Danfoss APP series User Manual
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Danfoss APP series User Manual

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MAKING MODERN LIVING POSSIBLE
L enntech
L enntech
Tel. +31-152-610-900
Tel. +31-152-610-900
Fax. +31-152-616-289
Fax. +31-152-616-289
User manual
Installation, Operation and
APP pumps (APP 16-22)
APP 16-22

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  • Page 1 MAKING MODERN LIVING POSSIBLE L enntech L enntech Tel. +31-152-610-900 Tel. +31-152-610-900 Fax. +31-152-616-289 Fax. +31-152-616-289 User manual Installation, Operation and Maintenance Manual APP pumps (APP 16-22) APP 16-22...

  • Page 2: Table Of Contents

    Local regulations............... 11 Pre mounting checklist, based on Danfoss preferred system design .....12 Lifting and positioning .

  • Page 3: Table Of Contents

    User manual Installation, Operation and Maintenance APP Pumps (APP 16-22) Maintenance and service of the pump unit ..........15 General safety information .
  • Page 4 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 Code no. 180B3254 Serial no. APP 16/1500 Code no. 180B3250 Serial no. APP 17/1200 Code no.
  • Page 5 EU Declaration of Conform- 180R9265 / IOM APP Pumps - v01 / 01.2013...

  • Page 6: Introduction

    Ensure that these instructions are always The APP pumps and pump units are manufac- readily available to all personnel concerned. tured by Danfoss A/S, and are sold and marketed by a net of authorized distributors world wide. 1.2 Symbols This manual contains the necessary instructions...

  • Page 7: Safety

    VFD operation. 2.5 In case of doubt Please contact Danfoss A/S in case of doubt. Contact information are listed in section 1.3, Manufacturer and customer service address. Before start-up, the settings for all protective...

  • Page 8: Technical Data

    3.1 Approved applications and operational limits for the pumps The pump and the pump units are designed for Danfoss recommends not to build a filter bypass the use in a Sea Water Reverse Osmosis (SWRO) function or use filters with an integrated bypass.

  • Page 9: Arrival Inspection, Transportation, Handling, Lifting And Storage

    User manual Installation, Operation and Maintenance APP Pumps (APP 16-22) Arrival inspection, 4.1 Arrival inspection Pumps which have a weight above 20 kilos (see transportation, The pump is packed in a cardboard or wood box Data sheet, appendix 1) must be handled by handling, lifting and with plugs in the port connections to protect the using lifting eyes and slings.

  • Page 10: Return To Supplier

    User manual Installation, Operation and Maintenance APP Pumps (APP 16-22) See below examples of where to/not to attach the lifting slings on the pump unit: Incorrect lifting can result in personally injury Correct lifting with 2 separate slings: and/or damage to the pump unit. 4.5 Return to supplier Please see maintenance chapter 7.

  • Page 11: Installation And Commissioning

    5.5 Local regulations Commissioning must always be done in accordance with valid regulations and local standards. 5.6 Pre mounting checklist, based on Danfoss preferred system design Schematic 1: Recommended system design 180R9265 / IOM APP Pumps - v01 / 01.2013...

  • Page 12: Lifting And Positioning

    See Data sheet or Instruction, pump. appendices 1 and 2. Filtration condition (10µm absolute (ß10 = 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, appendix 1.

  • Page 13: Ensure Free Flow

    Start the feed pump and ensure that the flow from the feed pump to the high pressure pump Danfoss offers commissioning and service at is unhindered. system manufacturer’s location. Rate quotes are offered upon request.

  • Page 14: Operation Of Motor Pump Unit

    Data sheet, appendix 1; APP pump instruction or Instruction for recommended service intervals in appendix 2 and 4. Danfoss offers service of the pump at the system manufacturer’s location as well as training in servicing the pump. Quotes are offered upon request.

  • Page 15: Maintenance And Service Of The Pump Unit

    For spare parts and service tools, please see Parts pump unit list, appendix 5. Remove all connections from the pump. Danfoss offers service of the pump at the system Disassemble the pump according to the manufacturer’s location and training in servicing Disassembling and Assembling Instruction the pump.

