Danfoss APP 16-22 Operation Manual
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Danfoss APP 16-22 Operation Manual

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Operation guide
APP pumps
APP 16-22
Installation, Operation and
Maintenance Manual
© Danfoss | 2023.03
180R9265 | AQ115586503035en-001003 | 1
hpp.dnfoss.com

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Summary of Contents for Danfoss APP 16-22

  • Page 1 Operation guide APP pumps APP 16-22 Installation, Operation and Maintenance Manual © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 1 hpp.dnfoss.com...
  • Page 2 Local regulations...............10 Pre mounting checklist, based on Danfoss preferred system design ..... 11 Lifting and positioning .

  • Page 3: Table Of Contents

    Recommended service intervals for APP pumps (AX290244627150en-000201)...51 Parts lists APP pumps APP 16-22 (AX274346749037en-000501) ......55 Trouble shooting guide for APP, APP S and APP S 674 pumps .
  • Page 4 Operation guide Installation, Operation and Maintenance APP 16-22 pumps This manual is valid for APP pumps both non In case the pump delivered is ATEX certi ed, the Validity ATEX and ATEX certi ed versions. An ATEX additional ATEX instruction must also be read.
  • Page 5 General The APP pumps and pump units are manufac- approval the warranty will automatically tured by Danfoss A/S, and are sold and marketed become void. by a net of authorized distributors world wide. It is important that these instructions are This manual contains the necessary instructions always available to the personnel concerned.
  • Page 6 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Your local Danfoss pump distributor can be 1.3 Manufacturer and customer service found on our homepage. address Data sheets and instructions on all accessories Danfoss A/S are available on hpp.danfoss.com High Pressure Pumps...
  • Page 7 Operation guide Installation, Operation and Maintenance APP 16-22 pumps • Do not try to lift the pump unit manually; most of the pumps weigh more than It is always the system builder´s responsibility 20 kilos, see speci c weight for the pump that the system design does not cause any kind in the appendix 1, Data sheet.
  • Page 8 Operation guide Installation, Operation and Maintenance APP 16-22 pumps 3.7 Filtration 3.9 Air bubbles (10µm absolute [ß ≥ 5000]) Large bubbles in a pressurised RO system can Requirements are speci ed in appendix 1, Data result in damage to piping, equipment and the sheet and in appendix 2, Instruction.
  • Page 9 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Pumps which have a weight above 20 kilos (see Wrong lifting: appendix 1, Data sheet) must be handled by using lifting eyes and slings. When lifting the pump unit, one sling must be attached to the electric motor and one sling around the pump.
  • Page 10 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Installation and commissioning 5.1 Important dimensions Physical dimensions and connections of the pump unit are described in appendix 1, Data sheet. 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 5.2 Cleanliness...
  • Page 11 Operation guide Installation, Operation and Maintenance APP 16-22 pumps 5.6 Pre mounting checklist, based on Danfoss preferred system design Table 1: Check points when assembling and commissioning system Check points Comment OK ? Ensure that the environmental conditions are safe.
  • Page 12 Operation guide Installation, Operation and Maintenance APP 16-22 pumps 5.12 Ensure free ow Ensure free ow from the safety/relief valves 8 5.17 Commissioning and 9 (schematic1, ). A blocked safety/ • Close all the bleeding and draining plugs. page 11 relief valve can cause excessive build-up of •...

  • Page 13: Operation Of Pump Unit

    Contact the maintenance Danfoss o ers service of the pump at the system department. manufacturer’s location as well as we o er training in how to service the pump. Quotes are Increased noise or vibration –...

  • Page 14: Disassembling And Assembling The Pump Unit

    3, Parts list. If the 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 ll out with product information.

  • Page 15: Troubleshooting And Scrapping Criteria

    Please use appendix 6, Trouble shooting guide as guideline or send the pump to Danfoss headquarter in Denmark for evaluation. 8.3 Mechanical failure If the pump is running dry, the temperature will quickly increase which can cause burns.
  • Page 16 Operation guide Installation, Operation and Maintenance APP 16-22 pumps 16 | 180R9265 | AQ115586503035en-001003 © Danfoss | 2023.03...

  • Page 17: Appendices

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps Operation guide APP pumps APP 16-22 Appendices for Installation, Operation and Maintenance Manual © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 17 hpp.danfoss.com...
  • Page 18 Recommended service intervals for APP pumps (AX290244627150en-000201)...51 Parts lists APP pumps APP 16-22 (AX274346749037en-000501) ......55 Trouble shooting guide for APP, APP S and APP S 674 pumps .

