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APP 16-22

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1. 33 APP parts ME Ee S 37 Foer 45 Rigntand wrong 180R9042 EEE EE 55 180R9265 IOM APP 16 22 Appendices v04 11 2013 MAKING MODERN LIVING POSSIBLE Data sheet Data sheet APP 16 22 ro solutions com Data sheet Data sheet for APP 16 22 pumps 521B1183 Table of Contents 1 General information APP 16 22 1 General information 2 Benefits gt Technical data 4 Variants 5 Flow at different rom 6 Flushing valve 7 Power requirements 8 Temperature and corrosion 8 1 Operation 8 2 Storage 9 Noise level 10 Filtration 11 Dimensions 12 Dimensions complete unit 13 Installation 13 1 Mounting 13 2 Open ended system with direct water supply 13 3 RO system with APP pump 14 Service 14 1 Warranty 14 2 Maintenance 14 3 Repair APP 16 22 pumps are designed to supply low viscosity and corrosive fluids under high pressure e g in seawater reverse osmosis filtration applications and for high pressure salt water pumping The pumps are based on the positive displace ment principle axial piston design which enables a very light and compact design and Shaft Sealing Bolts for bell housing Flushing valve Port plate fi VO CON A UN S UN Retainer ring SE Springs NS VAN Swash plate with bearing Port flange with bearing Drain plug Housing 180R9265 IOM APP 16 22 Appendices v04 11 2013 Bleeding
2. zs Pump mountin 125B4 For more details on the accessories please So contact the Danfoss RO Solutions Sales Organisation APP 16 APP 22 Parallel key mm 12x8x70 DIN 6885 In 0 47 x 0331 x 2 76 2 inlet hose 2 Victaulic 18020298 kit 2 m 79 2 inlet Vic 2 Victaulic 18020165 Super Duplex G Y Hexagon AF 6 mm Non return 2 Victaulic 180H0256 tlet metpon ms2x15 deptharmm kile l n 00 63 mm M52 x 1 5 depth 21 mm Pump mounting 125B4 For more details on the accessories please flange contact the Danfoss RO Solutions Sales Organisation 22 180R9265 IOM APP 16 22 Appendices v04 11 2013 Instruction A Initial start up Danfoti APP pump instruction APP 11 13 and APP 16 22 1 Flush inlet line before connecting the Warning pump to remove possible impurities from Make sure that the direction of rotation of the pipes hoses etc electric motor corresponds to the direction of 2 Connect pump inlet to inlet line and flush rotation of the pump see label on pump the pump for 5 min by means of the internal flushing valve to remove possible Otherwise the pump will be damaged if a impurities from pipes hoses etc check valve is placed between pump and feed 3 Loosen top bleeding plug C see item 3 3 pump using an allen key only plugs with internal hexagan sockets Retighten the plug when water appears from the bleeding plug 4 sure th
3. m l z s lu s m B CA Torque at 60 bar outlet 2BB 0 te fe Je Fintegratedushingvalve lm y s fv ves y v lm 07 Typical average flow at 60 bar 870 psi 7 For lower pressure please contact Danfoss RO Sales Organization 3 For higher pressure please contact Danfoss RO Sales Organization The pump is designed according to EN809 180R9265 IOM APP 16 22 Appendices v04 11 2013 5 Data sheet 4 5 Variants Flow at different rpm APP 16 22 Available as ATEX certified Category 2 zone 1 and category 3 zone 2 Available with material certificates on wetted parts For more details on the variants please contact the Danfoss RO Solutions Sales Organisation When using the diagrams shown below it is easy to select the pump which fits the application best if the flow required and the rotation speed rom of the pump are known 1200 rpm version 1000 1100 900 1000 1100 1200 1300 1400 rpm Furthermore these diagrams shows that the flow can be changed by changing the rotation speed of the pump The flow rpm ratio is constant and the required flow can be obtained by changing the rotation speed to a corresponding value Thus the required rpm can be determined as Required flow x Rated rpm Requiredrpm Rated flow 180R9265 IOM APP 16 22 Appendices v04 11 2013 1200 1500 Data sheet 6 7 Flushing valve Power requirements APP 16 22 Flushi
4. o oi U o U Q Q Q A SS N N N Li N gt Note E g g g g 2 g oi amp S S S ES bd The parts listed are not sold e o o Y oe ee separately only in various kits kb E SEISEISE SE SE SESE p SE SS a Se S SS 5 q Ea gt u U gt Q AE AS n AS m LL Exploded view see next page E IA AS O A ASA o si oa A ee 1 o un et e DI a um E o o or RE m Nol nol NOI NOI GO IG w IG w IG FI NNI NOY NAT NO Designation St St St St St St St b m b b q m q aoa Ma Ma Maqa Ma Ma Na Na Ma Ma Na a OA OA OA OA OA OA OA OA OA OA OA OA OL OL OL DME PT NT MDE OL OL OL OT OE Duplex PEEK Super Duplex X o ar fom EN ES s s TTT Tee RE Duplex PEEK 7 sing 7 gt RE IE E al 1 keener Superbuplexroie Lo SS o sm t x o 7 mon I x 1 oli eea Tas ap pp ppp VE TO E le s sss ore fy Tr TT TT A oe 7 fom lm fa f 1 Pai fromme 122 1 oringa INR te TTT SS 3 1 oring re Im xl PP ET TT J E f ff Coverforshaftseal SuperDupee Pin 6105x20 Duplex a PPT Screw mexig faste af I PPT o Screwimexzs Vase fa LI ii Li 1517 lp m Cx anze x x x x 2 LL ILL III AISI 316 pf f
5. 5 16 Verify direction of rotation The direction of rotation must always follow the arrow The arrow is placed on the pump or pump unit Check the direction of rotation before mounting the pump Unlock the safety circuit breaker Start the motor for 1 second and observe the direction of rotation either looking at the fan of the motor or the coupling through the inspection hole in the bell housings not available on all bell housings If the motor is turning the wrong direction switch two phases in the connection box of the motor or reprogram the direction in VFD When the motor is turning in the right direction the pump can be mounted 180R9265 IOM APP Pumps v02 09 2013 5 17 Commissioning Close all the bleeding and draining plugs Open the pressure valve at the brine site Svvitch the safety circuit breaker on for both motor s and VFD s o Start the feed pump Start the high pressure pump If a VFD or a soft starter is used a ramp time of minimum 10 seconds is required to avoid damage of the pump 9 Monitor the inlet and outlet pressure of the high pressure pump and look for leakages Check the function of the pressure indicators by slowly closing the valves The pump unit should stop when the minimum inlet pressure and maximum outlet pressure has been reached 9 Adjust the pressures to the specified inlet and outlet pressure for the system and let the pump unit run until the electric motor
6. 000000000 000000000 000000 000000 000000 mM 000000000 000 299999999 Locate the return filter in the return line Placing the return filter upstream of the System to be filled via filter Filling system with unfiltered immediately before the tank final load may damage the pump water causes damage Installation Impurities Prior to installation burrs and chips and Chips or other impurities in the system other impurities must be removed from May cause damage pipes and hoses eg with a felt plug Fittings in screwed components to be Using teflon tape or packing yarn in sealed with O rings or bonded seals joints may cause damage Grease Mi il 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 BS 000000000 299999009 Fill system with water before starting Starting without water will cause to ensure lubrication and cooling damage Starting procedure Cleaning procedure Level indicator 1 Fill cold water into the system via the return filter and bleed the pump Power Packs PP
7. naya dad tie 11 5 4 euge do ne EE 11 5 5 Loru dt CEET 11 5 6 Pre mounting checklist based on Danfoss preferred system design 11 57 Bette Ehe l l r ii olla o EE EE 12 5 8 Mount the different equipment acc ENEE EK KE AER EEN 12 5 9 o ee EE EE 12 5 10 NNN NN 12 5 11 ENN iy l 3033030709 12 5 12 EE EE EE 13 5 13 Verify setting of safety relief valveS 13 5 14 EU ie PUM EEN 13 5 15 Bleed and remove air from the pump 13 5 16 Verify direction FONN EE 13 5 17 As A II 13 5 18 Check the filter condition ua cr NENA 13 5 19 Instruct operator and maintenance personnel 13 6 Operation PIP UNIE serer TG 14 6 1 General safety information vare bd 14 6 2 What GSE and OOK te EE 14 180R9265 IOM APP Pumps v02 09 2013 User manual Installation Operation and Maintenance APP Pumps APP 16 22 7 Maintenance and service of the pump unit 14 7 1 General safety information echte aa 14 7 2 Service and inspection interval for the pump 14 7 3 SUP OOW MOL SE SE EE 14 74 Disassembling and assembling the pump unit 15 15 Assembling the EE Ee 15 7 6 Procedure for mounting the pump onto the electric m
8. installation wiring and troubleshooting In case the pump needs to be scrapped please follow your local environmental rules User manual Installation Operation and Maintenance APP Pumps APP 16 22 180R9265 IOM APP Pumps v02 09 2013 17 Danfoti User manual Installation Operation and Maintenance APP Pumps APP 16 22 Subject index A G S Address 7 8 15 General information 7 Safety 6 7 8 9 12 13 14 16 Air bubbles 9 Guideline we ews 16 Safety valve 7 Appendix 7 8 9 10 11 14 15 16 Scrapping at escocesa 16 Application range 8 H Serial number rn 4 Approval ee x 6 Handling ze s k c ses 7 9 12 15 Servicing a Gx l er Nee d 6 8 14 Arrival mobil 9 12 15 SIME COW iaa oe wae ekaia 14 15 Assembling 12 15 Space requirement 8 Inspection sp l sik Rk eRe SES 13 14 Spare P L eas s yu AB ode e 14 B Installation 6 7 8 11 12 14 15 16 Start UPD r s eni 7 8 Bleed 44 464 53590 oxu h 8 9 13 15 Instruction A a 3 6 7 8 9 10 12 14 15 o 45 45 68 eo 2 ees 9 10 12 15 nstrumentation 6 12 lee rre 6 C gos Cs SEENEN u 6 SVSTET sad TG 6 7 8 9 11 12 13 14 Checklist asociar ternera E 11 SYSTEMS EE 7 8 Check points eco ea ea 12 M nr Leda so
9. operation stop in order to minimize the risk of crevice corrosion 8 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 Frost protection is required at temperatures below 2 C Danfoss recommends to use DOW FROST from DOW Chemical Company or Chilsafe mono propylene glycol from Arco Chemical Company NaCl vs temperature The sound pressure levels L PA 1 m db A for APP 16 22 pumps are typically 82 dB A at 60 bar 1500rpm and 84 dB at 80 bar 1500rpm Generally noise will be reduced if speed is reduced and vice versa Use flexible hoses in order to minimize vibrations and noise Since the pump is typically mounted on a bell housing or frame the noise level must be determined for the complete unit system It is therefore very important that the motor pump unit is mounted correctly on a frame with antivibration isolation to minimize vibrations and noise 180R9265 IOM APP 16 22 Appendices v04 11 2013 100 000 160000 The noise level is influenced by The speed of the pump high rpm create more noise than low rpm o Rigid mounting of the pump generates more noise than flexible mounting 9 Pipe mounting direct to the pump increases the noise level compared to a flexible hose If using a VFD the motors can produce higher noise values depending on the operat
10. safety regulations and laws It is the responsibility of the safety officer or the chief operator to assure compliance with all local regulations that are not taken into account in this manual A Changing the pumps or pump units opera tional limits and hardware e Changes to the delivered pump or motor pump unit may only be done with a written approval from Danfoss High Pressure Pumps e Operation outside the Danfoss specifications requires a written approval from Danfoss High Pressure Pumps 180R9265 IOM APP Pumps v02 09 2013 e If any changes are made without written approval the warranty will automatically become void It is important that these instructions are always available to the personnel concerned 1 2 Symbols Indicates something to be noted by the reader Indicates a situation which will or could result in damage to the pump and its function Indicates a situation which will or could result in personal injury and or damage to the pump Electrical hazard Indicates a high voltage warning Safety glasses required Hearing protection required Safety shoes required Safety helmet required P rotective Protective garments garments 6 must be worn must be worn Do not touch A KE Electrical hazard User manual 2 Safety Installation Operation and Maintenance APP Pumps APP 16 22 1 3 Manufacturer and customer service add
