 0 6 1 0 Appendices v01 09 2012 APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 Parts list Exploded view APP 21 26 20 WNE WNOE 49 180R9262 IOM APP 0 6 1 0 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 86 06 195 Buiusn 4 07174081
9. 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 3k Exploded view APP 0 6 1 0 Compact 4 APP 0 6 1 0 and APM 0 8 1 2 5 Exploded view APP 0 6 1 0 APM 0 8 1 2 6 APP 1 5 2 5 and APM 1 8 2 9 7 Exploded view APP 1 5 2 5 APM 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 5 1 10 2 APPW 5 1 10 2 13 11 13 14 Exploded view APP 11 13 15 APP 16 19 16 Exploded view APP 16 19 17 22 18 Exploded view APP 22 19 21 26 20 Exploded view APP 21 26 21 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 30 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 APP 0 6 1 0 Compact APP 0 6 1 0 APM 0 8 2 9 APP 1 5 2 5 APP 3 0 3 5 APP 5 1 10 2 APPW 5 1 10 2 APP 11 13 APP 16 22 APP 21 38 as exploded views of the pumps motors APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Parts list 180 4189 Swash plate set APP 1 0 Compact 180 4184 Swash plate set APP 0 6 Compact 180B4181 Piston set APP 0 6 1 0 Compact 180B4182 Retainer set APP 0 6 1 0 Compact 180B4183 Valve plate set APP 0 6 1 0 Compact 180B4
10. IN ZZ i ANN MSS zz ioe gt VERE n TI v01 09 2012 180R9262 IOM APP 0 6 1 0 Appendices Parts list 6 APP 1 5 2 5 and APM 1 8 2 9 APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 Note The parts listed are not sold separately only in various kits Parts for APM 1 8 2 9 are equivalent to the parts for APP 1 5 2 5 except for valve plate sets Exploded view see next page 67 671 195 295 78081 62 671 195 aeq 9179081 5 2 5 1 ddV 195 e3e d 808 62 81 Wd 195 e1e d 0074081 0 2 8 1 8 1 9 1 ddV 195 2 17808 6 2 9 2 WdV 5 2 2 ddV 195 HHLYAOSL 62 61 195 uoisid 2 17808 S E ddV 195 92178081 Designation O ring 013 2 NBR 122 O ring 083 2 NBR 123 O ring 040 2 NBR N ASI316 NBR Wetted part PP Dry part AISI 316 1 Shaft seal 125 Mounting flange Shaftseal Mountingfange 130 O ring 04 5 1 5 NBR 152 Valve cone PEEK 153 Spring Duplex 154 Plug guide Duplex 155 O ring 011 11 1 78 NBR Instruction ET TT EET yy ey 11111111 _ eee Ey Peep eT eT EE ETT ee 11111041 214451 11111111111111111111111 18089262 IOM AP
11. 3 79 1 1 l min 0 26 1m h 4 40 gpm 0 23 m h 71 Operation Fluid temperature 2 C to 50 C 35 6 F to 122 F dependent on the NaCl concentration Ambient temperature 2 C to 50 C 35 6 F to 122 F The chart below illustrates the corrosive If the water pump is operated at high salinity resistance of different types of stainless steel always flush the water pump with fresh water at related to NaCl concentration and temperature operation stop in order to minimize the risk of All critical parts of the APP water pump is made crevice corrosion of Super Duplex Super Duplex 100 000 160000 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 7 Data sheet 8 Noise level 9 Filtration 8 APP 0 6 1 0 7 2 Storage Storage temperature 40 C to 70 C 40 F to 158 F provided that the pump is drained of fluid and stored plugged The table indicates the approximate noise level in dB A measured at a distance of 1 m from the Frost protection is required at temperatures below 2 C Danfoss recommends to use DOWFROST from DOW Chemical Company or Chilsafe mono propylene glycol from Arco Chemical Company pump in reverberation room Type 60 bar 870 psi 60 bar 870 psi 1500 rpm 3000 rpm APP 0 6 APP 0 8 APP 1 0 73 Generally n
12. Are control lights on blown fuse or short circuit Check power supply 15 the filter clogged and fuses and contact electrician Fill water into the system s the filter control Replace filter element light on Contact serviceman Trace leakage if any Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved DK 6430 Nordborg Denmark User manual Appendices for APP Pumps APP 0 6 1 0 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 69 User manual Appendices for IOM APP Pumps APP 0 6 1 0 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 t
13. 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 Mount the different equipment connections pipes tubes check and safety relief valves etc e The hard 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 e Misalignment of the hard pipes may place stress on the pump port connection and may damage the pump e Prevent excessive external pipe load connect piping by applying external force use of wrenches crane etc Piping must be aligned without residual stress mount expansion joints so that their force applies internal pressure on the pump connections 180R9262 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
14. 4 Flow at different rom 5 Flushing valve 6 Power requirements 7 Temperature and corrosion 7 1 Operation 7 2 Storage 8 Noise level 9 Filtration 10 Dimensions 10 1 Pump 10 2 Complete unit 11 Installation 11 1 Mounting 11 2 Open ended system with direct water supply 11 3 RO system with APP pump 12 Service 12 1 Warranty 12 2 Maintenance 12 3 Repair APP 0 6 APP 0 8 and APP1 0 pumps are designed to supply low viscosity and corrosive fluids under high pressure eg in seawater reverse osmosis filtration applications and for high pressure salt water pumping The pumps are based on the axial piston principle enabling a very light and compact design The design ensures that lubrication of the moving parts in the pumps is provided by the fluid itself No oil lubrication is thus required All parts included in the pumps are designed to provide long service life ie long service life with a constantly high efficiency and minimum of service required The pumps are fixed displacement pumps in which the flow is proportional to the number of revolutions of the input shaft and the pump displacement regardless of any counter pres sure The pumps are supplied with an integrated flushing valve that allows the salt water to flow from inlet to the outlet when the pump is not running Shaft sealing Mounting flange Retaining ring Piston shoe Valve plate Swash plate Cylinder barrel Spring Port plate 10
15. 5 72 5 psi 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 Data sheet APP 0 6 1 0 4 Flow at different rpm Using the diagram shown below it is easy to select the pump which fits the application best if the flow required and the rotation speed rpm of the pump are known 1500 2000 2500 3000 3500 Furthermore this diagram shows that the flow Required flow x Rated rom can be changed by changing the rotation speed Required rom 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 Rated flow The diagram shows pressure difference across 5 Flushing valve flushing valve APP 0 6 1 0 Flushing valve characteristic flow l min 9 2 3 Pressure bar 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 Data sheet 6 7 Power requirements Temperature and corrosion APP 0 6 1 0 uw a ws as as zason me _ The power requirements can be determined using one of the following guiding equations l min x bar 16 7 x m3 h x bar 0 26 x gpm x psi Required power kW kW Calc factor Calc factor Calc factor 1 0 75kw 1kW 134
16. 5 2 5 and APP 3 0 3 5 Instruction 3 Building up the pump unit Automatic pressure equalization between tank and surroundings must be ensured Inlet from the water supply and inlet to the pump should be placed in opposite ends of the tank to calm and deaerate the water and to ensure optimum opportunity for particles to settle Pump suction line should be placed relatively high above the tank bottom in order to prevent settled particles from being led into the pump We recommend a separation wall to separate the inlet from the outlet end of the tank Monitoring It is recommended to continuously monitor the following conditions Water level in the tank Filter contamination Pressure inlet and outlet side of the pump 3 1 Mounting Please also see hints in Right and Wrong If alternative mounting is desired please contact the Danfoss Sales Organization Choose proper tolerances to ensure an easy mounting of the elastic coupling without use of tools Elastic coupling housing Motor shaft Please take care to observe the recommended length tolerances of the chosen coupling as an axial force on the pump will damage the pump max 0 25 mm max 0 01 inch 3 2 Direction of rotation Is indicated by means of an arrow at the inlet side of the pump Outlet Inlet 18