  • Page 19: Data Sheet App Pumps App 16-22 (Ai274333290009En-000701)

    Data sheet APP Pumps APP 0.6-1.0 / APP 1.5-3.5 / APP (W) 5.1-10.2 / APP 11-13 / APP 16-22 / APP 21-46 © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 1 hpp.danfoss.com.
  • Page 20 APP 16-22 ow curves at 60 barg (870 psig) ....... .

  • Page 21: Introduction

    No pulsation dampeners necessary due IATF 16949, ISO 9001, ISO 14001. to extremely low pressure pulsation. • Mobile systems for humanitarian and Danfoss APP pumps are built into a broad range Application examples military organizations of RO desalination plants around the world: •...

  • Page 22: Technical Data

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps Technical data 4.5 APP 16-22 Pump size APP 16/1200 APP 16/1500 APP 17/1200 APP 17/1500 APP 19/1200 APP 19/1500 APP 22/1200 APP 22/1500 180B3254 180B3250 180B3255 180B3251 180B3256 180B3252 180B3257 180B3253...

  • Page 23: Flow At Di Erent Rpm

    Thus, the required rpm can be determined as: Required ow x Rated rpm Required rpm = Rated ow 5.5 APP 16-22 ow curves at 60 barg (870 psig) 22.0 APP 22/1200 20.0 APP 19/1200 18.0...

  • Page 24: Flushing Valve Curves

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps All pumps except APP (W) 5.1 - 10.2 are supplied Flushing valve curves with an integrated ushing valve that allows the uid to ow from inlet to the outlet, when the pump is not running.

  • Page 25: Motor Requirements

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps The power requirements can be determined using one of the following guiding equations: Motor requirements l/min x barg 16.7 x m /h x barg 0.´35 x gpm x psig Required power =...

  • Page 26: Temperature And Corrosion

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps In case of lower operating temperatures, please Temperature and 8.1 Temperature contact Danfoss High Pressure Pumps.operation corrosion Fluid temperature: stop in order to minimize the risk of crevice Min. +2°C to max. +50°C corrosion.

  • Page 27: Filtration

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps Filtration • Variable frequency drives (VFD): Motors regulated by VFDs can produce Proper ltration is crucial for the performance. more noise if the VFD does not have the maintenance and warranty of your pump.
  • Page 28 Operation guide Installation, Operation and Maintenance APP 16-22 pumps High pressure safety or relief valve: As the Danfoss APP pump begins to create pressure and ow immediately after start-up and regardless of any counter pressure, a safey or pressure relief valve (8)

  • Page 29: Dimensions And Connections

    Installation, Operation and Maintenance APP 16-22 pumps 10. Dimensions and 10.5 APP 16-22 connections Accessories see section12. Fore more details on the accessories, please contact the Danfoss High Pressure Pumps sales organisation. © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 29...

  • Page 30: Dimensions With Motor Unit

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps Dimensions with motor 11.4 APP 16.0-22.0 unit The examples of assemblies with motor are only for IEC motors and couplings. Please make sure to check required motor power and dimensions when selecting size of pump and motor. For ad- vice and calculation tool, please contact Danfoss.

  • Page 31: Accessories

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps 12.3 Accessories for APP 16–22 12. Accessories Accessories Type Code No. 2” Victaulic 180Z0298 2” inlet hose kit - 2m (79”) 2” Victaulic 180Z0140 2” outlet hose - 1.25m (49”) M52 - 2” Victaulic 180Z0165 2”...
  • Page 32 Operation guide Installation, Operation and Maintenance APP 16-22 pumps The APP pumps are made of Duplex/Super 13. Service Warranty Duplex materials with excellent corrosion Danfoss APP pumps are designed for long properties. It is, however, always recommended operation, low maintenance and reduced to ush the pump with freshwater when the lifecycle costs.

  • Page 33: Instruction App Pumps App 16-22 (180R9223)

    Instruction APP pumps APP 11 / APP 13 / APP 16 / APP 17 / APP 19 / APP 22 hpp.danfoss.com © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 1...
  • Page 34 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Table of Contents Contents Identi cation ................36 System design .

  • Page 35: System Design

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps The design of the system must ensure that Place the lter (1) in the water supply line in System design self-emptying of the pump during standstill is front of the pump.

  • Page 36: Preferred Ro System Design And P&Id

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps pressure relief valve (9) in order to avoid 2.2 Preferred RO system design and P&ID Dimension the inlet line to obtain mini- high-pressure peaks in case the pump mum pressure loss (large ow, minimum...