11. 1 meter 40 inches around the pump When working with high pressures it is important to have the right space available around the pump as Stated in the safety requirements User manual 4 Arrival inspection transportation handling lifting and storage Installation Operation and Maintenance APP Pumps APP 16 22 A A 3 7 Filtration 10um absolute f3 x 5000 Requirements are specified in appendix 1 Data sheet and in appendix 2 Instruction Danfoss recommends not to build a filter bypass function or to use filters with an integrated bypass If the above recommendation is not followed the warranty for the pump will automatically become void lt should be possible to monitor the condition of the filter via the differential delta pressure across the filter Using insufficient filtration or a filter bypass can cause a failure or decreased service life of the pump 3 8 Properties of water It is recommended NOT to use the pumps in feed water concentrations higher than 50 000 ppm TDS without consulting your local Danfoss pump distributor 4 1 Arrival inspection The pump is packed in a cardboard or wood box with plugs in the port connections to protect the pumps from damage during transportation When the shipment has arrived it is important to check the pump for any damages The name plate type designation must be in accordance with the delivery note and your order In case of damage and or miss
12. 10 17 40 Nm 1 Mount the coupling flush or maximum 6 Adjust respectively verify the measure 1 mm offset from the pump shaft end ment and secure both couplings with the Ensure an air gap between coupling and right torques on the locking screws see pump flange of min 4 mm 0 16 inch coupling operation amp mounting instruc 2 Mount the bell housing on pump Secure tion nuts with the right torque 7 Mount the elastic gear ring and mount the 3 Measure the longest distance A from top bell housing pump on the motor After of bell housing to the button of coupling mounting it must be possible to move the claw elastic gear ring 3 5 mm 0 12 0 2 inch 4 Mount the coupling on motor shaft Ensure axial C The check can be done through the coupling and motor flange are not in the inspection hole of bell housing Secure contact with each other flange bolts with the right torque 5 Measure from motor flange to the top of the coupling That measurement B shall be 3 5 mm 0 12 0 2 inch shorter than the measurement A 180R9265 IOM APP 16 22 Appendices v04 11 2013 19 Instruction 20 APP pump instruction APP 11 13 and APP 16 22 If alternative mounting is desired please contact the Danfoss RO Solutions Sales Organisation Choose proper tolerances to ensure an easy mounting of the elastic coupling without use of tools Please take care to observe the recommended length tolerances
13. above 20 kilos User manual Installation Operation and Maintenance APP Pumps APP 16 22 Pumps which have a weight above 20 kilos see appendix 1 Data sheet must be handled by using lifting eyes and slings Never use only one sling and make sure the slings does not slip off the pump When the pump is mounted together with an electric motor the pump unit always weigh more than 20 kilos and must be handled by using slings around the pump unit See below examples of where to not to attach the lifting slings on the pump unit Correct lifting with 2 separate slings 180R9265 IOM APP Pumps v02 09 2013 VVrong lifting VVhen lifting the pump unit one sling must be attached to the electric motor and one sling around the pump Some motors and pumps have specific lifting eyes Do not use connections nozzles for lifting Do not use only one sling Make sure that the unit load is balanced before lifting The centre of the mass varies from pump pump unit size to pump pump unit How to mount the pump and the electric motor correctly see appendix 1 Data sheet or appendix 2 Instruction A Incorrect lifting can result in personal injury and or damage to the pump unit see appendix 2 Instruction 4 5 Return to supplier Please see maintenance chapter 7 4 6 Storage Each pump is tested before shipment and will therefore contain water For storage temperature and fro
14. based on an ambient temperature of 25 C The values must be halved for every 15K increase in bearing temperature Higher speed operations e g frequency converter drive will require shorter greasing intervals Typically doubling the speed will reduce the values by 50 6 Special note for Atex Zone 22 motors Notice for the use of electrical equipment in areas with combustible dust Designation of motor according to EC directive 125 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
15. in wear on internal pump parts Mount a low pressure switch in front of the pump and check its set point function The low pressure switch will ensure that the pump does not start until the min inlet pressure has been reached 4 4 Pump reversing 4 4 1 Dismantle pump and check if anything is If pump rotates in wrong direction it will take in broken or worn See 1 No flow item 1 2 water from the high pressure outlet line Pump reversing Pressure will be built up inside the pump and it will eventually be damaged WARNING The pump must not run without water for more than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure and will eventually be damaged 4 5 High rotation speed rpm 5 1 If electric motor rpm is too high dismantle Higher rpm than specified in the pump data pump and check for damage sheet results in wear of the pistons i e pistons If the rpm is within the specified range of 1 may be damaged the pump data sheet and abnormal noise remains dismantle pump and check for High rpm will also increase pressure pulsations damage from the pump and the noise level will increase If rom is changed noise frequency will also change 4 6 Outlet pressure 6 1 If outlet pressure is too low check set At too low outlet pressure the pump will create point of outlet pressure valve higher pressure pulsations and thus make If outlet pressure is lower than mentioned noi
16. not try to lift the pump unit manually most of the pumps vveigh more than 20 kilos see specific vveight for the pump in the appendix 1 Data sheet Always bleed the pump prior to initial start up o Do not mount the pump without the bell housing and a flexible coupling Do not try to start the unit before the system components are mounted bleeded and adjusted Flush the system throughly before connecting the pump or pump unit Check rotation direction of the motor before mounting the pump 2 5 Incase of doubt Please contact Danfoss A S in case of doubt Contact information is listed in section 1 3 Manufacturer and customer service address 3 2 Application range See appendix 1 Data sheet 3 3 Electric motor data See recommended motor in appendix 1 Data sheet or appendix 3 IOM for motors The motors mentioned are the most common used motors by Danfoss High Pressure Pumps 3 4 Noise and vibration Noise level for a pump unit with a standard motor measured according to EN ISO 3744 2010 see appendix 1 Data sheet Possibilities to reduce noise and vibration are described in the same Data sheet 3 5 Dimension drawings Dimensions of the different pumps can be found in appendix 1 Data sheet 3 6 Space requirement When doing service or replacing the complete pump unit it is recommended to have sufficient space available around the pump in order to ensure easy access Sufficient space means at least
17. of the chosen coupling as an axial force on the pump will damage the pump 3 2 Direction of rotation Is indicated by means of an arrow on the pump label Pump Type APP d 1 Serial no no MADE IN DENMARK 3 3 Orientation The pump can be mounted orientated in any horizontal direction with the inlet and the outlet pointing upwards downwards or to either side C Bleeding 180R9265 IOM APP 16 22 Appendices v04 11 2013 Danfoti Instruction APP pump instruction APP 11 13 and APP 16 22 3 4 Protection against too high Both the inlet and outlet lines must be flexible outlet pressure soft hoses The pump should be protected against too high outlet pressure by means of a safety valve or a The valve outlet must not be connected pressure relief valve The valve should be placed directly to the pump suction line It must be as close to the pump as possible The opening connected directly to the drain characteristics of the valve must not result in peak pressures higher than 80 bar 1 160 psi 3 5 Connections Inlet Outlet Bleeding Parallel key 180R9265 IOM APP 16 22 Appendices v04 11 2013 21 Instruction APP pump instruction APP 11 13 and APP 16 22 APP 11 APP 13 Description APP 11 APP 13 Parallel key mm 10 x 8 x 45 DIN 6885 2 inlet hose kit 2 Victaulic 18070298 2m 79 2 inlet Vic 2 Victaulic 18020166 Non return 1 5 Victaulic 180H0053
18. pressure This may typically occur in boosted or open ended systems with direct water supply 2 1 Open ended systems with direct water supply The pump is supplied with water direct from a feed pump In order to eliminate the risk of cavitation a positive inlet pressure of at least 2 bar 29 psi is always to be maintained but it must not exceed 5 bar 72 5 psi continuously 1 Place the filter 1 in the water supply line in front of the pump 180R9265 IOM APP 16 22 Appendices v04 11 2013 2 Place a monitoring pressure switch 3 between filter and pump inlet set at min 2 bar 29 psi inlet pressure The monitoring pressure switch must stop the pump at pressures lower than 2 bar 29 psi inlet pressure 3 Install a low pressure safety valve or a low pressure relief valve 4 in order to avoid system or pump damage in case the pump stops momentarily high pressure peaks or starts spinning backwards Note If a non return valve 2 is mounted in the inlet line a low pressure relief valve is also required between non return valve and pump as protection against high pressure peaks Outlet Instruction APP pump instruction APP 11 13 and APP 16 22 2 2 Preferred RO system design and P amp ID 1 Dimension the inlet line to obtain mini mum pressure loss large flow minimum pipe length minimum number of bends connections and fittings with small pressure losses 2 Place an inlet filter 1
19. pump 2 Please consult section 10 pump The volume of water in the mem Filtration for guidance on how to select brane vessel works as an accumulator and the right filter Thoroughly clean pipes and will send flow backwards in case of the flush system prior to start up pump stops momentarily 3 Place a monitoring pressure switch 3 set 8 A safety valve or a pressure relief valve 8 at min inlet pressure between filter and can be installed in order to avoid system pump inlet The monitoring switch must damage as the Danfoss APP pump creates stop the pump at pressures lower than pressure and flow immediately after minimum pressure start up regardless of any counterpressure 4 Use flexible hoses 4 to minimize vibrations and noise 5 n order to eliminate the risk of damage Note If a non return valve is mounted in the and cavitation a positive pressure at the inlet line a low pressure relief valve is also inlet 5 is always to be maintained at min required between non return valve and pump inlet pressure and max inlet pressure as protection against high pressure peaks Recommend to install safety valve or a pressure relief valve 9 in order to avoid Media filter 8 K PI kl Permeate CS gt Q 14 Service 14 1 Warranty If the parts are not replaced more frequent Danfoss APP pumps are designed for long inspection is recommended according to our operation low maintenance and reduced guidelines lifecycle