17. Connecting flange 11 Housing with bearing 12 Flushing valve E di E 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 Data sheet 2 Benefits 3 Technical data APP 0 6 1 0 One of the smallest and lightest pumps on the market Can be powered by a combustion engine Long service life No preventive mainte nance required in the warranty period Generates insignificant pulsations in the high pressure line No oil lubricant required Integrated flushing valve All parts of the pump are made of high corrosion resistant materials e g Duplex EN1 4462 UNS 531803 532205 and Super Duplex EN1 4410 UNS 532750 stainless steel and carbon reinforced PEEK High efficiency _____ mm fos qe Rated flow 3000 rpm Outlet min pressure Outlet max pressure continuous Outlet max pressure intermittent 9 Inlet min pressure Inlet max pressure continuous inspires m m m _ 29 Power requirement at 80 bar and 3000 rpm Torque at 80 bar Weight ewe B d Typical average flow at 80 bar 1160 psi For lower pressure please contact Danfoss RO Sales Organization For higher pressure please contact Danfoss RO Sales Organzation Intermittent pressure is acceptable for less than 10 seconds per minute For speeds above 3000 rpm the pump must be boosted at a pressure of 1 5 bar 14
18. Noise and 8 3 5 General rece Ck oce creo I CICER ded 8 3 6 x a mure 8 3 7 Filtration 8 3 8 Properties Of water veio blew 8 3 9 gt 8 3 10 ilc Tc gt _ _ _ _ ___ 8 4 Arrival inspection transportation handling lifting and storage 9 4 1 Arrival inspect gt 9 4 2 9 4 3 General safety 9 4 4 Transport 9 4 5 Return to 35121 2 P 10 4 6 sro 10 5 Iristallation 5 11 5 1 Important GIMENSIONS 11 5 2 Cleanliness eset N S 11 5 3 Fluid temperatus os eua Veces 11 5 4 8 SERM Pa 11 5 5 Eocal 51611 514 s gia esto 11 5 6 Pre mounting checklist based on Danfoss preferred system design 11 5 7 Lifting and positi
19. Pumps 01 09 2012 9 User manual Installation Operation and Maintenance APP Pumps APP 0 6 1 0 See below examples of where to not to attach the lifting slings on the pump unit Correct lifting with 2 separate slings Wrong lifting When lifting the pump unit one sling must be attached to the electric motor and one sling around the pump 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 180R9262 APP Pumps v01 09 2012 A Incorrect lifting can result in personally injury and 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 NOT delivered frost protected from the factory User manual Installation Operation and Maintenance APP Pumps APP 0 6 1 0 5 Installation and A commissioning 5 1 Important dimensions Physical dimensions and connectio
20. abs when a non return valve is mounted in the inlet Instruction APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 2 4 General guidelines for calculation of The inlet line connection must be properly pressure losses tightened as possible entrance of air will cause In order to avoid the risk of cavitation the inlet cavitation pressure at the pump must be in accordance with the specifications mentioned in Data The suction conditions can be optimized sheet 521B0850 according to below guidelines bar m psi ft In smooth pipes and hoses 40 gpm US 150 I min bar psi In 90 bends 4 40 gpm US 150 l min 2 5 General comments Filtration Water tank A good filtration is vital to ensure a long and Must be made of corrosion proof material such trouble free life of the pump as stainless steel or plastic and must be sealed to prevent entrance of impurities from the environ When selecting a filter or strainer please note ment that filter materials should be compatible with water i e should neither corrode or dissolve Also be aware of the electrochemical series of the applied materials Main filter must have a fineness of 10 um abs B 10 gt 5000 The pressure loss across the filter should be monitored 16 18089262 IOM APP 0 6 1 0 Appendices v01 09 2012 APP pump instruction APP 0 6 1 0 APP 1
21. cannot be switched on again This also applies to the auxiliary power circuits e g anti condense heaters Check that supply voltage and frequency are the same as rated data Motors can be used with a supply deviation of 5 voltage and 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 in accordance with IEC 60352 2 Tightening torques for terminal board screws DNE EE SS EZ nose eec 55 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 22 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 HOYER MOTORS Bearing size and type are specified on the rating plate Motor types HMA2 and 2 is as standard with lifetime greased bearing with motor size lt 225 Motor types MS and 2 is as standard with lifetime greased bearing with motor size lt 160 Typical duty hours for lifetime
22. ended systems with direct water supply Disconnect the water supply to the pump 2 Through the lower bleeding plug empty the pump housing of water and close it again 3 Connect the pump to a tank of e g 25 litre 6 gal of anti freeze additive Connect a 6 Service 6 1 Periodic maintenance The APP pump is designed so that lubrication follows from the water itself and there is thus no oil in the pump The pump requires no periodic replacements of seals and valve parts Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark hose to the inlet port of the pump and via another hose return the flow from the outlet port port to the tank with anti freeze 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 6 2 Repair In case of irregular function in the pump please contact the Danfoss Sales Organisation Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 20 180R9262 A
23. lubricated bearings 55 160 2 8 40 0001 180 2 35 000h 200 2 27 000h 225 2 23 000h 150225 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 C to 150 C Motors are normal fitted with a data plate with greasing information if it is missing use the following re greasing intervals Frame Grease 2 pole 4 pole 6 pole 8 pole size 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 315 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 temperature of 25 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 not
24. on electric motor Noise from pump Noise from installation Typical signs of wear Valve plate Port plate Swash plate 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 ASION G asion Y 0 4015 11215 1105 Ly ainssaijd 9 7 gt peeds y Jepun Jadwep S S uo sedid sesoH 7 5 duing iz p 1972M t nss d 559 35 5 S 5 Jo 5 Z S 5949 5950 ping ur ary 3e 1n0o 1e U rs B ainssaid ysurebe 534615 Z E yy 00 L E dWfd 9L 5 ainssaid LL C jo uone301 2 jo 6122 JO UOI L O1 ON gt yeys uo jeixy ea Z L
25. pressure of the check valve must be bigger or equal to the inlet pressure 21 Open ended systems with water supply from a tank The numbers 1 3 refer to the drawing below In order to eliminate the risk of cavitation observe the following guidelines 1 Place the tank above the pump water level in the tank should always be above the pump 2 Place the inlet filter before the tank 3 Dimension the inlet line to obtain mini mum pressure loss large flow area minimum pipe length minimum number of bends connections fittings with small pressure losses 180R9262 APP 0 6 1 0 Appendices v01 09 2012 2 2 Open ended systems with direct water supply The pump is supplied with water direct from a booster pump The water pressure must not exceed 5 bar abs 72 5 psi 87 psi 2 3 Problems with reversing pumps If exposed to high pressure in the outlet while the electric motor is not energized the pumps will start spinning backwards This will not harm the pumps as long as the pressure in the inlet does not exceed the max pressure of 5 bar If a non return valve is mounted in the inlet line a low pressure relief valve will also be required Alternatively a high pressure check valve could be mounted in the pump discharge line to prevent the pump from reversing The dotted setup ensures that the inlet pressure does not exceed the 5 bar
