Danfoss APP series, APP 16/1200, APP 19/1500, APP 19/1200, APP 21/1200 User Manual

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APP 16-22

User manual

Installation, Operation and Maintenance Manual

APP pumps (APP 16-22)

MAKING MODERN LIVING POSSIBLE

Lenntech

LQIR#OHQQWHFKFRP Tel. +31-152-610-900 ZZZOHQQWHFKFRP Fax. +31-152-616-289

Lenntech

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

Table of Contents Validity .........................................................................................4

EC Declaration of Conformity

.......................................................................5

1. Introduction ............................................................................6

1.1 General.................................................................................6

1.2 Symbols ................................................................................6

1.3 Manufacturer and customer service address:............................................. 6

2. Safety ..................................................................................7

2.1 General information.....................................................................7

2.2 Preferred system design.................................................................7

2.3 Commissioning and servicing the unit ...................................................7

2.4 Adhere to the following important points ............................................... 7

2.5 In case of doubt .........................................................................7

3. Technical data ..........................................................................8

3.1 Approved applications and operational limits for the pumps .............................8

3.2 Application range .......................................................................8

3.3 Electric motor data...................................................................... 8

3.4 Noise and vibration .....................................................................8

3.5 General arrangement ................................................................... 8

3.6 Space requirement ......................................................................8

3.7 Filtration ................................................................................8

3.8 Properties of water ......................................................................8

3.9 Air bubbles .............................................................................8

3.10 Chemicals...............................................................................8

4. Arrival inspection, transportation, handling, lifting and storage .......................... 9

4.1 Arrival inspection .......................................................................9

4.2 Warning ................................................................................9

4.3 General safety information ..............................................................9

4.4 Transport and handling .................................................................9

4.5 Return to supplier ......................................................................10

4.6 Storage ................................................................................10

5. Installation and commissioning......................................................... 11

5.1 Important dimensions .................................................................11

5.2 Cleanliness............................................................................. 11

5.3 Fluid temperature......................................................................11

5.4 Electrical data.......................................................................... 11

5.5 Local regulations.......................................................................11

5.6 Pre mounting checklist, based on Danfoss preferred system design ..................... 12

5.7 Lifting and positioning .................................................................12

5.8 Mount the dierent equipment ........................................................12

5.9 Electrics ...............................................................................12

5.10 Instrumentation .......................................................................12

5.11 Connections ........................................................................... 12

5.12 Ensure free ow .......................................................................13

5.13 Verify setting of safety/relief valves .....................................................13

5.14 Flush the pump ........................................................................13

5.15 Bleed and remove air from the pump...................................................13

5.16 Verify direction of rotation .............................................................13

5.17 Commissioning ........................................................................13

5.18 Check the lter condition...............................................................13

5.19 Instruct operator and maintenance personnel .......................................... 13

6. Operation of motor pump unit .........................................................14

6.1 General safety information .............................................................14

6.2 What to listen and look for .............................................................14

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

7. Maintenance and service of the pump unit .............................................15

7.1 General safety information .............................................................15

7.2 Service and inspection interval for the pump ...........................................15

7.3 Shut down of the system ...............................................................15

7.4 Disassembling and assembling the pump unit ..........................................15

7.5 Assembling the pump unit .............................................................16

7.6 Procedure for mounting pump back onto electric motor ................................16

7.7 Getting the pump unit back into operation .............................................16

7.8 Storage of the pump ...................................................................16

8. Troubleshooting and scrapping criteria .................................................17

8.1 General safety information .............................................................17

8.2 Operational conditions which can cause pump failures..................................17

8.3 Mechanical failure...................................................................... 17

8.4 Electrical failure........................................................................17

8.5 Responsibility ..........................................................................17

8.6 Scrapping criteria ......................................................................17

Subject index .....................................................................................18

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

This manual is valid for APP pumps with the following code numbers/serial numbers:Validity