20. 0298 DIN 6885 in 0 47 x0 31X2 76 kit 2 m 79 Bleedi GWH AF 2 inlet Vic 2 Victaulic 180Z0165 Non return 2 Victaulic 180H0256 inletport MS2x1 5 depth 21mm yaive outlet OD 63 mm Pump mounting flange 125B 4 For more details on the accessories please contact the Danfoss RO Solutions Sales Organisation 12 Dimensions lied complete unit ection 347 4 13 68 308 12 14 209 1 8 23 209 1 8 23 Accessories 10 180R9265 IOM APP 16 22 Appendices v04 11 2013 APP 16 22 A mm B mm C mm mm E mm F mm G mm IEC Electric motor P HD H A B LB Data sheet Note Examples of different pump motor sizes and drawing dimensions are only for IEC motors and couplings Please always check required motor power and dimensions 13 Installation 13 1 Mounting The figure below illustrates how to mount the pump and connect it to the electric motor combustion engine To ensure easy mounting of the flexible coupling without using tools the tolerances must be dimensioned accordingly If alternative mounting is required please contact Danfoss RO Sales Organization for further information Note Any axial and radial loads on the pump shaft must be avoided Ensure 3 5 mm 0 12 0 2 inches air gap between coupling parts A Flexible coupling B Bell housing C Motor shaft 13 2 Open ended system with direct water supply In
21. 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 180R9265 IOM APP 16 22 Appendices v04 11 2013 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 through the filter in tunnels String wounded filters are typically channelling filters A string wounded filter may have a filtration efficiency of only 50 which will cause internal wear and must always be followed by a main filter Insufficient filtration means that too many or too large hard particles can pass the main filter because it is damaged bypassed or simply too poor Filtration efficiency must be 99 98 Beta 5000 at 10 um to prevent abnormal wear of the pump Temperature gt 50 C will cause wear on internal pump parts Mount a temperature switch and check its set point function The temperature switch will ensure that the pump stops at fluid temperatures gt 50 C If the pressure drop across the filters is too high the booster pump doe
22. 38 APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 10 il 12 13 14 15 16 17 18 19 20 21 22 2 24 General Parts list APP 0 6 1 0 Compact Exploded view APP 0 6 1 0 Compact Parts list APP 0 6 1 0 and APM 0 8 1 2 Exploded view APP 0 6 1 0 and APM 0 8 1 2 Parts list APP 1 5 2 5 and APM 1 8 2 9 Exploded view APP 1 5 2 5 and APM 1 8 2 9 Parts list APP 3 0 3 5 Exploded view APP 3 0 3 5 Parts list APP 5 1 10 2 Exploded view APP 5 1 10 2 Parts list APP W 5 1 10 2 Exploded view APP W 5 1 10 2 Parts list APP 11 13 Exploded view APP 11 13 Parts list APP 16 19 Exploded view APP 16 19 Parts list APP 22 Exploded view APP 22 Parts list APP 21 26 Exploded view APP 21 26 Parts list APP 30 43 Not included Exploded view APP 30 1200 and APP 43 1700 Tool sets 180R9265 IOM APP 16 22 Appendices v04 11 2013 Parts list Tool sets al APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 This parts list provides an overview of the content of the various service sets for the APP 0 6 1 0 Compact o APP 0 6 1 0 o APM 0 8 2 9 1 5 2 5 3 0 3 5 APP 5 1 10 2 APP VV 5 1 10 2 APP 11 13 APP 16 22 APP 21 43 as well as exploded views of the pumps 180R9265 IOM APP 16 22 Appendices v04 11 2013 39 Parts list APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 16 Parts list 16 19 a z dz 42
23. 4 21 38 APP S 21 38 are available on www ro solutions com Instruction 2 Reduced flow reduced pressure Danfoti Trouble shooting guide for APP APP S and APP S 674 pumps 2 1 Wear on pump Large internal leakage due to 2 2 Low inlet pressure 2 3 Rotation speed rpm 2 1 1 Dismantle the pump 2 1 2 Check valve plate Valve plate has marks scratches on the surface facing the port plate Minor wear on valve plate can cause large internal leakage See Index 6 1 Check port plate Port plate has marks scratches on the surface facing the valve plate Minor wear on port plate can cause large internal leakage See Index 6 2 Check cylinder barrel Liners in cylinder barrel may be scratched or worn Insert a piston in the liner and check the fit If there is any space clearance between liner and piston liner or piston is worn Pre treatment Analyse fluid for content of particles Check that filters are OK and working correctly Main filtration Check that the correct filter type is used particles in fluid must not exceed 10 um Danfoss High Pressure Pumps supplies filters please contact the sales office Fluid type The APP APP S and APP S 674 pumps are designed for seawater operation for any other fluid please contact Danfoss High Pressure Pumps sales office for further help High fluid temperature If fluid temperature is above 50 C stop the pump immediately Check internal parts see above 2
24. H 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 Level and temperature indicators Missing or incorrectly connected level 5 Empty the system of the cleaning agent solution must be fitted Follow installation and temperature indicators cause l instructions damage Flushing procedure 6 Fill cold water through the return filter and bleed the Rotation direction pump Power Packs PPH 4 6 3 10 and 12 5 are self bleeding 7 Run the system for 30 min and activate all components as often as possible 8 Empty the system of the water 9 Alternatively the system may be flushed by running the unit without the return hose while continuously filling up water The flushing should continue until there is no trace of cleaning agent in the return water Check pump drive motor rotation Incorrect rotation direction will direction matches that of the pump damage the pump 10 Change the return filter element fill cold water through ee the return filter and bleed the pump during start up 11 The system is now ready for operation Bleeding Starting procedure 0090000000 000000000 99999999 Bleeding the pump will ensure correct Insufficient bleeding may cause dam Observing the star
25. MAKING MODERN LIVING POSSIBLE Genf User manual Installation Operation and Maintenance Manual APP pumps APP 16 22 APP 16 22 ro solutions com User manual Table of Contents Installation Operation and Maintenance APP Pumps APP 16 22 Ee MEET 4 EU Declaration NNN NE 5 1 Idee EE 6 1 1 GL 6 1 2 SV EE SEE 5700007 6 1 3 Manufacturer and customer service address 7 2 SC ee eee eee 7 2 1 EEE ka 7 2 2 Preferred system design 7 2 3 Commissioning and servicing the HIE AAA ARE 8 2 4 Adhere to the following important points 8 2 5 leke 0000 EEE n ra 8 4 Cai A e EE 8 3 1 Approved applications and operational limits for the pumps 8 3 2 Applicaton TEE 8 3 3 Re gege e ae e EE EE 8 3 4 101 NN EE 8 39 DN 8 3 6 Space PENNEN 8 3 7 BI ET 9 3 8 Properties EE 9 3 9 QMOUDDU NN 9 3 10 Bn un EE 9 4 Arrival inspection transportation handling lifting and storage 9 4 1 Arrival inspections EE EE 9 4 2 KU te le EE 9 4 3 General safety information EE 9 4 4 Transport and handling d q els 9 4 5 Elei 10 4 6 MOTO roer EE 0003709 0000000090 5000007 10 5 Installation and commissioning TEE 11 5 1 H dimensions ET 11 5 2 TNS NNN 11 5 3
26. MOTORS Bearing size and type are specified on the rating plate Motor types HMA2 and HMC2 is as standard with lifetime greased bearing with motor size lt 225 Motor types MS and Y2E is as standard with lifetime greased bearing with motor size lt 160 Typical duty hours for lifetime lubricated bearings 56 160 DE 40 000h 180 2 35 000h 200 2 27 000h 225 2 23 000h 180 225 4 8 40 000h Motors with a re greasing system must be lubricated with high quality lithium complex grease NLGI grade 2 or 3 with a temperature range of between 40 C to 150 C Motors are normal fitted with a data plate with greasing information if it is missing use the following re greasing intervals Frame Grease 2 pole 4 pole 6 pole 8 pole size g 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 55 2000 6000 7000 7000 280 35 2000 6000 7000 7000 315 50 1500 5500 6500 6500 355 60 1000 4000 5000 6000 400 80 800 3000 4000 6000 Grease 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
27. O ring 182x4 O ring 9 19x2 62 End flange 2 5 UY JI Duplex AISI 316 Super Duplex PEEK Duplex Super Duplex Duplex PEEK Duplex Lifting eye LA 1 Swash plate Pin 10 5x20 6 Cylinder barrel OY N Spring AN Spring guide Super Duplex DLC Super Duplex Super Duplex PEEK AISI 316 Duplex Super Duplex PEEK Super Duplex PTFE Retainer ball 4 65 Retainer plate Piston Key 12x8x70 Pin 6 4x40 Port plate o 1 Valve plate LA Back up ring O ring 30 2x3 Port flange Duplex PEEK O ring 68x2 NBR O ring 182x4 Shaft seal Z CO JJ ziz CO JIJ 21 122 23 124 125 126 12 12 29 142 44 4 5 152 53 54 155 Z CO 2 Hastelloy NBR Super Duplex Cover for shaft seal Pin 10 5x20 Duplex Screw M6x16 AISI 316 0 Screw M8x75 AISI 316 Lifting eye AISI 316 N Stop for shaft seal Tail stock screw M12x60 Check nut M12 O ring 35x3 Valve cone Spring 1 9x 25x33 7 Plug guide O ring 47 22x3 53 Instruction AISI 316 AISI 316 FPM 75 Super Duplex UT Duplex Super Duplex NBR LH He HERR HE HHH HEH Hell 2 180R9265 IOM APP 16 22 Appendices v04 11 2013 SS APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 Parts list Exploded view APP 22 19 00 eu Ul dund 3y 01 1x9u pasejd ag UM PSJUNO
28. PP S 674 pumps 1 5 1 Ensure that the air gap between the two coupling parts is min 5 mm It should always be possible to move the plastic part on the coupling at least 3 mm 1 6 1 Contact Danfoss sales office for guidelines in how to troubleshoot internal pump parts 1 6 Pump damage the internal parts may be damaged 48 180R9265 IOM APP 16 22 Appendices v04 11 2013 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 minimum inlet pressure see User manual Rotation direction for the APP APP S or APP S 674 pump is shown by an arrow on the label on the pump If motor type relay or the electrical fuse is blown check that electric motor is sized correctly To ensure easy mounting of the flexible coupling without using tools the tolerances must be dimensioned accordingly WARNING Any axial and or radial loads on the shaft must be avoided Any axial or radial load will cause breakdown A Bell housing B Flexible coupling C Motor shaft Instructions on internal elements 180R9092 180R9085 for APP 0 6 1 0 180R9091 180R9147 180R9089 for APP 1 5 3 5 180R9093 180R9090 for APP 5 1 10 2 180R9228 180R9227 for APP 11 13 and APP 16 22 180R9121 180R9139 for APP 21 43 180R9281 for APP S 674 3 0 3 5 APP S 3 0 3 5 180R9280 for APP S 674 5 1 9 0 APP S 5 1 9 0 180R9278 for APP S 67
29. UW 90 JOU UW Gy PUE pyl 504 511777 mes usarerzz NE FUNDE Y 401 Lp TF 1434 8611 Y 141 27777 1191 8 Z WNL 2 WNZ gt Y 40 1301 2711 WNG Y 401 TTTF 449l ET TT Y 401 4 07 11141 Lv T WNL F WNZ WNL UNG Biq vL 03 1101 27711 JO Leer 44491 221 UN WNOE ES E WEI az LE vc LE U NZ 43 180R9265 IOM APP 16 22 Appendices v04 11 2013 Parts list APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 24 Toolsets Note The parts listed are not sold separately only in various kits Designation 180B4188 Tool set APP 0 6 1 0 Compact 180B4162 Tool set APP 5 1 10 2 180B4230 Tool set APP 11 13 180B4222 Tool set APP 16 22 180B4172 Tool set APP 21 43 180B4142 Tool set APP 0 6 1 0 180B4148 Tool set APP 1 5 3 5 Shaft bush EN Press bush Drift Torx T30 Shaft bush 18 Press bush 18 Allen key 4 mm Allen key 5 mm Allen key 6 mm Shaft bush 35 Shaft seal extractor O35 Press bush 35 Adjustable pin wrench Combination wrench 10 mm Combination wrench 13 mm Nut M8x6 5x13 Guide bolt M8x140 Shaft seal extractor 045 Press bush 045 Eye bolt M8 Press bush for valve plate Stop for retainer plate Screw M8x20 PITT x fT tt x tt x tt bu pa pb P txt ft xixixix lap I fete PI fete jAdjustablepinwre