26. pump Temperature gt 50 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 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 24 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 S
27. recommendation is not followed the warranty for the pump will automatically become void It should be possible to monitor the condition of the filter via the differential delta pressure across the filter Using insufficient filtration or a filter bypass can cause a failure or decreased service life of the pumps 3 8 Properties of water It is recommended NOT to use the pumps in feed water concentrations higher than 50 000 ppm TDS without consulting your local Danfoss pump distributor A 3 9 Air bubbles Large bubbles in a pressurised RO system can 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 A 3 10 Chemicals The pumps should not be exposed to any 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 0 6 1 0 41 Arrival inspection Pumps which have a weight above 20 kilos see The pump is packed in cardboard or wood Data sheet appendix 1 must be handled by with plugs in the port connections to protect the using lifting eyes and slings pumps from damage during transpo
28. 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 Prior to installation burrs and chips and Chips or other impurities the system other impurities must be removed from 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 1 0 Grease 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 Level indicator Level and temperature indicators Missing or incorrectly connected level must be fitted Follow installation and temperature indicators cause instructions damage Rotation direction Check pump drive motor rotation Incorrect rotation direction will direction matc
29. 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 appendix 1 3 3 Electric motor data See recommended motor in Data sheet appendix 1 for motors appendix 3 The motors mentioned are the most common used motors by Danfoss High Pressure Pumps 3 4 Noise 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 General arrangement Dimensions for the different pumps see Data sheet in appendix 1 180R9262 APP Pumps 01 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 5000 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
30. 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 18089262 IOM APP 0 6 1 0 Appendices 01 09 2012 23 Motor Manual Connection diagram AnschluBdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexi n Collegamento 1 L L Schemat polaczen 2 L5 L L5 wi vi W dli Y O 0 o 1 2 3 2 2 1 3 HOYER Svend Hoyer A S Over Hadstenvej 42 DK 8370 Hadsten 45 86 98 21 11 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 intervals The recommen dation is based upon good engineering practice and on experience gained from operation even under extreme conditions Danfoss APP pumps are designed for long operation and low maintenance and life cycle costs Danfoss guarantees 8 000 hours servi
31. 0R9262 APP 0 6 1 0 Appendices v01 09 2012 17 Instruction APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 3 3 Orientation The valve should be placed as close to the pump The pump can be mounted oriented in any as possible The opening characteristics of the horizontal direction Vertically only with the shaft valve must not result in peak pressures higher pointing upwards than 200 bar 2900 psi The valve outlet must not be connected 3 4 Protection from too high pressures directly to the pump suction line It shall be The pump should be protected against too high connected directly to the tank pressure by means of a pressure relief valve ora bypass unloading valve placed on the pressure side 3 5 Connections Pressure Tank Bleeding Parallel key 5 x 5 x 20 DIN 6885 APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 SENSN NNNM gt Thread size 1 2 x 15 1 2 15 M6 Hexagon 1 2 15 3 4 17 G 1 4 NV 6 NV 4 14 deep Max tighten 25 25 Nm 5Nm 25 Nm 25Nm 15Nm torque 18 Ibf ft 18 Ibf ft 3 5 Ibf ft 18 Ibf ft 18 Ibf ft 11 Ibf ft Recommended torque values refer to steel washers containing a rubber sealing element 180R9262 APP 0 6 1 0 Appendices v01 09 2012 Instruction 4 5 Initial start up Operation APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 Before start up loosen the top ble
32. 11 __ _ _ 10 8 0 ECCLES ERE Press Bush 218 Allen Key 4mm Allen Key 5mm Allen Key 6mm Shaft bush 035 Shaft seal extractor 035 Press bush 035 Adjustable pin wrench Combination wrench 10mm Nut M8x6 5x13 Guide bolt M8x140mm Shaft seal extractor 045 Press Bush 45 Eye bolt M8 Press bush for valve plate Stop for retainer plate Screw M8x20 Screw M8x70 Screw M8x140 Lifting eye Combination wrench 13mm 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 52 180R9262 IOM APP 0 6 1 0 Appendices 01 09 2012 MAKING MODERN LIVING POSSIBLE Guideline Trouble shooting guide for APP pumps ro solutions com Instruction Trouble shooting guide for APP pumps Table of Contents 54 Trouble shooting guide for APP pumps Trouble shooting fish bone chart 1 2 6 1 6 3 No flow no pressure Reduced flow reduced pressure High torque
33. 186 Cylinder barrel set APP 0 6 1 0 Compact 180B4187 Seal Flushing valve set APP 0 6 1 0 Compact The parts listed are not sold separately Exploded view see next page APP 0 6 1 0 Compact Note 2 ERHI ILLI m LLL be LII S p e wp emm bbb s eackupring mre NBR gt __ unex NBR a asisiemer f fi _ ro Washerforshattseal d Shaft seal us 22 122 O ring 053 1 5 121 151 screw TIT PEEK 2111 p omenwe xf m p bm po 01 fs 0 1 gt me x s p eem 8 po x m o weme 2 O ring 28733178 31 18089262 IOM APP 0 6 1 0 Appendices v01 09 2012 APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Exploded view APP 0 6 1 0 Compact Parts list 3 2 BIS 7 22772241 yyy 77 ES 4 i 222 2277 5 2 12 7778 2 E 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 32 Parts list 4 APP 0 6 1 0 and APM 0 8 1 2 APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 Note The pa
34. 195 003514 66178081 195 5 1 17808 86 06 ddV Japulj AD 9917808 86 06 195 08179081 Exploded view see next page 195 6 1 8081 0051 05 195 79174081 0051 05 195 e3e d ysems 89174081 0061 pue 0001 86 06 ddV 195 ysems 8 178081 0061 8 pue 0021 05 y screw ago 7 Hn Somoza n imge 1 swash plate 1 otinder barrer Super Duplex x songgi Je 1 Retainerball 2 Superbuple DLC Lr Retainerpiate s Pon no Super Duplex PEEK 1 Ponpe Super Duplex PEEK 01 o exui 00 PE __ NR Port fange omsomn fn 1 2 4 4 4 1 4 1 4 1 1 4 1 2 3 4 5 O O rin O ring 0228 4 NR x x Cover for shaft seal Super Duplex Pin 10 5x20 Screw 8 90 AISI 316 O ring 23588 mus Sid x 1 wwecne 019050687 Puggude Ins
35. 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 maybe check valve s Mount and tighten as specified User manual Installation Operation Maintenance APP Pumps APP 0 6 1 0 5 12 Ensure free flow Ensure that the flow from safety relief valves 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
36. 8 2 9 APPW 5 1 10 2 e parts listed are not sold separately only in various kits Se las 25 lee 1 cx cll GEM 1 N uccisi Exploded view see next page e A 55 a lt 5 oz Os et pH F 5 ES E o 5 5 35 35 gt 35 g m 5 E Vo 8 o e esignation m e 5 3 ats 1777 p een faso ___ ___ esee ws ________ a mme __________ swashplate _____________ swashplate ____________ SuperDuplex Pesk _ _ nosa superou Duplex PEEK spring lee smmagide Ph Retainer ball SuperDuplex Retainer plate SuperDuplex ese pir Oo T EE s Lx T px a 1 5 Uu ct 5 ww ________ ______ EUCTU TN NN NR Tailstock screw M12x60 AISI 316 sorna eraros hs ro emen dw bo do dl gt A 145 nii