  • Page 37: Mounting

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps For more information on the importance of Monitoring proper ltration, 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 ltration de nitions •...

  • Page 38: Direction Of Rotation

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps If alternative mounting is desired, please contact Danfoss High Pressure Pumps. 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: Protection Against Too High Outlet Pressure

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps Both the inlet and outlet lines must be exible 3.4 Protection against too high soft hoses. outlet pressure 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 Operation guide Installation, Operation and Maintenance APP 16-22 pumps APP 11 - APP 13 Description APP 11 - APP 13 Accessories Type Code no. 2” Victaulic 180Z0298 2” inlet hose kit 2 m / 79” 10 × 8 × 45 Parallel key, 2”...

  • Page 41: Initial Start-Up

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps Flush inlet line before connecting the Initial start-up 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 ush rotation of the pump (see label on pump).

  • Page 42: Operation

    1600 16000 160000 5.2 Pressure 5.5 Storage The inlet pressure for APP 11-13 and APP 16-22 Storage temperature: must be min. 2 barg (29 psig) and max. 5 barg Min. -40°C to max. +70°C (72.5 psig). (Min. -40°F to max. +158°F) At lower pressures the pump will cavitate, resulting in damage of the pump.

  • Page 43: Service

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps Storage: Storage of pump that have been in operation: For shorter periods of storage ush the pump with permeate rotating the pump for 10 sec., empty permeate and store. For long term storage (more than 2 months) Danfoss recommends sevicing the product and clean any biological growth of the surfaces.
  • Page 44 Operation guide Installation, Operation and Maintenance APP 16-22 pumps 44 | 180R9265 | AQ115586503035en-001003 180R9223 | 521B1184 | DKCFN.PI.013.T3.02 © Danfoss | DCS-SGDPT/SI | 2023.03...

  • Page 45: Iom Electric Motors (180R9230)

    Electric Motors Motor Manual hoyermotors.com M a n u a l...
  • Page 46 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Motor Manual General etc.) using suitable tools, never hit the drive components with a hammer as this will cause damage to the bearing. This manual concerns the following types of standard...
  • Page 47 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Motor Manual connections must be checked and tightened if necessary. The table values are based on an ambient temperature of Bearing size and type are specified on the rating plate. Motor 25°C.
  • Page 48 Connection diagram Operation guide Installation, Operation and Maintenance APP 16-22 pumps Anschlußdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexión Collegamento Schemat polacsen 48 | 180R9265 | AQ115586503035en-001003 © Danfoss | 2023.03...
  • Page 49 Operation guide Installation, Operation and Maintenance APP 16-22 pumps © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 49...
  • Page 50 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Hoyer Motors, Motor Manual, April 2019 Head Offices Branch Offices Denmark Germany Benelux Over Hadstenvej 42 · DK-8370 Hadsten Landsberger Straße 155 · 80687 München Vasteland 78 · 3011 BN, Rotterdam T +45 86 98 21 11 ·...

  • Page 51: Recommended Service Intervals For App Pumps (Ax290244627150En-000201)

    Instruction APP pumps APP 11 - 22 Recommended service intervals © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 1 hpp.danfoss.com...
  • Page 52 Operation guide Installation, Operation and Maintenance APP 16-22 pumps General information..............52 Table of Contents Design/features .
  • Page 53 Operation guide Installation, Operation and Maintenance APP 16-22 pumps If the pistons break down, the pump will su er a Appendix 1 Pistons: The pistons are the heart of the pump regarding breakdown.In case of doubt - the pistons must service.
  • Page 54 Operation guide Installation, Operation and Maintenance APP 16-22 pumps 54 | 180R9265 | AQ115586503035en-001003 AX290244627150en-000201 © Danfoss | DCS-SGDPT/SI | 2023.03...

  • Page 55: Parts Lists App Pumps App 16-22 (Ax274346749037En-000501)