30. and pump temperature is stable If the system is running within the system design limits the system is released for operation A 5 18 Check the filter condition Evaluate contamination found in filter replace filter elements if necessary A 5 19 Instruct operator and maintenance personnel Before using the pump pump unit the personnel must be instructed in using the pump pump unit its function components documentation and safety Danfoss offers commissioning and service at system manufacturer s location Rate quotes are offered upon request 13 User manual 6 7 Operation of pump unit Maintenance and service of the pump unit Installation Operation and Maintenance APP Pumps APP 16 22 A 6 1 General safety information Before inspecting the pump unit read the Safety chapter 2 in this user manual 6 2 What to listen and look for If one or more of the following examples are observed please act as indicated A Loose bolts check all bolts and if necessary contact the maintenance department in order to have all bolts tightened to the specified torque s B Leakage if a small leakage from the bell housing is observed Contact the mainte nance department C Leakage if there is a large leak the unit should be stopped immediately Contact the maintenance department D High frequency tones safety relief valves are either damaged or running very close to the
31. appendix 6 the Trouble shooting guide Both appendices give good advises regarding design installation wiring and troubleshooting See also service and warranty section in appendix 1 Data sheet and appendix 2 Instruction If the pump is not stopped for inspection as recommended it can lead to damage of the pump or break down See also service and warranty section in the appendix 1 Data sheet in appendix 2 Instruction or appendix 4 Instruction for recommended service intervals Danfoss offers service of the pump at the system manufacturer s location as well as we offer training in how to service the pump Quotes are offered upon request Danfoss recommends simultaneously to check the filter and membrane condition and to evaluate contamination filter and membrane elements must be replaced if necessary Danfoss offers service of the pump at the system manufacturer s location and training in how to service the pump Quotes are offered upon request 7 3 Shut down of the system A Open the pressure valves at the brine site to release the pressure B Stop the high pressure pump C Stop the feed pump Switch off the safety circuit breaker for both the high pressure pump feed pump and VFD and lock them Only personnel servicing the pump unit should be able to unlock activate the switch again E Open bleeding and drain plugs Wait until the pump and system are emptied for water User manual Install
32. ar of CE marking CEoz Signed by IP fars foyer Managing Director Date December 2010 Page 1 1 180R9265 IOM APP 16 22 Appendices v04 11 2013 31 Tlf 45 86 98 21 11 Main office Svend H yer A S Over Hadstenvej 42 DK 8370 Hadsten Tel 45 86 98 21 11 Fax 45 86 98 17 79 E mail svendhoyer svendhoyer dk http www svendhoyer dk Sverige Svend H yer AB Malm v gen 18 S 331 42 Varnamo Tel 46 37 04 77 13 Fax 46 37 01 00 46 E mail svendhoyer svendhoyer se http www svendhoyer se Norge Svend H yer AS Torvet 1 N 3256 Larvik Tel 47 33 18 00 11 Faks 47 33 18 00 13 e mail svendhoyer svendhoyer no http www svendhoyer no Deutschland Svend H yer A S Over Hadstenvej 42 DK 8370 Hadsten Tlf 0800 1890415 Fax 45 87 61 21 19 E mail svendhoyer svendhoyer dk http www svendhoyer de HOYER Svend Hoyer A S Over Hadstenvej 42 DK 8370 Hadsten T 45 86 98 21 11 F 45 86 98 17 79 svendhoyer svendhoyer com svendhoyer com MAKING MODERN LIVING POSSIBLE Instruction Recommended service intervals for APP pumps ro solutions com Instruction Table of Contents Recommended service intervals for APP pumps 180R9199 1 General information 2 Design features 34 Recommended service intervals for APP pumps 1 General information 2 Design features Appendix 1 This guideline provides information on the The recommendatio
33. at the direction of rotation of the electric motor corresponds to the direction of rotation of the pump see label on pump 5 Now the pump is ready for start up Internal Flushing valve Outlet 180R9265 IOM APP 16 22 Appendices v04 11 2013 23 Instruction 5 Operation 24 APP pump instruction APP 11 13 and APP 16 22 5 1 Temperature Fluid temperature Min 2 C to max 50 C Min 35 6 F to max 122 F Ambient temperature Min 2 C to max 50 C Min 35 6 F to max 122 F In case of lower operating temperatures please contact the Danfoss RO Solutions Sales Organisa tion 5 2 Pressure The inlet pressure for APP 11 13 and APP 16 22 must be min 2 bar 29 psi and max 5 bar 72 5 psi At lower pressures the pump will cavitate resulting in damage of the pump Max inlet pressure peak e g in case the pump stops momentarily up to 10 bar 145 psi are acceptable Max pressure on the pump s outlet line should be limited at 80 bar 1 160 psi continuously NB The pump unit should include a pressure gauge on the high pressure side 5 3 Dry running When running the pump must always be connected to the water supply in order to avoid damage if it should run dry 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 proced
34. ater comes out of the pump no water supply to the pump 1 1 1 Check that inlet valve is open 1 1 2 Check that booster pump is running 1 2 Pump reversing electric motor is running the wrong direction i e counter clockwise 1 2 1 Change the phase on the electric motor to make it run clockwise WARNING The pump must not run without water for more than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure in pump housing and will eventually break down 1 3 1 Check that main switch is switched on 1 3 2 Check the electricity at the facility 1 3 3 Ensure that motor relay is switched on 1 3 4 Ensure that fuse is not blown 1 3 5 Ensure that booster pump is started 1 3 6 Check that the monitor switches are working correctly 1 3 7 Disconnect pump from electric motor and check that the motor is capable of running with no load 1 3 No rotation of electric motor 1 4 No rotation of pump 1 4 1 Ensure that coupling between electric motor and pump is connected 1 4 2 Check if coupling is damaged 1 4 3 Check that electric motor is sized correctly 1 4 4 Check that the electrical installation is correctly sized 1 4 5 Contact Danfoss Sales office for guidelines in how to troubleshoot internal pump parts 1 5 Axial load on pump shaft may cause high internal leakage Only applying to APP 0 6 to APP 3 5 and APP 21 to APP 26 only Also applying to APP S and A
35. ation Operation and Maintenance APP Pumps APP 16 22 A F Slowly unscrew and remove the bolts and gaskets from the inlet outlet hoses or pipes be careful about jets of water Beware that the system can be pressurized G Attach the lifting equipment to the pump unit For instructions on lifting the complete pump unit see chapter 4 Arrival inspection transportation handling lifting and storage H For the small pumps unscrew the bolts holding the pump to the bell housing For the bigger pumps unscrew the bolts nuts from the pump and bell housing to the motor Afterwards unscrew the bolts nuts holding the pump and bell housing Carefully pull the pump out of the bell housing by using lifting equipment if necessary J Hold the pump in different positions above a drip tray this should allow most of the water trapped in the pump to drain Clean and dry the pump surface and plug the bleeding and draining plugs K Move the pump to a clean and safe location where the pump can be inspected serviced 7 4 Disassembling and 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 Clean all parts and surfaces with a fluid compatible with the materials found in the pump Wipe the parts clean and dry witha lint free clothing C Inspect all parts including shaft seal and if necessa
36. costs Pump shutdown Provided that the pump has been running The APP pumps are made of Duplex Super according to the Danfoss specifications Danfoss Duplex materials with excellent corrosion guarantees 8 000 hours service free operation properties It is however always recommended however max 18 months from date of produc to flush the pump with freshwater when the tion system is shut down If Danfoss recommendations concerning system design are not followed it will strongly 14 3 Repair influence the life of the APP pumps In case of irregular function of the APP please contact the Danfoss RO Solutions Sales Organisation 14 2 Maintenance After 8 000 hours of operation it is strongly recommended to inspect the pump and change any worn parts e g pistons and shaft seal This is done in order to prevent a potential breakdown of the pump 12 180R9265 IOM APP 16 22 Appendices v04 11 2013 Data sheet APP 16 22 180R9265 IOM APP 16 22 Appendices v04 11 2013 13 Data sheet APP 16 22 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 mater
37. cteur R amp D User manual 1 Introduction Danfotk Installation Operation and Maintenance APP Pumps APP 16 22 1 1 General The APP pumps and pump units are manufac tured by Danfoss A S and are sold and marketed by a net of authorized distributors world wide This manual contains the necessary instructions for the installation operation and service of the pumps used in a Sea Water Reverse Osmosis SWRO system or Brackish Water Reverse Osmosis BWRO system In case the pump delivered is ATEX certified the additional ATEX instruction must also be read The APP pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor A Use of the pump in other applications that are not suitable for the pump unit can cause damages to the pump unit with risk of personal injury A All personnel being responsible for operation and maintenance of the pump unit must read and fully understand these instructions especially the section Safety before e Transportation of the pump unit e Lifting the unit e Installing the pump unit e Connecting the pump unit to the water system e Connecting the electric motor and instru mentation e Commissioning the unit Servicing the pump unit mechanical and electrical parts e Decommissioning the pump unit The pump must always be installed and used in accordance with existing national local sanitary
38. de 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 54 180R9265 IOM APP 16 22 Appendices v04 11 2013 MAKING MODERN LIVING POSSIBLE Right and wrong Trouble shooting guide for water hydraulic systems SOREN uzun Meee on lll ST danfoss high pressurepumps com 180R9042 Pump location Getters 1000000000 299090999 Pump always to be placed below water Pump location above water surface surface level level will cause damage Choice of material Suction conditions Rubber Plastic Stainless steel Always use system components made Non corrosion proof materials System to be dimensioned to provide Poor suction conditions will cause of corrosion proof materials may cause damage a suction pressure of the pump inlet of malfunction and damage the pump max 0 1 bar vacuum Choice of filter Pressure Relief valve 000000000 000000000 000000000 Install a 10 micron absolute filter with Return filter with bypass valve and Pressure relief valve to be mounted Coupling the pressure relief valve outlet pressure switch poorer filterability than 10 u will vertically or with vertical outlet and directly to the pump inlet may damage damage the system connected to return hose or tank the pump Filter location Water supply 900000000
39. ding which can cause slipping tripping or falling 180R9265 IOM APP Pumps v02 09 2013 If water is leaking into the electric motor it can cause electric shock fire short circuit or even death When mounting the pump vertically always mount the motor above the pump to avoid water leaking into the electric motor AYI 8 4 Electrical failure If the vviring of the electric motor is incorrect or the ground connection is missing it can cause electric shock burn damages fire or even death If a VFD is used and wrongly programmed it can damage the pump and lead to high tempera tures or other dangers All electrical installation must be carried out by authorized personnel in accordance with EN60204 1 and or local regulations 8 5 Responsibility Danfoss takes no responsibility for any abnormal injuries risks or damages that could arise caused by abnormal conditions vibrations corrosion abrasives foreign objects or excessive tempera tures and shall not be liable for any consequen tial or incidental damages 8 6 Scrapping criteria Whether the pump can be repaired or need to be scrapped depends on in which conditions the internal parts are or how damaged the whole unit is Please use appendix 6 Trouble shooting guide as guideline or send the pump to Danfoss headquarter in Denmark for evaluation For other observations or troubles please see appendix 7 Right and Wrong which gives good advises regarding design