37. 81 2701 195 e1e d 6517808 2 8 1 5 MddV 195 98078081 C OL 195 8078081 28 15 195 uoisid 1 78081 2 01 ddV 195 003514 78081 1 5 44 195 ysems 62808 5 9 ddV 195 exejd ysems 06178081 195 ysems 18179081 2 8 195 9219 usews ZELVAOBL 2 01 ddV 195 usews 179081 5 Swash plate Super Duplex Pin 26 10 AISI 316 O ring 0117 2 5 N 4 Cylinder barrel Super Duplex PEEK Retainer ball Super Duplex DLC Key 10x8x45 AISI 316 Super Duplex PEEK Valve plate Super Duplex Back up ring PTFE O ring 018 3 2 4 N 31 31 31 31 31 34 36 61 64 65 65 67 91 91 92 93 94 181 182 183 184 185 186 21 212 213 214 215 216 217 218 219 BR BR Super Duplex O ring 0135 3 NBR Pin 6x10 AISI 316 BR BR Pin 26 10 PEEK Screw M8x20 AISI 316 40 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 APP 0 6 38 APM 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 6 WN 09 1D Ta UNL WN g y 69 S 55520 lt e Li SSS y 7 2 227722 41 18089262 IOM APP 0 6 1 0 Appendices 01 09 2012 Parts list APP 0 6 38 APM 0
38. 92 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 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 Trouble shooting guide for APP pumps 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 lum 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 ope
39. 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 Operation and Maintenance APP Pumps APP 0 6 1 0 21 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 e Costly damages and claims 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 Ab 8 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 Da
40. Instruct operator and maintenance personnel Before using the pump pump unit the personnel must be instructed in using the pump pump unit its function Components documentation and safety Danfoss offers commissioning and service at system manufacturer s location Rate quotes are offered upon request User manual 6 14 Operation of motor pump unit Installation Operation and Maintenance APP Pumps APP 0 6 1 0 61 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 check all bolts and if necessary contact the maintenance department in order to have all bolts tighten to the specified levels Leakage if a small leak dripping from the bell housing is observed contact the maintenance department 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 E 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 stopp
41. MAKING MODERN LIVING POSSIBLE User manual Installation Operation and Maintenance Manual APP pumps APP 0 6 1 0 6 S ro solutions com User manual Table of Contents Installation Operation and Maintenance APP Pumps APP 0 6 1 0 S 4 2 Declaration Gf COMIOMMINY oci os arena rho nrc uet 5 1 aie 6 1 1 RN MR 6 1 2 SUDO et incense eee ees 6 1 3 Manufacturer and customer service 5 6 2 7 2 1 7 2 2 system 7 2 3 Commissioning and Servicing the 7 2 4 Adhere to the following important points 7 2 5 5 7 3 1401 4 Bald pe dais a tone 8 3 1 Approved applications and operational limits for the 8 22 Application Talde 8 3 3 Electric Motor PARU EEEREN EEEE AED e d aa 8 3 4
42. P 0 6 1 0 Appendices v01 09 2012 35 APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 Parts list PN gt aN 5 g c lt 7 2 A 2 510 510 2 10 ON lt lt br gt 2 222 18089262 IOM APP 0 6 1 0 Appendices 01 09 2012 36 Parts list 8 APP 3 0 3 5 0 6 38 0 8 2 9 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 44 195 295 2917808 5 195 e1e d 15194081 6 2 0 2 195 061748081 6 2 0 2 195 uoisid 60194081 0 44 195 e1e d usews 76178081 S E ddV 195 usews 66 8081 6 6 195 Buiusnj4 961978081 Designation s 0 ddV 195 26198081 Housing Duplex PEEK Pin 04 14 AISI 316 Swash plate Super Duplex beer wm m p ower 1 mp DL x ___ m p 1
43. POSSIBLE APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 ro solutions com Instruction APP pump instruction APP 0 6 3 5 180R9065 Table of Contents APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 Identification System design Open ended systems with water supply from a tank Open ended systems with direct water supply Problems with reversing pumps General guidelines for calculation of pressure losses General comments on Building up the pump unit Mounting Direction of rotation Orientation Protection from too high pressures Connections Initial start up Operation Temperature Pressure Dry running Disconnection Storage Open ended systems with water supply from tank Open ended systems with direct water supply Service Periodic maintenance Repair 18089262 IOM APP 0 6 1 0 Appendices v01 09 2012 Instruction 1 Identification 2 System design APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 NESSIE MADE IN DENMARK The design of the system must ensure that self emptying of the pump during standstill is avoided The inlet pressure of the pump must never exceed the outlet pressure This may typically occur in boosted or open ended systems with direct water supply In order to avoid this it is recommended to install a pre stressed check valve or a pressure switch in the pump inlet The opening
44. PP 0 6 1 0 Appendices v01 09 2012 Electric Motors Motor Manual hoyermotors com 4 y B E 4 HOYER MOTORS 180R9230 HOYER 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 C to 40 C and site altitudes lt 1000 m above sea level Low voltage motors are components for installation in machinery They are CE marked according to the Low Voltage Directive 2006 95 EC 2 Transport and storage Check the motor for external damage immediately upon receipt and if found inform the forwarding agent right away Check all rating plate data and compare it with the requirement of the motor Turn the shaft by hand to check free rotation remove transport locking if used Transport locking must be used again for internal transport also It 15 also important that transport locking is used when motors are transported mounted on equipment All motors should be stored indoors in dry vibration and dust free conditions Lifting eyebolts must be tightened before use Damaged eyebolts must not be used check before use Lifting eyes at motor must not be used to lift the motor when it is attached to other equipment Before commissioning measure the insulat
45. V 195 95179081 Z OL 195 45179081 C 8 L S 195 uoisid 179081 Z OL 195 UOISId SSLESOSL ddV 195 ysems 62179081 6 9 195 exejd ysems 08179081 CZ 195 ee d 16178081 2 8 195 2219 ysems 81 2 01 ddV 195 e1e d ysems 1859081 mph I Super Duplex Swash plate Super Duplex PEEK Super Duplex 5 5 Valve plate Super Duplex Back up ring PTFE O ring 018 3 2 4 NBR 31 31 31 31 31 34 36 61 64 65 65 67 91 91 92 93 94 181 182 183 184 185 186 211 212 213 214 215 216 217 218 219 Super Duplex O ring 0135 3 Key 10x8x45 AISI 316 Hastelloy NBR g 21111111 TT ETT 2 21 11111 LTT TTT e 11110 11111111111 1111 A e 2 LTT TTT TTT ET 21111111 LTTE X X X X X X X 180R9262 APP 0 6 1 0 Appendices v01 09 2012 39 Parts list APP 0 6 38 APM 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 ddV 195 295 19174081 2 01 1 5 peq Aapul AD 09179081 2 8 1 5 ddV 195 851790
46. 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 phases 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 a 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 indicator function by slowly closing the valves The pump unit should stop when the minimum inlet pressure and maximum outlet pressure has been reached 18089262 IOM APP Pumps v01 09 2012 Adjust the pressures to the specified inlet and outlet pressure for the system and let the pump unit run until the electric motor and pump temperature is stable If the system is running within the system design limits the system is released for operation 5 18 Check the filter condition Evaluate dirt found in filter replace filter elements if necessary 5 19
47. anager d partement qualit Normes harmonis es appliqu es DS EN 12100 2011 Signature du fabricant Titre Ju LM 2012 08 30 Date Welm Friedrichsen Directeur R amp D User manual 1 Introduction Installation Operation and Maintenance APP Pumps APP 0 6 1 0 11 General The APP pumps and pump units are manufac tured by Danfoss A S and are sold and marketed by a net of authorized distributors world wide This manual contains the necessary instructions for the installation operation and service of the pumps used in a Sea Water Reverse Osmosis SWRO 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 A Use of the pump in other applications not suitable for the pump unit can cause damages to the pump unit with risk of personal injury personnel being responsible for operation and maintenance of the pump unit must read and fully understand these instructions especially the section Safety before e Installing the pump unit Connecting the motor pump unit to the water system Connecting the electric motor and instru mentation e Commissioning the unit e 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 exis