    Parts list APP pumps APP 0.6-46 / APM 0.8-2.9 / APP W 5. 1 -10.2 © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 1 hpp.danfoss.com...
  • Page 56 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Table of Contents Table of Contents General ................57 Parts list APP 16-19 .
  • Page 57 Operation guide Installation, Operation and Maintenance APP 16-22 pumps This parts list provides an overview of the General content of the various service sets as well as Non ATEX ATEX explodede views for both non ATEX and ATEX APP 16-19 APP 16-19 Ex certi ed pumps.
  • Page 58 Operation guide Installation, Operation and Maintenance APP 16-22 pumps 14. Parts list 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 (Ø6x10)
  • Page 59 Operation guide Installation, Operation and Maintenance APP 16-22 pumps 15. Exploded view APP 16-19 © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 59...
  • Page 60 Operation guide Installation, Operation and Maintenance APP 16-22 pumps 16. Parts list 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 (Ø6x10)
  • Page 61 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Exploded view APP 22 © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 61...
  • Page 62 Operation guide Installation, Operation and Maintenance APP 16-22 pumps 22. Tool sets Note: The parts listed are not sold separately, only in various kits. Designation Shaft bush Press bush Drift Torx (T30) Shaft bush (Ø18) Press bush (Ø18) Allen key (4 mm)
  • Page 63 Operation guide Installation, Operation and Maintenance APP 16-22 pumps ro-solutions.com © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 63...
  • Page 64 Operation guide Installation, Operation and Maintenance APP 16-22 pumps AX274346749037en-000501 64 | 180R9265 | AQ115586503035en-001003 © Danfoss | DCS-SGDPT/SI | 2023.03...

  • Page 65: Trouble Shooting Guide For App, App S And App S 674 Pumps

    Guideline Trouble shooting guide APP, APP S and APP S 674 pumps © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 1 ro-solutions.com...
  • Page 66 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Table of Contents Table of contents Table of contents ................. .66 Trouble shooting sh bone chart .

  • Page 67: Trouble Shooting Sh Bone Chart

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps Trouble shooting sh bone chart © Danfoss | 2023.03 180R9265 | AQ115586503035en-001003 | 67...

  • Page 68: No Ow/No Pressure

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps No ow/no pressure Cause Remedy Comments If no water comes out of the pump: Mount a low pressure switch in front of the 1.1 Dry running (no water supply to the pump) pump and check its set point/ function.

  • Page 69: Reduced Ow/Reduced Pressure

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps Reduced ow/reduced pressure Cause Remedy Comments 2.1.1 Dismantle the pump. 2.1 Wear on pump Typical signs of wear: Large internal leakage due to: 2.1.2 Check valve plate. Polished surface all over the swash plate.

  • Page 70: High Torque On Electric Motor

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps High torque on electric motor Cause Remedy Comments 3.1.1 Check uid salinity. Pump conditions may change (more salt, lower 3.1 Too high outlet pressure from pump 3.1.2 Check temperature. water temperature or scaling of RO membrane) 3.1.3 Check pressure drop across RO membrane.

  • Page 71: Noise From Pump

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps Noise from pump Cause Remedy Comments 4.1.1 Ensure that the entire inlet line is bled Small air bubbles will accumulate and create 4.1 Air in uid before starting up the system.

  • Page 72: Noise From Installation

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps Noise from installation Cause Remedy Comments 5.1.1 Use exible hoses at inlet/outlet connec- Non- exible connections mounted directly on 5.1 Inlet/outlet connections (hoses/pipes) tions. Danfoss can provide exible hoses. the frame will cause even small pressure...

  • Page 73: Typical Signs Of Wear

    Operation guide Installation, Operation and Maintenance APP 16-22 pumps 6.1 Valve plate Typical signs of wear 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 at and level.

  • Page 74: Port Plate

    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 o ce for further infor- mation. 74 | 180R9265 | AQ115586503035en-001003...

  • Page 75: Right And Wrong (180R9042)

    Service guide Right and wrong Trouble shooting guide for water hydraulic systems hpp.danfoss.com...
  • Page 76 Pump location Pump location Operation guide Installation, Operation and Maintenance APP 16-22 pumps Design Pump always to be placed below water Pump always to be placed below water Pump location above water surface Pump location above water surface surface level...
  • Page 77 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Installation Assembly of coupling Impurities Prior to installation, burrs and chips and Never use force when assembling the Chips or other impurities in the system The coupling must be easy and simple...
  • Page 78 Operation guide Installation, Operation and Maintenance APP 16-22 pumps Wiring Starting procedure Level indicator Cleaning procedure 1. Fill cold water into the system via the return filter and bleed the pump (Power Packs PPH 4 - 6.3 - 10 and 12.5 are self-bleeding) 2.
  • Page 79 Operation guide Installation, Operation and Maintenance APP 16-22 pumps 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 water in the tank...
  • Page 80 Trouble shooting Operation guide Installation, Operation and Maintenance APP 16-22 pumps Closed water systems The system does not work Is there sufficient water in the tank? Is the electric motor Is the water in the tank of the pump unit...

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