APP 16/1200 Code no. 180 B325 4

Serial no. 01

APP 16/1500 Code no. 180 B3250

Serial no. 01

APP 17/1200 Code no. 180 B3255

Serial no. 01

APP 17/1500 Code no. 180 B3251

Serial no. 01

APP 19/1200 Code no. 18 0B32 56

Serial no. 01

APP 19/1500 Code no. 180 B3252

Serial no. 01

APP 21/1200 Code no. 180B3051

Serial no. 05

APP 21/1500 Code no. 180B3052

Serial no. 03

APP 22/1200 Code no. 180 B3257

Serial no. 01

APP 22/1500 Code no. 180 B3253

Serial no. 01

180R9265 / IOM APP Pumps - v01 / 01.2013

EU Declaration of Conform- ity

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

1.1 General

The APP pumps and pump units are manufactured by Danfoss A/S, and are sold and marketed by a net of authorized distributors world wide.

This manual contains the necessary instructions for the installation, operation and service of the pumps used in a Sea Water Reverse Osmosis (SWRO) or Brackish Water Reverse Osmosis (BWRO) system.

The APP pumps must not be used for other purposes than those recommended and specied without rst consulting your local pump distributor.

Use of the pump in other applications not suitable for the pump unit can cause damages to the pump unit, with risk of personal injury.

All personnel being responsible for operation and maintenance of the pump unit must read and fully understand these instructions, especially the section “Safety” before:

tTransportation of the motor pump unit

tLifting the unit

tInstalling the pump unit

t

Connecting the motor pump unit to the water system

t

Connecting the electric motor and instrumentation

tCommissioning the unit

t

Servicing the motor pump unit, mechanic and electric parts

tDecommissioning the motor pump unit

The pump must always be installed and used in accordance with existing national/local sanitary, safety regulations and laws.

It is the responsibility of the safety ocer or the chief operator to assure compliance with all local regulations that are not taken into account in this manual.

Changing the pumps’ or motor pump units’ operational limits and hardware:

t

Changes to the delivered pump or motor pump system may only be done with a written approval from Danfoss RO Solutions.

t Operation outside the Danfoss specications

requires a written approval from Danfoss RO Solutions.

t If any changes are made without written

approval the warranty will automatically become void.

Ensure that these instructions are always readily available to all personnel concerned.

1.2 Symbols

Indicates something to be noted by the

reader

Indicates a situation which will or could

result in damage to the pump and its function

Indicates a situation which will or could

result in personal injury and/or damage to the pump

Electrical hazard - Indicates a high-

voltage warning

Safety glasses required

Hearing protection required

Safety shoes required

Safety helmet required

1.3 Manufacturer and customer service address:

Danfoss A/S RO Solutions

Nordborgvej 81, D25 DK-6430 Nordborg Denmark

Tel ep hon e: +45 7488 4024 Fax: +45 7445 3831 Email: ro-solutions@danfoss.com Homepage: www.ro-solutions.com

Your local Danfoss pump distributor can be found on our homepage.

Data sheets and instructions on all accessories are available on www.ro-solutions.danfoss.com

CE Declaration of Conformity can be found on page 5.

1. Introduction

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

2.1 General information

Dangers that can arise from not following the instructions:

When the pump or pump system is managed by untrained personal, there is a danger of:

tDeath or fatal injuries

tCostly damages and claims

Electrical

hazard

All electrical installation work must only be carried out by authorized personnel in accordance with EN60204-1 and/or local regulations.

Install a lockable circuit breaker to avoid inadvertent starting.

Protect the motor and other electrical equipment from overloads with suitable equipment.

Protective garments must be wor n

It is recommended to place a local safety switch near by the pump, enabling service personal to cut power for the electric motor. This prevents unintentionally starting the unit during servicing.

Always wear suitable safety clothing when handling the pump.

When working near the pump system, safety proof boot/shoes, safety glasses, ear protection and safety helmet must always be worn.

Under certain operational conditions the surface of the pump can be above 60°C / 140°F. Under these conditions the pump must be labelled with a “Danger Hot” sign.

When using an electric motor, the motor must always be supplied with adequate cooling ventilation.