40. enance APP Pumps APP 16 22 5 6 Pre mounting checklist based on Danfoss preferred system design Table 1 Check points when assembling and commissioning system CP1 Ensure that the environmental conditions are safe See Arrival inspection transportation handling lifting and storage chapter 4 CP2 Minimum and maximum start up temperature for fluid and See Data sheet or Instruction pump appendices 1 and 2 Filtration condition 10 um absolute 8 5000 See Danfoss requirements in Data sheet and Instruction appendices 1 and 2 Power supply for electric motor and VFD See Data sheet for the used motor and VFD 5 Safety circuit breaker must be sized for the motor and See Data sheet for the used environment corrosion and humidity safety circuit CP6 Bolts and screws must conform to environmental conditions as well as fluid and torque requirements i 7 CP4 P C CP7 Instrumentation pressure switch should be designed to See Data sheet for the used conform to the environment corrosion and humidity equipment CP8 Check the factory settings of the safety relief valves or See Data sheets for the used pressure relief valves 8 amp 9 valves CP9 Check the settings of the pressure transmitter switch 3 set See Data sheet or Instruction at min inlet pressure appendices 1 and 2 CP10 Check that all pressure indicators Pl are selected to be able Scaling should at least be 1 Bar to measure the system pressu
41. greed 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 180R9265 IOM APP 16 22 Appendices v04 11 2013
42. he right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 26 180R9265 IOM APP 16 22 Appendices v04 11 2013 Electric Motors Motor Manual 28 HOYER MOTORS 1 General This manual concerns the following types of standard induction motors from Hoyer HMA2 HMC2 HMD HMT MS Y2E1 Y2E2 YDT These motors are manufactured in accordance with 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 Itis also important that transport locking is used when motors are transported mounted on equipment All motors should be stored
43. hours day so that the motor can breathe thus ensuring a dry motor 4 Electrical connection Work is only permitted to be carried out by qualified specialists and must to be carried out in accordance with local regulations Before work commences ensure that all power is switched off and cannot be switched on again This also applies to the auxiliary power circuits e g anti condense heaters Check that supply voltage and frequency are the same as rated data Motors can be used with a supply deviation of 5 voltage and 2 frequency according to 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 in Pos bn 7 ve WEE 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 180R9265 IOM APP 16 22 Appendices v04 11 2013 HOYER
44. ial are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 14 180R9265 IOM APP 16 22 Appendices v04 11 2013 MAKING MODERN LIVING POSSIBLE APP pump instruction APP 11 13 and APP 16 22 a s e LE A s x i www ro solutions com Instruction APP pump instruction APP 11 13 and APP 16 22 180R9223 Table of Contents 1 Identification APP pump instruction APP 11 13 and APP 16 22 1 Identification 2 System design 2 1 Open ended systems with direct water supply 2 2 Preferred RO system design and P amp ID 2 3 Reversible pumps 2 4 General comments on 3 Building up the pump unit 3 1 Mounting 3 2 Direction of rotation 3 3 Orientation 3 4 Protection against too high outlet pressure 3 5 Connections 4 Initial start up 5 Operation Temperature 52 Pressure 5 3 Dry running 5 4 Disconnection 5 5 Storage 5 5 1 Recommended procedure 6 Service 6 1 Warranty 6 2 Maintenance 6 3 Repair F I Pump Type APP Serial no Code no MADE IN DENMARK 180R9265 IOM APP 16 22 Appendices v04 11 2013 Instruction 2 System design Danfoti APP pump instruction APP 11 13 and APP 16 22 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
45. in front of the APP pump 2 Please consult the Danfoss filter data sheet for guidance 521B1009 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 n order to eliminate the risk of damage and cavitation a positive pressure at the inlet 5 is always to be maintained at min inlet pressure and max inlet pressure Recommend to install safety valve or a Media filter ey en be 2 3 Reversible pumps If exposed to high pressure in the outlet while the electric motor is not energized the pump will start spinning backwards This will not harm the pump as long as the pressure in the inlet does not exceed the max pressure peak of 10 bar 145 psi If a non return valve is mounted in the inlet line a low pressure relief valve is also required as protection against high pressure pulses and high pressure in general Alternatively a high pressure check valve can be mounted in the pump discharge line to prevent the pump from reversing The dotted setup ensures that the inlet pressure does not exceed 10 bar 145 psi when a non return valve is mounted in the inlet Attention In order to avoid the risk of cavita tion the inlet
46. indoors in dry vibration and dust free conditions Lifting eyebolts must be tightened before use Damaged eyebolts must not be used check before use Lifting eyes at motor must not be used to lift the motor when it is attached to other equipment Before commissioning measure the insulation impedance If values are lt 10M at 25 C the winding must be oven dried The insulation resistance reference is halved for each 20 C rise in motor temperature It is recommended that shafts are rotated periodically by hand to prevent grease migration 3 Installation The motor must be fixed on a stable clear and flat founda tion It must be sufficiently rigid to withstand possible short circuit forces It is important to ensure that the mounting conditions do not cause resonance with the rotational frequency and the doubled supply frequency Only mount or remove drive components pulley 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
47. ing parts a report should be documented and presented to the carrier at once A 4 2 Warning Before any lifting operation is performed environmental conditions must be taken into consideration Ex rated areas wind speed wet dry conditions lifting height etc 4 3 General safety information Personnel involved in lifting and transporting the equipment see Safety chapter 2 must be trained in handling and in safety procedures for lifting heavy loads Many of the pumps and pump units weigh more than 20 kilos which requires lifting slings and suitable lifting devices e g an overhead crane or industrial truck to be used as minimum 180R9265 IOM APP Pumps v02 09 2013 3 9 Airbubbles Large bubbles in a pressurised RO system can result in damage to piping equipment and the pump All air must be bleeded from both the low pressure and high pressure side before the RO system is pressurised Special consideration should be given in order to minimize air bubbles in the feed flow Air bubbles can cause cavitation A 3 10 Chemicals The pump should not be exposed to any chemicals as it can result in damage to piping equipment and internal parts in the pump 4 4 Transport and handling Small pumps which have a weight below 20 kilos weight can be found in appendix 1 Data sheet can be handled by hand if they are not mounted together with an electric motor The weight of a small pump with a motor will be
48. intended stress on the pump port Mount the pressure switch sensors according to connections and may damage the pump the manufacturer s instructions e Prevent excessive external pipe load e Do not connect piping by applying external force use of wrenches crane etc Piping 5 11 Connections must be aligned without residual stress Mount and tighten connections and check e Do not mount expansion joints so that their valve s as specified force applies internal pressure on the pump connections 180R9265 IOM APP Pumps v02 09 2013 User manual Danfoti Installation Operation and Maintenance APP Pumps APP 16 22 5 12 Ensure free flow Ensure free flow from the safety relief valves 8 and 9 figure 1 item 5 6 A blocked safety relief valve can cause excessive build up of pressure and thereby cause dangerous situations and damage to the whole system 5 13 Verify setting of safety relief valves Make sure the safety relief valves 8 and 9 are placed correctly Check the pressure settings on the name plates of the safety relief valves If they are within specifications you can continue 5 14 Flush the pump Fully open the pressure valve at the brine outlet Close all the bleeding and draining plugs on the high pressure pump Start the feed pump and ensure free flow to the high pressure pump 5 15 Bleed and remove air from the pump Open the bleeding plugs Keep the plugs open until the high pressure pump is bleeded
49. ion point 1 meter from the pump unit surfaces refer ence box acc to EN ISO 20361 section 6 2 Deviation oTOT 1 6 dB A Data sheet 10 Filtration 11 Dimensions APP 16 22 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 1510x5000 equivalent to a filtration efficiency of 99 98 Bag filters and string wound filter cartridges typically have only 50 filtration 436 95 17 2 180R9265 IOM APP 16 22 Appendices v04 11 2013 Danfoti efficiency This means that for each 100 000 parti cles reaching the filter 50 000 particles pass through it compared to only 20 particles ina filter with an efficiency of 99 98 For more information on the importance of proper filtration please consult our publication Filtration code number 521B1009 which also will provide you with an explanation of filtration definitions and a guidance on how to select the right filter 125 4 92 212 8 35 44 5 1 75 69 83 2 75 39 99 1 57 Data sheet APP 16 22 APP 16 APP 22 Parallel key mm 12x8x70 2 inlet hose 180Z
50. ir design pressure stop the unit immediately Contact the maintenance department E Increased noise or vibration requires the unit to be stopped immediately Contact the maintenance department F Very high temperatures may indicate that one or more parts are damaged inside the pump The pump must be stopped immediately and inspected before it is restarted Contact the maintenance department A 7 1 General safety information Before servicing the pump unit it is necessary to read and understand this user manual especially the Safety chapter 2 Remember to wear suitable safety equipment according to Safety chapter 2 7 2 Service and inspection interval for the pump Maintenance and service intervals are depending on the cleanliness level of the water hydraulic load and temperature of the pump unit The most important parameter is the filtration of the water See the section Service and warranty in the appendix 1 Data sheet in appendix 2 Instruc tion and appendix 4 Instruction for recom mended service intervals For spare parts and service tools please see appendix 3 Parts list 180R9265 IOM APP Pumps v02 09 2013 G Drop in flow and or pressure may indicate wear on one or more parts inside the pump The pump must be stopped immediately and inspected before it is restarted Contact the maintenance department Other observations or troubles please see appendix 7 Right and Wrong or
51. ize 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 1510x5000 equivalent to a filtration efficiency of 99 98 Bag filters and string wound filter cartridges typically have only 50 filtration efficiency This means that for each 100 000 particles reaching the filter 50 000 particles pass through it compared to only 20 particles ina filter with an efficiency of 99 98 Instruction 3 Building up the pump unit Danfoti APP pump instruction APP 11 13 and APP 16 22 For more information on the importance of Monitoring proper filtration please consult our data sheet It is recommended to continuously monitor the Filtration 521B1009 which also will provide following conditions you with an explanation of filtration definitions filter clogging and a guidance on how to select the right filter e pressure inlet and outlet side of the pump 3 1 Mounting max 0 25 mm max 0 01 inch Elastic coupling Bell housing Motor shaft Pump flange Bolts and nuts torque 75 Nm 5 Nm Bolts and nuts torque 40 Nm 4 Nm Torque see table below 1 Thread M4 1 M5 1M6 M8 M10 M12 M16 size Torque 1 5 2 48