  • Page 16: Assembling The Pump Unit

    Installation, Operation and Maintenance APP Pumps (APP 16-22) Assembling the pump unit Assemble the pump according to the Dis- assembling and Assembling Instruction (available at www.ro-solutions.danfoss.com). Procedure for mounting pump back onto electric motor Do always follow the procedure delivered with...

  • Page 17: Troubleshooting And Scrapping Criteria

    Please use appendix 6, Trouble shooting guide as the operational specification. guideline or send the pump to Danfoss head- quarter in Denmark for evaluation. approved fluid. For other observations or troubles, please see direction.

  • Page 18: Subject Index

    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.
  • Page 19 MAKING MODERN LIVING POSSIBLE Front page for Appendices User manual Appendices for Installation, Operation and Maintenance Manual APP pumps (APP 16-22) APP 16-22...
  • Page 20 User manual Appendices for IOM Manual for APP Pumps (APP 16-22) Table of Contents Data sheet for APP 16-22 pumps (521B1183) ..........3 APP pump instruction APP 11-13 and APP 16-22 (180R9223) .
  • Page 21 MAKING MODERN LIVING POSSIBLE Data sheet for APP 16-22 pumps (521B1183) Data sheet Data sheet APP 16-22 ro-solutions.com...
  • Page 22 Data sheet APP 16-22 Data sheet for General information APP 16-22 pumps (521B1183) Benefits Table of Contents Technical data Variants Flow at different rpm Flushing valve Power requirements Temperature and corrosion Operation Storage Noise level Filtration Dimensions Dimensions, complete unit Installation 13.1 Mounting...
  • Page 23 251.5 201.4 Weight Integrated flushing valve Typical average flow at 60 bar (870 psi) For lower pressure, please contact Danfoss RO Sales Organization For higher pressure, please contact Danfoss RO Sales Organization The pump is designed according to EN809. 180R9265 / IOM APP 16-22 Appendices - v02 / 01.2013...
  • Page 24 Available with material certificates on wetted parts For more details on the variants, please contact the Danfoss RO Solutions Sales Organisation Flow at different rpm When using the diagrams shown below, it is easy to select the pump which fits the application best if the flow required and the rotation speed (rpm) of the pump are known.
  • Page 25 Data sheet APP 16-22 Flushing valve Flushing Valve characteristic Flow [l/min] Power requirements Pump Flow Pressure Calc. model factor 60 bar 70 bar 80 bar l/min 870 psi 1015 psi 1160 psi APP 16 16.0 70.5 32 kW 38 kW 43 kW 1180 1200...
  • Page 26 Ambient temperature: +2° Cto +50° C (+35.6° F to 122° F) Frost protection is required at temperatures below 2°C. Danfoss recommends to use DOW- The chart on the next page illustrates the FROST from DOW Chemical Company or Chilsafe corrosive resistance of different types of stainless...
  • Page 27 Data sheet APP 16-22 10. Filtration As water has very low viscosity, the APP pumps efficiency. This means that for each 100,000 parti- have been designed with very narrow clearance cles reaching the filter, 50,000 particles pass in order to control internal leakage rates and through it compared to only 20 particles in a improve component performance.