48. antle pump and check for damage If the RPM is within the specified range of the pump data sheet and abnormal noise remains dismantle pump and check for damage If outlet pressure is too low check set point of outlet pressure valve If outlet pressure is lower than mentioned in the pump data sheet please contact Danfoss A S RO Solutions Technical Support If outlet pressure has exceeded its maximum check set point of outlet pressure valve 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 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
49. ase 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 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 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 27 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 28 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 MAKING MODERN LIVING POSSIBLE Parts list
50. ce 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 3161 x 5 7 9 Piston Super Duplex and PEEK Recommended inspection ona yearly basis and evaluated acc to app 1 92 Valve plated Super Duplex 24 000 hours 1 Cylinder barrel Super Duplex 40 000 hours 5 Retaining plate Super Duplex 24 000 hours 64 Retaining ball Super Duplex 40 000 hours 7 Retaining guide Super Duplex 40 000 hours 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 SS _ Back up ring 24 000 hours EMEN O ring overall NBR 24 000 hours 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 26 180R9262 IOM APP 0 6 1 0 Appendices 01 09 2012 Instruction 3 Appendix 1 Recommended service intervals for APP pumps Pistons In c
51. consult section 9 Filtration for guidance on how to select the right filter Thoroughly clean pipes and flush system prior to start up 3 Place a monitoring pressure switch 3 set at min inlet pressure between filter and pump inlet The monitoring switch must stop the pump at pressures lower than minimum pressure 4 Use flexible hoses 4 to minimize vibrations and noise 5 In order to eliminate the risk of damage and cavitation a positive pressure at the inlet 5 is always to be maintained at min inlet pressure and max inlet pressure Media mer X 12 1 Warranty Danfoss APP pumps are designed for long operation low maintenance and reduced lifecycle costs Provided that the pump has been running according to the Danfoss specifications Danfoss guarantees 8 000 hours service free operation however max 18 months from date of produc tion If Danfoss recommendations concerning system design are not followed it will strongly influence the life of the APP pumps 12 2 Maintenance After 8 000 hours of operation it is strongly recommended to inspect the pump and change any worn parts eg pistons and shaft seal This is done in order to prevent a potential breakdown of the pump 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 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 ord
52. ct pump from electric motor and check that the motor is capable of running with no load 1 3 7 Ensure that coupling between electric motor and pump is connected Check if coupling is damaged Check that electric motor is sized correctly Check that the electrical installation is correctly sized Contact Danfoss Sales office for guidelines in how to troubleshoot internal pump parts 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 180R9262 IOM APP 0 6 1 0 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 180R90
53. cy of 99 9896 For more information on the importance of proper filtration please consult our publication Filtration code number 521B1009 which also will provide you with an explanation of filtration definitions and a guidance on how to select the right filter Data sheet APP 0 6 1 0 10 Dimensions 10 1 Pump 36 142 gt ae 9119 8 4 72 106 4 4 19 8 0 31 A 6 0 23 2811 10 gt 110 04 9 001 070 66 SL 10 7 0 42 Description Port position mm in Port position mm in mm in mm in oes E Bleeding Inlet connection Outlet connection Pump mounting flange 10 2 Complete unit APP 0 6 APP1 0 15 9 0 63 15 9 0 63 2 88 3 5 131 5 2 5x5x20 0 20 x 0 20 x 0 78 Hexagon AF 5 mm BSP G 15 0 59 deep BSP G 15 0 59 deep SAEA2 Examples of different pump motor sizes Check required power atm Gti 100 125 100 H mm IEC Electric motor 100 131 1 5 kW IEC 90S 2 131 2 2 kW IEC 90L 2 265 290 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 120 131 3 0 kW IEC 100L 2 Data sheet 11 Installation 10 APP 0 6 1 0 11 1 Mounting The figure below illustrates how to mount the pump and connect it to electric motor co
54. e 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 180R9262 APP Pumps v01 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 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 B 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 C Inspect all parts including shaft seal and if necessary replace them see Parts list appendix 5 and APP pump instruction appendix 2 or general instruct
55. e for Atex Zone 22 motors Notice for the use of electrical equipment in areas with combustible dust Designation of motor according to 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 dry it must be lubricated It is recommended that the seal is re lubricated regularly Always use the original seal ring when replaced Replacing bearings also means replacing the seals All machines must be inspected regularly for mechanical damage The
56. e 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 180R9262 APP Pumps v01 09 2012 MAKING MODERN LIVING POSSIBLE User manual Appendices for Installation Operation and Maintenance Manual APP pumps APP 0 6 1 0 BW APP 0 6 1 0 Pp ro solutions com User manual Appendices for IOM APP Pumps APP 0 6 1 0 Table of Contents 1 Data sheet for APP 0 6 1 0 pumps 2181136 i4 ea en ra a CR eR PEE ER NF Cen 3 2 APP pump instruction APP 0 6 3 5 180R9065 0is esses e e e ew 13 3 IOM Electric motors 180R9230 sce e Ea dera e a a ar acu eara A 21 4 Recommended service intervals for APP pumps 180R9199 25 5 APP Parts list 521B0941 29 6 Troubleshooting o 53 7 Right and wrong 18089042 C AC 63 2 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 MAKING MODERN LIVING POSSIBLE Data sheet Data sheet APP 0 6 1 0 ro solutions com Data sheet Data sheet for APP 0 6 1 0 pumps 521B1136 Table of Contents 1 General information APP 0 6 1 0 1 General information 2 Benefits 3 Technical data
57. ed immediately and inspected before running again Contact the maintenance depart ment Drop flow and or pressure can indicate wear 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 Other 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 180R9262 APP Pumps v01 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 Maintenance and service of the pump unit Installation Operation and Maintenance APP Pumps APP 0 6 1 0 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 accordi
58. eding plug When water appears from the bleeding plug retighten the plug With its inlet line connected to the water supply or the tank the pump is now started with open outlet port At the initial start of the system the pump should be run without pressure for about 5 minutes thus removing possible impurities from pipes hoses etc However the system should be flushed before start up without the connected pump WARNING Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump Otherwise the pump will be damaged if a check valve is placed between pump and tank 5 1 Temperature Fluid temperature Min 3 C to max 50 C Ambient temperature Min 0 C to max 50 C In case of lower operating temperatures please contact the Danfoss Sales Organization 5 2 Pressure The inlet pressure must be min 0 9 bar 13 psi and max 5 bar 72 5 psi abs At lower pressures the pump will cavitate resulting in damage to the pump Max pressure on the pump s outlet line should be limited at 80 bar 1160 psi continuously Short term pressure peaks e g in connection with closing of a valve of up to 100 bar 1450 psi are acceptable NB The pump unit should include a pressure gauge on the high pressure side 5 3 Dryrunning When running the pump must always be connected to the water supply in order to avoid damage if it should run dry In s