52. k Pumpe Maschinentyp APP 0 6 1 0 APP 1 5 3 5 APP 5 1 10 2 APP 11 13 APP 16 22 APP 21 43 Seriennummer Technisches Dossier Kontaktperson Leiter Qualitatsabteilung Angewandte harmonisierte Normen DS EN ISO 12100 2011 Hersteller Unterschrift Titel DIDIER rr i LLL IL EEE ETO EEE EEE Ad dia EEE ETE EE EEE 2013 05 27 Datum Welm Friedrichsen Leiter F amp E EC Declaration of Conformity according to 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 43 Technical dossier Contact person Manager Quality Department Used harmonised standards DS EN ISO 12100 2011 2013 05 27 Date Welm Friedrichsen Director R amp D 180R9265 IOM APP Pumps v02 09 2013 We hereby declare that the machine is designedaccording to the directive 2006 42 EC Machine description High pressure pump D claration de conformit CE conform ment la Directive 2006 42 CE Par la pr sente nous d clarons que la machine est concue conform ment a la Directive 2006 42 CE Description de la machine Pompe haute pression Type de machine APP 0 6 1 0 APP 1 5 3 5 APP 5 1 10 2 APP 11 13 APP 16 22 APP 21 43 2 Personne de contact pour le dossier technique Manager d partement qualit Normes harmonis es appliqu es DS EN ISO 12100 2011 Signature du fabricant Titre 2013 05 27 Date Welm Friedrichsen Dire
53. leaned Are control lights on A blown fuse or short circuit e Check power supply s the filter clogged and fuses and contact electrician Fill water into the system s the filter control e 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 60 180R9265 IOM APP 16 22 Appendices v04 11 2013 User manual Appendices for IOM Manual for APP Pumps APP 16 22 180R9265 IOM APP 16 22 Appendices v04 11 2013 61 User manual Appendices for IOM Manual for APP Pumps APP 16 22 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 a
54. n is for guidance only recommended service intervals The recommen dation is based upon good engineering practice and on experience gained from operation even under extreme conditions Danfoss APP pumps are designed for long If the Danfoss recommendations concerning operation and low maintenance and life cycle system design see our data sheet are not costs followed the service life of the APP pumps might be affected Danfoss guarantees 8 000 hours service free operation however max 18 months from date of The recommended service intervals on the production After 8 000 operation hours it is different parts in the APP pumps appear from the recommended to inspect the pump and replace table below worn parts if any Pos q Description Tu 2117 end flange Dry part AISI 316L I m Super Duplex and PEEK Recommended inspection on a yearly basis and evaluated acc to app 1 uz T supu Jm Nowearpar 124 215 1 Shaft seal Hastelloy and NBR It is good practice to change the seal after each disassembly of the pump 5 7 9 Back up ring PIFE 24 000 hours Valve cone flushing valve Duplex or PEEK 40 000 hours depends on pump size 180R9265 IOM APP 16 22 Appendices v04 11 2013 Instruction 3 Appendix 1 Danfoti Recommended service intervals for APP pumps Pistons In case of doubt the pistons must be replaced The pistons are the heart of the pump regarding service The pictures belo
55. nch x x x x BREESE T xixix xixix le le PITT PITT fee PIT ep PITT fr PITT xixix PITT det Screw M8x70 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 44 180R9265 IOM APP 16 22 Appendices v04 11 2013 MAKING MODERN LIVING POSSIBLE Guideline Trouble shooting guide for APP APP S and APP S 674 pumps ro solutions com Instruction Table of Contents Trouble shooting guide for APP APP S and APP S 674 pumps 46 Trouble shooting guide for APP APP S and APP S 674 pumps Trouble shooting fish bone chart 1 2 6 1 6 2 6 3 No flow no pressure Reduced flow reduced pressure High torque on electric motor Noise from pump Noise from installation Typical signs of wear Valve plate Port plate Swash plate 180R9265 IOM APP 16 22 Appendices v04 11 2013 Trouble shooting guide for APP APP S and APP S 674 pumps Instruction Trouble sho
56. ng Valve characteristic Pressure drop bar 150 200 250 Flow l min Calc f ebe foe APP 16 16 0 0 5 32 kVV 38 kVV 43 Hn 1180 1200 APP 16 263 15 8 69 5 31 kVV 36 kVV 41 kVV 1480 511 1500 APP 17 287 17 2 75 8 35 kVV 40 kVV 46 kVV 1180 498 1200 APP 17 281 16 9 74 2 33 kW 38 kW 44 kW 1480 513 1500 APP 19 314 18 8 82 9 38 kW 44 kW 50 kW 1180 499 1200 APP 19 313 18 8 82 7 37 kW 43 kW 49 kW 1480 509 1500 APP 22 358 21 5 94 6 43 kW 50 kW 57 kW 1180 501 1200 1500 The power requirements can be determined using one of the following guiding equations l min x bar 16 7 x m h x bar 0 26 x gpm x psi Required power kW or 1 kW Calc factor Calc factor Calc factor 0 75 kW 1 34 hp 3 79 min 0 26 gpm 4 40 gpm 0 23 m h 180R9265 IOM APP 16 22 Appendices v04 11 2013 7 Data sheet 8 9 Temperature and corrosion Noise level APP 16 22 8 1 Operation Fluid temperature 2 C to 50 C 35 6 F to 122 F dependent on the NaCl concentration Ambient temperature 2 Cto 50 C 35 6 F to 122 F The chart on the next page illustrates the corrosive resistance of different types of stainless steel related to NaCl concentration and tempera ture All critical parts of the APP water pump are made of Super Duplex If the water pump is operated at high salinity always flush the water pump with fresh water at
57. nnections to the frame by a vibration dampener mounting plate Mount a vibration dampener below the motor pump Non flexible connections mounted directly on the frame will cause even small pressure pulsations from pump and create vibrations in the system plant Too small pipes or too many bends may create too fast flow turbulence through the pipes and thus increase the noise level Too stiff hoses cannot dampen the small pressure pulsations from the pump and subsequently vibrations occur in the system plant If the hoses are mounted directly on the frame the small pressure pulsations from the pump can be transferred to the frame and the rest of the system plant When no dampener is installed below the electric motor vibrations from the motor and pump may be transferred to the frame and the rest of the system plant 52 180R9265 IOM APP 16 22 Appendices v04 11 2013 Instruction Trouble shooting guide for APP APP S and APP S 674 pumps 6 Typical signs of wear 6 1 Valve plate Picture 1 A normally worn valve plate has no marks scratches but only a slightly polished surface No scratches or marks should be felt The surface must be flat and level Picture 2 A worn valve plate has scratches and or a polished surface Even small scratches will give a loss of flow Scratches Picture 3 A good way to identify a worn valve plate is to hold a straight knife edge over the valve plate When holding it up to the ligh
58. o EEE 9 Maintenance 6 7 10 13 14 T Cleanliness 11 14 Mechanical failure 16 Table of Contents 2 Commissioning 6 8 11 12 13 15 16 Mounting WEEN 8 11 13 15 Technical data Sou n es eee 8 Connections 7 9 10 11 12 15 Temperature 7 10 11 12 13 14 16 COMBINA EE 8 12 13 15 16 N Transportation 6 9 12 15 Nameplate 9 11 12 13 Trouble shooting 14 16 D O KEE 8 14 Danger seara sad tase da 6 7 13 16 V Datasheet 7 8 9 10 11 12 14 L VEE 7 11 12 13 14 16 Declaration of Conformity 5 7 EE DEENEN 16 Design 7 8 9 11 12 13 14 16 Lifting xal s bee a ee 6 9 10 12 15 W Distributor a Ab AC 444 as 6 7 8 9 Local regulations 6 7 8 11 12 16 Warning e m posa bb 6 9 DIMensioS s x a a sea 8 11 Disassembling eu str s a R b Kor 15 o Operation 6 7 8 9 13 14 15 16 E Operational conditions 7 16 EC Declaration of Conformity 5 7 Electric motor 6 7 8 9 10 11 12 13 15 16 P Electrical failure 16 PIDIO 4 9 5 2905 e aa 9 11 12 16 ElectricalMaza e e e 6 7 POSItIONINO ero 909 002 12 Elects JE EE EEE 12 Preferred system design 7 11 Pre mounting oc aS 4 3 ds b n 11 F PIOTECTION eh A Ae 8 6 7 8 10 Failure s a Ow S
59. order to eliminate the risk of cavitation a positive inlet pressure is always to be maintained 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 3 Install a low pressure safety valve ora pressure relief valve 3 in order to avoid system or pump damage in case the pump stops momentarilly or spinning backwards 180R9265 IOM APP 16 22 Appendices v04 11 2013 Note If a non return valve is mounted in the inlet line a low pressure relief valve is also required between non return valve and pump as protection against high pressure peaks Data sheet APP 16 22 13 3 RO system with APP pump high pressure peaks in case the pump stops 1 Dimension the inlet line to obtain mini momen tarilly or spinning backwards mum pressure loss large flow minimum 6 For easy system bleeding and flushing a pipe length minimum number of bends bypass non return vavle 6 is integrated in connections and fittings with small the APP pump pressure losses 7 A non return valve 7 in outlet can be 2 Place an inlet filter 1 in front of the APP installed in order to avoid backspin of the
60. oting fish bone chart G311V4 dWnd uonej eISul WO4 S ON S duind wodj ASION Tr J0 OW 214129 3 34 Jadwep uonelqis S S 4020Uu UO nb 10 YBIH ldu p ds UbIH Sy UO An lip s did s soH be SSJUJJIIS SOH Ce dung r r 9INSSIAH J9 UI xew uUIN EE 9u 19 3n0 39 U1 JO suoisu w p y bu Z S dune SUO IPUOD ev sadid sasou u0123UU02 3 nno lul Le ping ut aly b C Ndy C nss d J9 UI MOT eu piny YBIH 8 L T adh p n CU 2beyeay leul ul duind ul seam UC uoneEniu ul 9 LT lu une ld q Uz d4nssaud moly pa gt npay Z do1s 14815 1 0S Cp ainssaid anno 977 abewep dund Ge anbio 3uv3suo ee anss ud ysurebe s31e3s dund Z duund uo ainssaid anno uf ool Le 14eys dund uo 3240 elXy G L abewep dung 9 1 dund jo 10138301 ON vi inss id MOU ON L JOJOUI 21112 JO UONEJOJON Cl dung z L C Buluun Aig 47 180R9265 IOM APP 16 22 Appendices v04 11 2013 Instruction 1 No flow no pressure Danfotk Trouble shooting guide for APP APP S and APP S 674 pumps 1 1 Dry running If no w
61. otor 15 del Getting the pump unit back into operatoru rr 15 7 8 Storage OF ING Romo A 15 8 Troubleshooting and scrapping riterla RS 16 8 1 General safety information Ra aa aaa asar aa aaa sala 16 8 2 Operational conditions vvhich can cause pump failures 16 8 3 Mean 16 8 4 FEET 16 8 5 RESPONSO EE 16 8 6 cabina Ke ETE EEE NE ee 16 so adi e EE EEE EEE E 18 Appendices for Installation Operation and Maintenance Manual 1 Ze 180R9265 IOM APP Pumps v02 09 2013 Data sheet for APP 16 22 pumps B21B UB Divorce 3 APP pump instruction APP 16 22 18089259 e Sg eg erre GE an 15 MN rv 27 Recommended service intervals for APP pumps 180R9199 33 APP parts PAN r o 37 roe SNOOUING QUITE EE 45 1101000000 EE 55 User manual Installation Operation and Maintenance APP Pumps APP 16 22 Validity This manual is valid for APP pumps with the following code numbers serial numbers APP 16 1200 18083254 APP 16 1500 18083250 4 180R9265 IOM APP Pumps v02 09 2013 EC Declaration of Conformity Danfoss A S Danfoss High Pressure Pumps Nordborgvej 81 6430 Nordborg Denmark EG Konformit tserkl rung gem EG Richtlinie 2006 42 EG Hiermit erkl ren wir dass die Maschine gem 2006 42 EG entwickelt ist Beschreibunq der Maschine Hochdruc
62. plug I SS ees a ANS E SS A they are designed so that the lubrication of the moving parts in the pumps is provided by the fluid itself No oil lubrication is thus required The pumps are supplied with an integrated flushing valve that allows the salt water to flow from inlet to the outlet when the pump is not running paa AN s i aA 3 4 Danfoti Data sheet APP 16 22 All parts included in the pumps are designed to The pumps are fixed displacement pumps in provide long service life i e long service life with which the flow is proportional to the number of a constantly high efficiency and minimum revolutions of the input shaft and the pump service required displacement 2 Benefits One of the smallest and lightest pumps on No oil lubricant required the market Integrated flushing valve Can be povvered by a combustion engine o All parts of the pump are made of non provided that a special coupling is used corrosive materials e g Duplex EN1 4462 Long service life No preventive mainte UNS 531803 532205 and Super Duplex nance required in the warranty period EN1 4410 UNS 532750 stainless steel and Generates insignificant pulsations in the carbon reinforced PEEK pressure line High efficiency 3 Technical data 1200 1500 1200 1500 1200 1500 1200 1500 Geometric displacement cm rpm 185 252 198 272 220 311 252 Outlet min Pressure 2 A E pe pe e e Power requirement at max