When using an electric motor together with a VFD, the motor must be designed for operation with VFD. VFD operation may increase the temperature inside the electric motor if the motor is not designed for VFD operation.

Before start-up, the settings for all protective devices, for example, sensors/switches and safety valves must be veried and free ow from safety valves must be ensured.

All pipe and hose connections must be stressfree mounted, securely fastened to the pumps and well supported. Improper installation will or could result in personal injury and/or damage to the pump.

Use of this manual does not relieve operation and maintenance personnel of the responsibility of applying normal good judgment in the operation and care of the pump and its components.

2.2 Preferred system design

Danfoss recommends building systems with a high degree of safety. See Danfoss preferred system design and PI&D in Data sheet and Instruction which are found in appendix 1 (Data sheet) and 2 (APP pump instruction).

It is always the system builders responsibility that the system design does not cause any kind of hazard and is adapted to local regulations and standards.

Proper installation, care of start up and shutdown devices and over-pressure protection equipment is essential.

2.3 Commissioning and servicing the unit

It is recommended that commissioning and servicing are carried out by a minimum of two people, where one is acting as a supervisor.

2.4 Adhere to the following important points

t

Before using the pump/pump unit it is very important to read and understand this user manual.

t Do not try to lift the pump unit manually;

most of the pumps weight more than 20 kilos, see specic weight for the pump in the Data sheet, which is found in appendix 1.

t Do not run the pump if it is completely dry

and not bleeded.

t Do not mount the pump without the bell

housing and a exible coupling.

t Do not try to start the unit before the

system components are mounted, bleeded and adjusted.

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.

2. Safety

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

3.1 Approved applications and operational limits for the pumps

The pump and the pump units are designed for the use in a Sea Water Reverse Osmosis (SWRO) or Brackish Water Reverse Osmosis (BWRO) systems.

The APP pumps must not be used for other purposes than those recommended and specied without rst consulting your local pump distributor.

Use of the pump in other applications not suitable for the pump unit can cause damages to the pump unit, with risk of personal injury.

For system integration of the pumps, please see Data sheet and Instruction which are found in appendix 1 (Data sheet) and 2 (APP pump instruction).

3.2 Application range

See Data sheet in appendix 1.

3.3 Electric motor data

See recommended motor in Data sheet, appendix 1 or IOM for motors, appendix 3. The motors mentioned are the most common used motors by Danfoss High Pressure Pumps.

3.4 Noise and vibration

Noise level for a motor pump unit with a ”standard” motor measured according to EN ISO 3744:2010, see Data sheet in appendix 1. Possibilities to reduce noise and vibration are described in the same Data sheet.

3.5 General arrangement

Dimensions for the dierent pumps, see Data sheet in appendix 1.

3. Technical data

3.6 Space requirement

For service and replacement of the complete motor pump unit, it is recommended having sucient space around the unit.

For easy access to the unit, at least 1 meter/ 40 inches available space should be kept free around the pump. When working with high pressures, space demands should reect the required safety requirements.

3.7 Filtration

(10µm absolute [ß10 =5000]) Requirements are specied in Data sheet, appendix 1 and APP pump instruction, appendix

Danfoss recommends not to build a lter bypass function or use lters with an integrated bypass. If the above recommendation is not followed the warranty for the pump will automatically become void.

It should be possible to monitor the condition of the lter via the dierential/delta pressure across the lter.

Using insucient ltration or a lter bypass can cause a failure or decreased service life of the pumps.

3.8 Properties of water

It is recommended NOT to use the pumps in feed water concentrations higher than 50,000 ppm TDS without consulting your local Danfoss pump distributor.

3.9 Air bubbles

Large bubbles in a pressurised RO system can result in damage to piping, equipment and the pumps.

All air must be bleeded from both the lowpressure and high-pressure side before the RO system is pressurised. Special consideration should also be given to air bubbles in feed ow and continuously feed into the pumps as it else can give cavitation.