  • Page 28 Outlet port M52 x 1.5; depth 21 mm Pump mounting flange 125 B 4 For more details on the accessories, please contact the Danfoss RO Solutions Sales Organisation. 12. Dimensions, complete unit Accessories 180R9265 / IOM APP 16-22 Appendices - v02 / 01.2013...
  • Page 29 If alternative mounting is required, please Note: Any axial and radial loads on the pump contact Danfoss RO Sales Organization for shaft must be avoided. further information. Ensure 3-5 mm (0.12-0.2 inches) air gap between coupling parts.
  • Page 30 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.
  • Page 31 Data sheet APP 16-22 180R9265 / IOM APP 16-22 Appendices - v02 / 01.2013...
  • Page 32 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.
  • Page 33 MAKING MODERN LIVING POSSIBLE APP pump instruction APP 11-13 and APP 16-22 (180R9223) Instruction APP pump instruction APP 11-13 and APP 16-22 www.ro-solutions.com...
  • Page 34 Instruction APP pump instruction APP 11-13 and APP 16-22 APP pump instruction Identification APP 11-13 and APP 16-22 (180R9223) System design Open-ended systems with direct water supply Table of Contents Preferred RO system design and P&ID Reversible pumps General comments on Building up the pump unit Mounting Direction of rotation...
  • Page 35 Instruction APP pump instruction APP 11-13 and APP 16-22 System design The design of the system must ensure that Place a monitoring pressure switch (3) self-emptying of the pump during standstill is between filter and pump inlet - set at min. avoided.
  • Page 36 (6) is integrated in Place an inlet filter (1) in front of the APP the APP pump. pump (2). Please consult the Danfoss filter data sheet for guidance (521B1009) on how A non-return valve (7) in outlet can be to select the right filter.
  • Page 37 Instruction 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.
  • Page 38 Instruction 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 of the chosen coupling, as an axial force on the pump will damage the pump.
  • Page 39 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.
  • Page 40 Super Duplex Outlet port M42 x 1.5; depth 17 mm For more details on the accessories, please Pump mounting 125 B 4 contact the Danfoss RO Solutions Sales flange Organisation. APP 16 – APP 22 Description APP 16 – APP 22...
  • Page 41 Instruction APP pump instruction APP 11-13 and APP 16-22 Initial start-up 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 Connect pump inlet to inlet line and flush rotation of the pump (see label on pump).
  • Page 42 (Min. +35.6°F to max. +122°F) to minimise the risk of crevice corrosion. In case of lower operating temperatures, please contact the Danfoss RO Solutions Sales Organisa- tion. 80 º Duplex Super Duplex...
  • Page 43 APP pump instruction APP 11-13 and APP 16-22 Service 6.1 Warranty of the pump. If the parts are not replaced, more Danfoss APP pumps are designed for long frequent inspection is recommended according operation, low maintenance and reduced to our guidelines.
  • Page 44 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.
  • Page 45 IOM Electric motors (180R9230) Electric Motors Motor Manual hoyermotors.com Manual 180R9265 / IOM APP 16-22 Appendices - v02 / 01.2013 180R9230...