63. pressure at the pump must be min 2 bar 29 psi The inlet line connection must be properly tightened as possible entrance of air will cause cavitation 180R9265 IOM APP 16 22 Appendices v04 11 2013 pressure relief valve 9 in order to avoid high pressure peaks in case the pump stops momentarily or starts spinning backwards 6 For easy system bleeding and flushing a bypass non return vavle 6 is integrated in the APP pump 7 A non return valve 7 in outlet can be installed in order to avoid backspin of the pump The volume of water in the mem brane vessel works as an accumulator and will send flow backwards in case of the pump stops momentarily 8 A safety valve or a pressure relief valve 8 can be installed in order to avoid system damage as the Danfoss APP pump creates pressure and flow immediately after start up regardless of any counter pressure Note If a non return valve is mounted in the inlet line a low pressure relief valve is also required between non return valve and pump as protection against high pressure peaks Permeate gt 2 4 General comments on Filtration A good filtration is vital to ensure a long and trouble free life of the pump As water has very low viscosity the APP pumps have been designed with very narrow clearance in order to control internal leakage rates and improve component performance Therefore it is important that the inlet water is filtered properly to minim
64. r homepage Data sheets and instructions on all accessories are available on www ro solutions danfoss com EC Declaration of Conformity can be found on page 5 Under certain operational conditions the surface of the pump can be above 60 C 140 F Under these conditions the pump must be labelled with a Danger Hot sign VVhen using an electric motor the motor must alvvays be supplied vvith adequate cooling ventilation VVhen using an electric motor together vvith a VFD the motor must be designed for operation vvith a VFD VFD operation may increase the temperature inside the electric motor if the motor is not designed for VFD operation This can damage the motor and cause unintended breakdovvn A Before start up the settings for all protective devices such as sensors switches and safety valves must be verified and free flow from safety valves must be ensured A All pipe and hose connections must be stress free mounted securely fastened to the pump and well supported Improper installation will or can result in personal injury and or damage to the pump Use of this manual does not relieve operation and maintenance personnel of the responsibil ity of applying good judgment when operating and maintaining the pump and its compo nents 2 2 Preferred system design Danfoss recommends to build systems with a high degree of safety Danfoss preferred system design and P amp ID are found in appendix 1 Da
65. re range or more precise P11 Check coupling distance air gab movement of the spider ider P12 Check correct connections on the pump in amp outlet 11177 CP13 Check piping for possible air gaps gt 5 7 Lifting and positioning 5 9 Electrics Lift the pump unit onto base Remember All electrical installation work must be carried vibration dampeners if needed Fasten the out by authorized personnel in accordance with motor to the base EN60204 1 and or local regulations see also Safety chapter 2 See also chapter 4 Arrival inspection transporta tion handling lifting and storage Turn off the safety circuit breaker and lock it Mount the power cable on the electric motor 5 8 Mount the different equipment connections pipes tubes check and safety relief Ifa VFD is used adjust the protective motor valves etc switch VFD to the current limits found on the name plate of the electric motor e hard piping and flexible hoses used must be of proper design and must be installed in accordance with the manufactur 5 10 Instrumentation er s recommendations see also Data sheet The pressure switch sensor should be mounted for Hose and hose fittings and Instruction for as close to the pump as possible It is recom Assembling Hose kit both available on mended to test the pressure sensor switch via an www ro solutions danfoss com instrumentation manifold e Misalignment of the hard pipes may give un
66. regularly checked and if dry it must be lubricated It is recommended that the seal is re lubricated regularly Always use the original seal ring when replaced Replacing bearings also means replacing the seals All machines must be inspected regularly for mechanical damage The user is responsible for changing parts in accordance with the lifetime of parts in particular bearings grease and lubrication of shaft sealing Maintenance repairs and replacement on zone 22 motors must only be carried out by qualified specialists 180R9265 IOM APP 16 22 Appendices v04 11 2013 29 30 HOYER MOTORS Connection diagram AnschluBdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexion Collegamento coeHHHEHMH Schemat polaczen wif ul Na d O OS O D Lo La Wi U1 Vi o ep O O U V W OO O 1 L L gt L iz L Oo 180R9265 IOM APP 16 22 Appendices v04 11 2013 Motor Manual EC Declaration of Conformity The Manufacturer SVEND HOYER A S Over Hadstenvej 42 DK 8370 Hadsten Denmark Hereby declares that The products HOYER MOTORS 3 phased induction motors Aluminium motors MS A22 MS 56 180 HMA A22 HMA 56 180 Cast iron motors Y2E A22 Y2E 80 400 HMC A22 HMC 80 400 Are in conformity vvith the follovving Standards EN 60 034 1 and EN 60 072 Directive Lovv Voltage Directive 2006 95 EC Ye
67. ress Danfoss A S Danfoss High Pressure Pumps RO Solutions Nordborgvej 81 D25 DK 6430 Nordborg Denmark Telephone 45 7488 4024 Fax 45 7445 3831 Email ro solutions danfoss com Homepage www ro solutions com A 2 1 General information Dangers that can arise from not following the instructions When the pump or pump unit is managed by untrained personnel there is a danger of e Death or fatal injuries e Costly damages and claims NE All electrical installation work must only be carried out by authorized personnel in accordance with EN60204 1 and or local regulations It is recommended to install a lockable circuit breaker to avoid inadvertent starting and or electrical hazard The lockable circuit breaker must be used during installation operation and maintenance It is recommended to place a local safety switch nearby the pump enabling service personnel to cut power for the electric motor Protect the motor and other electrical equip ment from overloads with suitable equipment In case the pump delivered is ATEX certified the additional ATEX instruction must also be read Protective garments must be worn Always wear suitable safety clothing when handling the pump When working near the pump system safety shoes safety glasses hearing protection and safety helmet must always be worn 180R9265 IOM APP Pumps v02 09 2013 Your local Danfoss pump distributor can be found on ou
68. ressure If the electric motor is too small for the APP APP S or APP S 674 pump it cannot provide sufficient torque Too heavy damage in the pump will increase friction causing a high torque see item 6 Typical signs of wear Danfoti Instruction Trouble shooting guide for APP APP S and APP S 674 pumps 4 Noise from pump 4 1 Air in fluid 4 1 1 Ensure that the entire inlet line is bled Small air bubbles will accumulate and create before starting up the system large bubbles causing internal cavitation and 4 1 2 Ensure that air cannot enter into the inlet thus making the pump very noisy line WARNING The pump can only run few minutes with air in the fluid without being damaged 4 2 Bleeding conditions of pump 4 2 1 Follow the instructions Initial start up The pump and the inlet line must be com supplied with the new pump pletely bled before start up otherwise the 4 2 2 Ensure that the pump is completely bled pump will cavitate and make high noise before start up WARNING The pump can only run few minutes with air in the fluid without being damaged 4 3 Min max nominal inlet pressure 4 3 1 Ensure that inlet pressure is within the Too high inlet pressure causes too high limits specified in the User manual pressure inside the pump damaging the pistons 4 3 2 Check the pump for internal damage and eventually the pump Inlet pressure below min limit causes cavitation and insufficient internal lubrication resulting
69. ry replace them see appendix 3 Parts list D Ifthe pump is going to be returned to Danfoss for repair or a warranty claim it is important to contact Danfoss in order to receive a return number and a form to fill out with product information A copy of the form together with contact information and reason for returning should be sent to the email address on the form The same documents should be attached to the shipment 180R9265 IOM APP Pumps v02 09 2013 Productinformation see label on product Only 1 product on each report Product type Code number Operational conditions Application Inlet pressure Rpm pump motor only pum Hours of operation Number of duty cycles valves only Filtration q absolute nominal ow Water temperature Pumps in parallel yes no Returns without a return number will be rejected 11 7 5 Assembling the pump unit Assemble the pump according to the Dis assembling and Assembling Instruction available at www ro solutions danfoss com 7 6 Procedure for mounting the pump onto the electric motor A Mount the flexible coupling and bell housing according to appendix 2 Instruction 7 7 Getting the pump unit back into operation Find instructions of how to put the pump unit back into operation in chapter 4 Arrival inspec tion transportation handling lifting and storage and Installation and commissioning chapter 5 7 8 Storage ofthe pump If the pump has
70. s not deliver sufficient flow pressure No pressure or low pressure results in cavitation and insufficient internal lubrication causing wear on internal pump parts Mount a low pressure switch in front of the pump and check its set point function The low pressure switch ensures that the pump does not start until the inlet pressure has reached 1 bar Speeds below min limit see User manual result in insufficient internal lubrication causing wear on the internal pump parts 49 Instruction 3 High torque on electric motor Trouble shooting guide for APP APP 5 and APP S 674 pumps 3 1 Too high outlet pressure from pump 3 2 Pump starts against pressure 3 3 Constant torque 3 4 Water pump damage 3 1 1 Check fluid salinity 3 1 2 Check temperature 3 1 3 Check pressure drop across RO membrane 3 2 1 Check that electric motor is correctly sized 3 2 2 Check internal parts see item 2 1 3 2 3 Systems with more than one electric motor installed Start motors simultaneously 3 3 1 Please contact Danfoss High Pressure Pumps sales office 3 4 1 Dismantle pump and check for wear 50 180R9265 IOM APP 16 22 Appendices v04 11 2013 Pump conditions may change more salt lower water temperature or scaling of RO membrane causing higher pressure resulting in higher motor torque Pumps run in parallel with cascade start may switch off the motor relay due to too high torque caused by high outlet p