59. er to avoid backspin of the pump The volume of water in the membrane vessel works as an accumulator and will send flow backwards in case of the pump stops momentarily 8 safety valve 8 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 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 12 3 Repair In case of irregular function of the APP please contact the Danfoss RO Solutions Sales Organisation 11 Data sheet APP 0 6 1 0 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 12 18089262 IOM APP 0 6 1 0 Appendices v01 09 2012 MAKING MODERN LIVING
60. g 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 flooding which again can cause 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 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 18089262 IOM APP Pumps v01 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 o
61. 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 18089262 APP Pumps v01 09 2012 User manual 8 Troubleshooting and scrapping criteria Installation Operation Maintenance APP Pumps APP 0 6 1 0 8 1 General safety information Before inspecting the pump unit it is necessary to read and understand this user manual especially the Safety chapter 2 Remember to wear suitable safety equipment according to Safety chapter 2 8 2 Operational conditions which can cause pump failures The following conditions can cause a pump failure The pump is running dry The inlet pressure is too high The 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 The pump is running against a blocked port closed manual valve The pump is operating at a pressure above the operational specification The pump is running with a non specified approved fluid The pump is running in the wrong direction The filtration is insufficient The pump is not being serviced according to Danfoss specifications end of life There is excessive mechanical load on the shaft coupling and piping Ab 8 3 Mechanical failure If the pump is runnin
62. he respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 70 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012
63. hes that of the pump damage the pump prior to installation Bleeding Bleeding the pump will ensure correct Insufficient bleeding may cause dam cooling and lubrication age not applicable to Power Packs Starting procedure Cleaning procedure 1 Fill cold water into the system the return filter and bleed the pump Power Packs PPH 4 6 3 10 and 12 5 are self bleeding 2 Start and bleed the system without pressure by opening the bypass valve 3 Add the cleaning agent to give 3 agent water solution 4 Run the system for 60 min and activate all components as often as possible to ensure effective flushing with the cleaning agent 5 Empty the system of the cleaning agent solution Flushing procedure 6 Fill cold water through the return filter and bleed the pump Power Packs PPH 4 6 3 10 and 12 5 self bleeding 7 Run system for 30 min and activate all components as often as possible 8 Empty the system of the water 9 Alternatively the system may be flushed by running the unit without the return hose while continuously filling up water The flushing should continue until there is no trace of cleaning agent in the return water 10 Change the return filter element fill cold water through the return filter and bleed the pump during start up 11 The system is now ready for operation Starting procedure Observing the starting procedure will If the system is not cleaned before ensure prob
64. in rosx2n ome 151 3 hz semen mme x m sewwaes ume fx ms 00 De h sees __ e _ 7 De mme uns _ Ds meam ds owes mes 1 1 2 _ hm 1 x hs r soring x _ __ ____ 5 hs v oweemansss ws do ERR 44 18089262 IOM APP 0 6 1 0 Appendices v01 09 2012 APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Parts list Exploded view APP 16 19 16 WNOL WNL WNZ WNL WNZ WNL F WNZ A 2 X ESSE ET aaa 2222224 2224 1 X 6 22 KX 45 180R9262 IOM APP 0 6 1 0 Appendices v01 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 195 296 907VAOSL 0051 ZZ 0021 ZZ 91 4 ysems 81778081 195 10774081 195 003514 0079081 ysems 270274081 195 70278081 195
65. ion 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 Preduct information see label on preduct Only 1 product om each report Operational comdition rn 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 0 6 1 0 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 bell 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
66. ion impedance If values are 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 outdoors and not running 24 hours day so that the motor can breathe thus ensuring a dry motor 4 Electrical connection Work is only permitted to be carried out by qualified specialists and must to be carried out in accordance with local regulations Before work commences ensure that all power is switched off and
67. lem free operation starting the filter will clog Trouble shooting Open ended water systems 5 water coming out of the tap Are all taps open e Is the control light for low pump suction pressure on lt filter is clogging 5 water coming through the filter Replace filter element Turn on the tap for water supply No water supply s the water supply ok e Is water supplied to the pump e Is the electric motor of the pump unit rotating 555555555 590500090 Lower inlet s the water in the tank Yes very hot le above 50 temperature Qr provide better cooling s the power supply ok control lights on e Is the filter clogged s the filter control light on Yes blown fuse or short circuit Check power supply and fuses and contact electrician Replace filter element Contact serviceman Trouble shooting Closed water systems The system does not work e s there sufficient water in the tank e s the electric motor of the pump unit rotating 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
68. mbustion engine If alternative mounting is required please contact Danfoss Sales Organization for further information ensure easy mounting of the flexible coupling without using tools the tolerances must be dimensioned accordingly Note Any axial and or radial loads on the shaft must be avoided The pump should be connected to the rest of the plant with flexible hoses Min 3 mm air gap between coupling parts A Flexible coupling B Bell housing C Motor shaft 11 2 Open ended system with direct water supply In order to eliminate the risk of cavitation a positive inlet pressure is always to be main tained Please see technical data section 3 for specific pressure values 1 Place the filter 1 in the water supply line in front of the pump 2 Place a monitoring pressure 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 180R9262 APP 0 6 1 0 Appendices v01 09 2012 Data sheet 12 Service APP 0 6 1 0 11 3 ROsystem with APP pump 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 Place an inlet filter 1 in front of the APP pump 2 Please
69. mperature 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 environment corrosion and humidity CP6 as well as fluid and torque requirements CP8 Check the factory 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 CP9 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 1 Bar to measure the system pressure range 79 Bolts screws must conform to environmental conditions or more precise 11 Check coupling distance air gab movement of the spider CP12 Check correct connections on the pump outlet Po CP13 Check piping for possible air gaps gt 5 7 Lifting and positioning