  • Page 46: Electrical Connection

    Motor Manual Correct alignment is essential to avoid bearing, vibration 1. General and shaft failure. This manual concerns the following types of standard Use appropriate methods for alignment. induction motors from Hoyer: Re-check the alignment after the final tightening of the HMA2, HMC2, HMD, HMT, MS, Y2E1, Y2E2, YDT bolts or studs.
  • Page 47 Motor Manual Bearing size and type are specified on the rating plate. The table values are based on an ambient temperature of Motor types HMA2 and HMC2 is as standard with lifetime 25°C. The values must be halved for every 15K increase in greased bearing with motor size ≤225.
  • Page 48 Motor Manual...
  • Page 49 MAKING MODERN LIVING POSSIBLE Recommended service intervals for APP pumps (180R9199) Instruction Recommended service intervals for APP pumps...
  • Page 50 Design/features 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.
  • Page 51 Instruction Recommended service intervals for APP pumps Appendix 1 Pistons: In case of doubt - the pistons must be replaced. The pistons are the heart of the pump regarding service. The pictures below is ment as a guideline for evaluating the wear of the sliding surface. If the pistons break down, the pump will suffer a breakdown.
  • Page 52 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.
  • Page 53 MAKING MODERN LIVING POSSIBLE APP parts list (521B0941) Parts list APP Pumps APP 16-22 APP 0.6-38 / APM 0.8-2.9 / APPW 5.1- 10.2 APP 16-22...
  • Page 54 Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2 15. APP 16 - 19 APP 16 - 19 Note: The parts listed are not sold separately, only in various kits Exploded view, see next page. Pos. Qnt. Designation Material Housing Duplex / PEEK Pin (Ø6 x 10)
  • Page 55 Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2 16. Exploded view Exploded view APP 16 - 19 APP 16 - 19 180R9265 / IOM APP 16-22 Appendices - v02 / 01.2013...
  • Page 56 Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2 APP 22 APP 22 Note: The parts listed are not sold separately, only in various kits Exploded view, see next page. Pos. Qnt. Designation Material Housing Duplex / PEEK Pin (Ø6 x 10) AISI 316 Pin (Ø6 x 10) AISI 316...
  • Page 57 Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2 18. Exploded view Exploded view APP 22 APP 22 180R9265 / IOM APP 16-22 Appendices - v02 / 01.2013...
  • Page 58 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.
  • Page 59 MAKING MODERN LIVING POSSIBLE Trouble shooting guide Guideline Trouble shooting guide for APP pumps...
  • Page 60 Instruction Trouble shooting guide for APP pumps Trouble shooting guide Trouble shooting fish bone chart for APP pumps No flow/no pressure Table of Contents 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...
  • Page 61 Instruction Trouble shooting guide for APP pumps Trouble shooting fish bone chart 180R9265 / IOM APP 16-22 Appendices - v02 / 01.2013...
  • Page 62 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 1.5.1 Ensure that the air gap between the two...
  • Page 63 Insufficient filtration means that too many or operation; for any other fluid, please too large hard particles can pass the main filter contact Danfoss sales office for further because it is damaged, bypassed or simply too help. poor. Filtration efficiency must be 99.98% (Beta = 5000) at 10 μmto prevent abnormal...
  • Page 64 Start motors simultaneously. 3.3 Constant torque 3.3.1 Please contact Danfoss sales office. If the electric motor is too small for the APP pump it cannot provide sufficient torque. 3.4 Water pump damage 3.4.1 Dismantle pump and check for wear.
  • Page 65 4.6.2 If outlet pressure is lower than mentioned noise. Too low pressure also causes insufficient in the pump data sheet, please contact internal lubrication and wear on internal parts. Danfoss A/S RO Solutions Technical Pump may eventually be damaged. Support. 4.6.3 If outlet pressure has exceeded its...
  • Page 66 5.3 Hose stiffness 5.3.1 Use amore flexible hose. Danfoss A/S can Too stiff hoses cannot damp the small pressure provide flexible hoses. Please contact pulsations from the pump, and subsequently Danfoss sales office for further informa- vibrations occur in the system/plant.
  • Page 67 Instruction Trouble shooting guide for APP pumps 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.
  • Page 68 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.
  • Page 69 MAKING MODERN LIVING POSSIBLE Right and wrong (180R9042) Right and wrong Trouble shooting guide for water hydraulic systems 180R9042...
  • Page 70 Pump location Design Pump always to be placed below water Pump location above water surface surface level level will cause damage Choice of material Suction conditions Iron Rubber Copper Plastic Brass Stainless steel Aluminium Always use system components made Non-corrosion proof materials System to be dimensioned to provide Poor suction conditions will cause of corrosion proof materials...
  • Page 71 Installation Assembly of coupling Impurities Chips or other impurities in the system Prior to installation, burrs and chips and Never use force when assembling the The coupling must be easy and simple may cause damage other impurities must be removed from coupling parts, as this will damage the to assemble (see product instruction) pipes and hoses, eg with a felt plug...

  • Page 72: Starting Procedure

    Wiring Starting procedure Cleaning procedure 1. Fill cold water into the system via the return filter and Level indicator bleed the pump (Power Packs PPH 4 - 6.3 - 10 and 12.5 are self-bleeding) 2. Start and bleed the system -without pressure by opening the bypass valve 3.

  • Page 73: Trouble Shooting

    Trouble shooting Open ended water systems No water supply Is the water supply ok? Is water supplied to the pump? Lower inlet Is water coming Is the electric motor of Is the water in the tank temperature or the pump unit rotating? very hot? Ie above 50 out of the tap? provide better cooling...
  • Page 74 Trouble shooting Closed water systems The system does not work Is there sufficient water in the tank? Is the electric motor of Is the water in the tank the pump unit rotating? very hot? Ie above 50 At temperatures higher than 50 pump drive cuts out.
  • Page 75 User manual Appendices for IOM Manual for APP Pumps (APP 16-22) 180R9265 / IOM APP 16-22 Appendices - v02 / 01.2013...
  • Page 76 Fax. +31-152-616-289 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.

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