71. se Too low pressure also causes insufficient in the pump data sheet please contact internal lubrication and wear on internal parts Danfoss High Pressure Pumps technical Pump may eventually be damaged support If outlet pressure has exceeded its Too high outlet pressure may damage the maximum check set point of outlet pump pressure valve Check internal parts for wear damage 4 7 Soft start stop 4 71 Check if noise is normal when the pump is Noise frequency changes during soft start up running at operation speed stop 4 7 2 If noise is abnormal at operation speed check internal parts see above 180R9265 IOM APP 16 22 Appendices v04 11 2013 51 Instruction Trouble shooting guide for APP APP 5 and APP S 674 pumps 5 Noise from installation 5 1 Inlet outlet connections hoses pipes 5 2 Length dimension of inlet outlet line 5 3 Hose stiffness 5 4 Hoses pipes mounted directly on frame 5 5 Vibration dampener under the electric motor 5 1 1 Use flexible hoses at inlet outlet connec tions Danfoss can provide flexible hoses Please contact Danfoss High Pressure Pumps sales office for further information Mount the connections to the frame by a vibration dampener mounting plate Increase pipe diameter and or reduce the number of bends Use a more flexible hose Danfoss can provide flexible hoses Please contact Danfoss High Pressure Pumps sales office for further information Mount the co
72. si 8 16 Filter condition ser al ak R sra 13 R Filtration s cos bazar b 9 12 14 16 Relief valve 12 13 14 FOM ee 7 9 13 14 Responsibility 6 7 8 16 PINGS 6 e 11 12 15 16 KE EE 10 15 F L de sanan 8 11 13 ROTACION 6 EN 8 13 Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 18 180R9265 IOM APP Pumps v02 09 2013 MAKING MODERN LIVING POSSIBLE User manual Appendices for nstallation Operation and Maintenance Manual APP pumps APP 16 22 APP 16 22 ro solutions com User manual Table of Contents Appendices for IOM Manual for APP Pumps APP 16 22 Oe E eg Data sheet for APP 16 22 pumps 521B1183 3 APP pump instruction APP 11 13 and APP 16 22 180R9223 15 IOM Electric motors 180R9230 ee 27 Recommended service intervals for APP pumps 180R9199
73. st protection see appendix 2 Instruction The pumps are NOT delivered frost protected from the factory User manual 5 Installation and commissioning Installation Operation and Maintenance APP Pumps APP 16 22 A 5 1 Important dimensions Physical dimensions and connections of the pump unit are described in appendix 1 Data sheet A 5 2 Cleanliness It is very important that the tubes and pipes are completely clean no dirt chips or burrs are allowed Flush all piping before connecting the high pressure pump to ensure the system is clean Internal surfaces of the piping must not be corroded If dirt or rust is not removed the pump and the valves can be damaged In worst case the pump can be damaged beyond repair A 5 3 Fluid temperature Before start up the fluid and pump housing temperature must be within the specified temperature range listed see appendix 1 Data sheet Schematic 1 Recommended system design Media filter vest Se 180R9265 IOM APP Pumps v02 09 2013 5 4 Electrical data Check voltage current frequency and rated power on the electric motor and VFD settings on the name plate placed on both the motor and the VFD A 5 5 Local regulations Commissioning must always be done in accordance with valid regulations and local standards Permeate p Brine User manual Danfoti Installation Operation and Maint
74. t 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 180R9265 IOM APP 16 22 Appendices v04 11 2013 53 Instruction Trouble shooting guide for APP APP S and APP S 674 pumps 6 2 Portplate Picture 1 h h i If the port plate has scratches level differences or both between the arrows i 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 High Pressure Pumps sales office for further infor mation Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be ma
75. t PP PG 11 81 00 tt fff x LT L T 1 x LJ LL ILL II EES O ring 4722x353 wer x IO LIT 1736 EE EEE BEE EC a UT D x lt x x x 40 180R9265 IOM APP 16 22 Appendices v04 11 2013 APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 Parts list Exploded view APP 16 19 17 04 941 Ul dwnd 3y 01 1x9U paoejd op WIM HAI Lb T 31141 8E D344 Ly TF 31341 8 Z p lunoul eq 100 UW GYL pue py SO WNZ WNOL WO 12 2 4401 T 2Z WNE WNOE hi Jal 4777 UNL F WNZ 4401 8921 D JA bL OF Tl Y 401 1Z Z HI ET d 4301 7 02 y 401 2711 WNL UNG WNE UNG 4401 7 02 4401 271 7 DU N VEZ 1 D rh SE 1 il San V 7 E 41 180R9265 IOM APP 16 22 Appendices v04 11 2013 Parts list APP 0 6 43 APM 0 8 2 9 APP W 5 1 10 2 18 Parts list Note APP 22 The parts listed are not sold separately only in various kits Exploded view see next page Designation 180B4205 Cylinder barrel set 180B4202 Swash plate set 180B4203 Flushing valve set APP 22 1200 rpm 180B4218 Svvash plate set 180B4204 Valve plate set APP 22 1500 rpm 180B4201 Retainer set 180B4200 Piston set o Vi o l N St ca o 00 q ala o Duplex in 6x10 AISI 316 Bleeding plug Super Duplex O ring 11 0x2 NBR 2 Screw M8x30 AISI 316
76. ta sheet and appendix 2 Instruction User manual 3 Technical data Danfotk Installation Operation and Maintenance APP Pumps APP 16 22 A It is always the system builders responsibility that the system design does not cause any kind of hazard and is adapted to local regulations and standards Proper installation proper start up and shut down devices as well as high pressure protection equipment is essential 2 3 Commissioning and servicing the unit It is recommended that commissioning and servicing are carried out by a minimum of two people where one is acting as a supervisor 2 4 Adhere to the following important points Before using the pump pump unit it is very important to read and understand this user manual 3 1 Approved applications and operational limits for the pumps The pump and the pump units are designed for the use in a Sea Water Reverse Osmosis SWRO or Brackish Water Reverse Osmosis BWRO systems and Brackish Water Reverse Osmosis BWRO system The APP pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor A Use of the pump in other applications not suitable for the pump unit can cause damages to the pump unit with risk of personal injury For system integration of the pump please see appendix 1 Data sheet and appendix 2 Instruction 180R9265 IOM APP Pumps v02 09 2013 Do
77. ting procedure will If the system is not cleaned before cooling and lubrication age not applicable to Power Packs ensure problem free operation starting the filter will clog Trouble shooting Open ended water systems No water supply e Is the water supply ok e s water supplied to the pump Lower inlet Yes temperature or provide better cooling e Is the water in the tank very hot le above 50 e Is the electric motor of the pump unit rotating s water coming out of the tap Are all taps open e Is the control light for low pump suction pressure on e Is the power supply ok 1 Are control lights on The filter is clogging s the filter clogged e Is the filter control light on e s water coming through the filter e A blown fuse or short Circuit Check power supply and fuses and contact electrician Replace filter element Replace filter element Contact serviceman Turn on the tap for water supply Trouble shooting Closed water systems The system does not work e Is there sufficient water in the tank e Is the electric motor of the pump unit rotating e Is the water in the tank BE very hot le above 50 At temperatures higher than 50 the e Is the power supply ok pump drive cuts out Consequently the cooler must be checked c
78. to be shut down for a longer period instructions can be found in appendix 2 Instruction 15 User manual 8 Troubleshooting and scrapping criteria Danfoti Installation Operation and Maintenance APP Pumps APP 16 22 A 8 1 General safety information Before inspecting the pump unit it is necessary to read and understand this user manual especially the Safety chapter 2 Remember to wear suitable safety equipment according to Safety chapter 2 8 2 Operational conditions which can cause pump failures The following conditions can cause a pump failure The pump is running dry The inlet pressure is too high The inlet pressure is too low The temperature of the fluid is too high The ambient temperature is too high The pump is running against a blocked port closed manual valve o The pump is operating at a pressure out of specification The pump is running with a non specified approved fluid The pump is running in the vvrong direction The filtration is insufficient The pump is not being serviced according to Danfoss specifications end of life o There is excessive mechanical load on the shaft coupling and piping 8 3 Mechanical failure If the pump is running dry the temperature will quickly increase which can cause burns If there is any leakage at start up or during operation a high pressure jet can cause eye or skin damage Leakage can result in floo
79. uction 6 Service Danfotk APP pump instruction APP 11 13 and APP 16 22 6 1 Warranty Danfoss APP pumps are designed for long operation low maintenance and reduced lifecycle costs Provided that the pump has been running according to the Danfoss specifications Danfoss guarantees 8 000 hours service free operation however max 18 months from date of produc tion If Danfoss recommendations concerning system design are not followed it will strongly influence the life of the APP pumps 6 2 Maintenance After 8 000 hours of operation it is strongly recommended to inspect the pump and change any worn parts e g pistons and shaft seal This is done in order to prevent a potential breakdown 180R9265 IOM APP 16 22 Appendices v04 11 2013 of the pump If the parts are not replaced more frequent inspection is recommended according to our guidelines Stand still The APP pumps are made of Duplex Super Duplex materials with excellent corrosion properties It is however always recommended to flush the pump with freshwater when the system is shut down 6 3 Repair In case of irregular function of the APP please contact the Danfoss RO Solutions Sales Organisation 25 Instruction APP pump instruction APP 11 13 and APP 16 22 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 t
80. ure described under section 4 Initial start up 180R9265 IOM APP 16 22 Appendices v04 11 2013 ae y The chart below illustrates the corrosive resistance of different types of stainless steel related to NaCl concentration and temperature The APP water pump is made of Duplex and Super Duplex If the water pump is operated above the Super Duplex line always flush water pump with fresh water at operation stop in order to minimise the risk of crevice corrosion de 100 000 160000 5 5 Storage Storage temperature Min 40 C to max 70 C Min 40 F to max 158 F When preparing the pump for long term storage or for temperatures below the freezing point flush the pump with an anti freeze medium type monopropylene glycol to prevent internal corrosion or frost in the pump For further information on anti freeze media please contact the Danfoss RO Solutions Sales Organisation 5 5 1 Recommended procedure 1 Disconnect the water supply to the pump 2 Through the lower bleeding plug empty the pump housing of water and close it again 3 Connect the pump to a tank containing anti freeze additive Connect a hose to the inlet port of the pump and via another hose return the flow from the outlet port to the tank with 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 Instr
81. w is ment as a guideline for evaluating the wear of the sliding surface If the pistons break down the pump will suffer a breakdown Cavitation of the piston shoes Cavitation of the piston shoes New inspection is required in 3 000 4 000 hours All pistons must be replaced within the next 500 1 000 hours Cavitation of the piston shoes Cavitation of the piston shoes All pistons must be replaced within the next All pistons must be replaced immediately 100 200 hours Abrasive wear of the piston shoes All pistons must be replaced immediately 180R9265 IOM APP 16 22 Appendices v04 11 2013 35 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 36 180R9265 IOM APP 16 22 Appendices v04 11 2013 MAKING MODERN LIVING POSSIBLE APP S pumps APP 16 22 APP 16 22 ro solutions com Parts list Table of Contents Parts list APP 21 43 521B0941

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