70. n equipment is essential 2 3 Commissioning and servicing the unit It is recommended that commissioning and servicing are carried out by a minimum of two people where one is acting as a supervisor 2 4 Adhere to the following important points Before using the pump pump unit it is very important to read and understand this user manual Do not try to lift the pump unit manually most of the pumps 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 it is 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 0 6 1 0 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
71. ng 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 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 Openthe pressure valves at the brine site to release the pressure B Stop the high pressure pump C Stop the feed pump D Turn 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 E Open bleeding and drain plugs Wait until the pump and system are emptied for water A F Slowly unscrew and remove the bolts 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 th
72. nger 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 electric motor if the motor is not designed for VFD operation A 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 180R9262 IOM APP Pumps v01 09 2012 All pipe and hose connections must be stress free mounted securely fastened to the pumps and 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 It is always the system builders responsibility that the system design does not cause any kind of hazard and is adapted to local regulations and standards Proper installation care of start up and shut down devices and over pressure protectio
73. 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 sheet results in wear of the pistons i e pistons may be damaged High RPM will also increase pressure pulsations from the pump and the noise level will increase If RPM is changed noise frequency will also change 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 59 Instruction Trouble s 5 Noise from installation 5 1 Inlet outlet connections hoses pipes 5 2 Length dimension of inlet outlet line 5 3 Hose stiffness 5 4 Hoses pipes mounted directly on frame 5 5 Vibration damper under the electric motor 60 hooting guide for APP pumps 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 5 1 2 Mount the connections to the frame by a vibration damper mounting plate 5 2 1 Increase pipe diameter and or reduce the number of bends 5 3 1 Use amore flexible hose Danfos
74. ns for the pump unit are described in Data sheet appendix 1 5 2 Cleanliness It is very important that the tubes and pipes are completely clean no dirt chips or burrs are allowed Flush all piping before connecting the high pressure pump to ensure the system is clean Internal surfaces of the piping must not be corroded If dirt or rust is not removed the pump and the valves can be damaged 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 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 9 Feed 5 1 7 2 Brine 180R9262 IOM APP Pumps v01 09 2012 11 User manual 12 Installation Operation and Maintenance APP Pumps APP 0 6 1 0 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 te
75. oise 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 As water has very low viscosity the APP pumps have been designed with very narrow clearance in order to control internal leakage rates and improve component performance Therefore it is important that the inlet water is filtered properly to minimize the wear of the pump The main filter must have a filtration efficiency of 99 98 at 10 um We recommend to use precision depth filter cartridges rated 10um abs 810 gt 5000 equivalent to a filtration efficiency of 99 98 Bag filters and string wound filter cartridges typically have only 50 filtration efficiency 180R9262 APP 0 6 1 0 Appendices 01 09 2012 vibrations and noise The noise level is influenced by The speed of the pump high rpm create more noise than low rpm Rigid mounting of the pump generates more noise than flexible mounting Pipe mounting direct to the pump increases the noise level compared to a flexible hose This means that for each 100 000 particles reaching the filter 50 000 particles pass through it compared to only 20 particles in a filter with an efficien
76. 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 62 18089262 APP 0 6 1 0 Appendices v01 09 2012 MAKING MODERN LIVING POSSIBLE Right and wrong Trouble shooting guide for water hydraulic systems danfoss high pressurepumps com 180R9042 Choice of material Plastic Stainless steel Always use system components made Non corrosion proof materials of corrosion proof materials may cause damage Choice of filter Install a 10 micron absolute filter with Return filter with bypass valve and pressure switch poorer filterability than 10 u will damage the system Filter location Locate the return filter in the return line Placing the return filter upstream of the immediately before the tank final load may damage the pump Pump location Pump always to be placed below water Pump location above water surface surface level level will cause damage Suction conditions System to be dimensioned to provide Poor suction conditions will cause a suction pressure of the pump inlet of malfunction and damage the pump max 0 1 bar vacuum Pressure Relief valve Pressure relief valve to be mounted Coupling the pressure relief valve outlet vertically or with vertical outlet and directly
77. oning 12 5 8 Mount the different equipment 2 2 tag 12 5 9 sla MTM MT 12 5 10 gt 12 511 CONNECTORS 55555 12 5 12 Ensure free flOW EcL 13 5 13 Verify setting 13 5 14 Flush et 13 5 5 Bleed and remove dir from the pump sacs ia aso 13 5 16 Verify direction OF rotations s ee ud EEEE Fe ATED 13 5 17 COMMISSIONING 555255 Ea 13 5 18 Check the filter E abr RO C ate 13 5 19 Instruct operator and maintenance 13 6 Operation of motor etc oreerex eee ecc exe gir 14 6 1 General Safety Us 14 6 2 What to listen and M EG RUE 14 180R9262 APP Pumps v01 09 2012 User manual Installation Operation and Maintenance APP Pumps APP 0 6 1 0 7 Maintenance and service of the pump unit cessere 9X Rd XN Y 15 71 General safety aqu de 15 7 2 Service inspection interval for the pump eor ida 15 7 3 Sh
78. orn valve plate is to hold a straight knife edge over the valve plate When holding it up to the light it will be possible to see any space between the knife edge and the valve plate See picture 3 If any light can be seen between the two arrows on the picture the valve plate is worn If any scratches or marks can be felt by running a fingernail over the surface the valve plate is worn The valve plate on picture 3 is highly damaged 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 61 Instruction Trouble shooting guide for APP pumps 6 2 Port plate Picture 1 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 it is an indication of insufficient filtration The surface of the swash plate must be plane and even at same level all over To check this please see item 6 1 picture 3 If the surface has any marks scratches it is worn damaged and a new one is required Please contact Danfoss 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
79. ps v01 09 2012 EC Declaration of Conformity Danfoss A S Danfoss High Pressure Pumps Nordborgvej 81 6430 Nordborg Denmark EG Konformit tserkl rung gem EG Richtlinie 2006 42 EG EC Declaration of Conformity according to Directive 2006 42 Hiermit erkl ren wir dass die Maschine gemafi 2006 42 EG entwickelt 151 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 Leiter Qualititsabtellung Angewandte harmonisierte Normen DS EN ISO 12100 2011 Hersteller Unterschrift Titel 2012 08 30 Datum Welm Friedrichsen Leiter We hereby declare that the machine 15 designedaccording to the directive 2006 42 EC Machine designation APP 0 6 1 0 APP 1 5 3 5 APP 5 1 10 2 APP 11 13 APP 16 22 APP 21 38 Technical dossier Contact person Manager Quality Department Used harmonised standards DS EN ISO 12100 2011 signature Title 2012 08 30 Date Welm Friedrichsen Director R amp D 180R9262 APP Pumps v01 09 2012 D claration conformit CE conform ment la Directive 2006 42 CE Par la pr sente nous d clarons que la machine est concue conform ment la Directive 2006 A2 CE Type de machine APP 0 6 1 0 APP 1 5 3 5 APP 5 1 10 2 APP 11 13 APP 16 22 APP 21 38 Personne de contact pour le dossler technique M
80. r 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 appendix 7 Right and Wrong which gives good advises in design installation wiring and troubleshooting User manual Subject index A Address 6 7 15 Airb bbles 8 Appendix 7 8 9 10 11 12 14 15 16 17 8 fisso MEM PT Spe 6 Arrival 9 12 15 16 Assembling ios 224 42 54 12 15 16 B 7 8 13 15 Checklist sv rg RR 11 12 8 Cleanliness 11 Commissioning 6 7 11 12 13 16 17 Connections 7 9 10 11 12 15 7 12 13 16 17 Danger x a ate 7 13 17 Datasheet 7 8 9 10 11 12 14 15 16 Declaration of Conformity 5 6 Design 7 8 9 11 12 14 17 6 8 8 11 Disassembling 15 16 Electric motor 6 7 8 9 10 11 12 13 16 17 Electrical failu
81. ration 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 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 180R9262 APP 0 6 1 0 Appendices v01 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 umto prevent abnormal wear of the
82. re 17 6 ElecttleS 5 53 RES 12 EU Declaration of Conformity F Fail t amp ei oe tuu a 8 17 Filtercondition 0 13 8 12 17 PION ved tete dete ad E 7 8 13 14 i 11 12 15 17 Flush 11 13 Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark G Generalinformation 7 17 H wre ee RS 7 9 12 15 16 Inspection 9 12 14 15 16 Installation 6 7 11 12 14 16 17 6 7 8 10 12 14 15 16 Instrumentation 6 12 Introduction 6 M Maintenance 6 7 10 13 14 15 17 Mounting 16 plate 9 11 12 13 NOISG 14 L eke 17 Lifting og eo a 6 9 10 12 15 16 Local regulations 6 7 11 12 17 Operation 6 7 8 9 13 14 16 17 Operational conditions 7 17 PIPINO uuo ale ee e 8 11 12 17 0 12 Preferred system design 7 11 Pre Mounting 11
83. rtation 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 should be drawn up and presented to the carrier at once A 4 2 Warning Before any lifting operation is performed environmental conditions must be taken into consideration Ex rated areas wind speed wet dry conditions lifting height etc 4 3 General safety information Personnel involved in lifting and transporting the equipment see Safety chapter 2 must be trained in handling and 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 willbe _ Never use only 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 180R9262 APP
84. rts listed are not sold separately only in various kits Parts for APM 0 8 1 2 are equivalent to the parts for APP 0 6 1 0 except for valve plate sets Exploded view see next page 90 195 Aapul AD 17808 0 1 9 0 195 e1e d 62178081 21 8 0 195 9 00174081 0 1 9 0 195 82 17808 0 1 9 0 195 40154 2 17808 Designation 0 1 9 0 195 295 17179081 V emen mer aom m TET ao I E TT m T m mem foe emo 11 1 36 eem m 4 O ring 08 73 1 78 NBR ven m owes ws fel wp wee 0 11 2 155 O ring 07 0 1 5 NBR 18089262 IOM APP 0 6 1 0 Appendices v01 09 2012 33 APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 Parts list Exploded view APP 0 6 1 0 5 0 8 1 2 jo di O NS N NEP e vb NA 4 gt gt Qu 5
85. s A S can provide flexible hoses Please contact Danfoss sales office for further informa tion 5 4 1 Mount the connections to the frame by a vibration damper mounting plate 5 5 1 Mount a vibration damper below the motor pump 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 Non flexible 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 6 Typical signs of wear 6 1 Valve plate Picture 1 Picture 2 Scratches Picture 3 Trouble shooting guide for APP pumps A normally worn valve plate has no marks scratches but only a slightly polished surface No scratches or marks should be felt The surface must be flat and level A worn valve plate has scratches and or a polished surface Even small scratches will give a loss of flow A good way to identify a w
86. tart 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 torque see item 6 Typical signs of wear 58 180R9262 IOM APP 0 6 1 0 Appendices 01 09 2012 Instruction Trouble shooting guide for APP pumps 4 Noise from pump 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 18089262 IOM APP 0 6 1 0 Appendices v01 09 2012 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 Checkthe pump for internal damage 4 4 1 Dismantle pump and check if anything is broken or worn See 1 No flow item 1 2 Pump reversing WARNING The pump must not run without water for more than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure and will eventually be damaged If electric motor RPM is too high dism
87. ting 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 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 18089262 APP Pumps v01 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 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
88. truction 8 1 2 s ENT E ________ 0 2 1 17 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 15 1 1 1 1 1 1 1 1 10 11 12 13 3 3 6 62 63 6 65 67 7 9 92 93 9 12 12 12 12 12 12 12 14 14 14 14 14 15 15 15 15 50 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 APP 0 6 38 0 8 2 9 APPW 5 1 10 2 Parts list Exploded view APP 30 38 22 WNOL WNG WN WNE WNOE 0 609 Ni ly WNZ NOL SN N NSS SS CE 7 BZ S NS 2222 7 WVU 22 lt lt SN 9 2277 5 WNZ WNOL 5 YOT 22 23 ES 1 222242 N 51 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 Parts list APP 0 6 38 APM 0 8 2 9 APPW 5 1 10 2 23 Tool sets Note The parts listed are not sold separately only in various kits lt A gt 79 79 0 1 9 0 195 00 77178081 S S L ddV 195 00 89104081 EL LL ddV 195 00 0 Zv 8081 22 91 ddV 195 001 727 7 081 8E LZ ddV 195 00 2117808 1 C OL L S ddV 195 001 29178081 3 m Shaft bush Press bush 22 Torx T30 Shaft bush 218 o Designation __ _ 1 5 0 11
89. utdown of ING _ 8 rds 15 7 4 Disassembling and assembling the pump 15 7 5 Assembling the pump _ 16 7 6 Procedure for mounting pump back onto electric 16 7 7 Getting the pump unit back into operation deep PX eines 16 7 8 Storage or the mp es susce Ta E PS 0 NS 16 8 Troubleshooting and scrapping Criteria uen odd Sends ERE RAYS naa 17 8 1 General safety ERR SPA EPA 17 8 2 Operational conditions which can cause pump 17 8 3 Mechanical TANNING os basato trt p eb ERO vC PERSPSER REM AUS T ERES 17 8 4 Electrical failus 17 8 5 Responsibility REX Rx UR CE ea a Op alae mehwwex even aes 17 8 6 Scrapping see Ed esa ca eic CR 17 SUDbISCEIBEIBX eI P 18 18089262 APP Pumps v01 09 2012 3 User manual Validity Installation Operation and Maintenance APP Pumps APP 0 6 1 0 This manual is valid for APP pumps with the following code numbers serial numbers APP 0 6 180B3048 APP 0 8 180B3037 1 0 180 3049 E 180R9262 IOM APP Pum
90. ystems with water tank it is recommended to build in a level gauge in the tank to avoid the risk of running dry 5 4 Disconnection If the inlet line is disconnected from the water supply the pump will be emptied of water through the disconnected inlet line When starting up again follow the bleeding procedure described under section 4 Initial start up 180R9262 IOM APP 0 6 1 0 Appendices v01 09 2012 5 5 Storage Storage temperature Min 40 C to max 70 C 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 Sales Organization Recommended procedure 5 5 1 Open ended systems with water supply from tank 1 Empty the tank of water and empty the pump housing through the lower bleeding plug When the pump is empty retighten the plug 2 Through the upper bleeding plug fill the pump housing with anti freeze medium Pour anti freeze medium into the tank Connect a hose to the outlet of the pump and lead the other end of the hose back to tank 3 Quickly start and stop the pump Make sure that the pump does not run dry The pump is now protected against internal corrosion and frost Instruction APP pump instruction APP 0 6 1 0 APP 1 5 2 5 and APP 3 0 3 5 5 5 2 Open

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