3.10 Chemicals

The pumps should not be exposed to any chemicals that can result in damage to piping, equipment and internal parts of the pumps.

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

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.

Immediately check the shipment for damage on arrival and make sure that the name plate/type designation is in accordance with the packing slip and your order.

Remove all packing materials immediately after delivery. In case of damage and/or missing parts, a report should be drawn up and presented to the carrier at once.

4.2 Warning

Before any lifting operation is performed, environmental conditions must be taken into consideration (Ex-rated areas, wind speed, wet/ dry conditions, lifting height, etc.).

4.3 General safety information

Personnel involved in lifting and transporting the equipment (see Safety, chapter 2) must be trained in handling and safety procedures when lifting heavy loads. Many of the pumps and pump units weigh more than 20 kilos, which requires lifting slings and suitable lifting devices; e.g. an overhead crane or industrial truck to be used as minimum.

4.4 Transport and handling

Small pumps which have a weight below 20 kilos (weight can be found in the Data sheet in appendix 1) can be handled by hand if they are not mounted together with an electric motor. The weight of a small pump with a motor will be above 20 kilos.

Pumps which have a weight above 20 kilos (see Data sheet, appendix 1) must be handled by using lifting eyes and slings.

Never use only one sling and make sure the slings does not slip o the pump.

When the pump is mounted together with an electric motor, the pump unit always weight more than 20 kilos and must be handled by using slings around the pump unit.

4. Arrival inspection, transportation, handling, lifting and storage

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

See below examples of where to/not to attach the lifting slings on the pump unit:

Correct lifting with 2 separate slings:

When lifting the pump unit, one sling must be attached to the electric motor and one sling around the pump.

Only some motors and pumps have specic lifting eyes.

Do not use connections/nozzles for lifting! Do not use only one sling!

Make sure that the unit/load is balanced before attempting to lift, as the centre of the mass is dierent from pump to pump and pump unit to pump unit.

How to mount the pump and the electric motor correctly together, see Data sheet in appendix 1 or APP pump instruction in appendix 2.

Wrong lifting:

Incorrect lifting can result in personally injury and/or damage to the pump unit.

4.5 Return to supplier

Please see maintenance chapter 7.

4.6 Storage

Each pump is tested before shipment and therefore holds water, so for storage temperature and frost protection see Data sheet in appendix 1 or APP pump instruction in appendix

The pumps are NOT delivered frost protected from the factory.

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

5.1 Important dimensions

Physical dimensions and connections for the pump unit are described in Data sheet, appendix 1.

5.2 Cleanliness

It is very important that the tubes and pipes are completely clean: no dirt, chips or burrs are allowed. Flush all piping before connecting the high pressure pump to ensure the system is clean. Internal surfaces of the piping must not be corroded. If dirt or rust is not removed, the pump and the valves can be damaged and in the worst case damaged beyond repair!

5.3 Fluid temperature

Before start-up, the uid and pump housing temperature must be above the minimum start-up temperature, see Data sheet, appendix 1.

5.4 Electrical data

Check voltage, current frequency and rated power on the electric motor and VFD setting name plate on both the motor and the VFD.

5.5 Local regulations

Commissioning must always be done in accordance with valid regulations and local standards.

5.6 Pre mounting checklist, based on Danfoss preferred system design

Schematic 1: Recommended system design

5. Installation and commissioning

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

Table 1: Check points when assembling and commissioning system

Check points Comment OK ?

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 uid and

pump.

See Data sheet or Instruction, appendices 1 and 2.

CP3 Filtration condition (10µm absolute (ß10 = 5000) See Danfoss requirements in

Data sheet and Instruction, appendices 1 and 2

CP4 Power supply for electric motor and VFD. See Data sheet for the used

motor and VFD, appendix 1.

CP5 Safety circuit / breaker must be sized for the motor and

environment (corrosion and humidity)

See Data sheet for the used safety circuit.

CP6 Bolts and screws must conform to environmental conditions

as well as uid and torque requirements.

CP7 Instrumentation, pressure switch should be designed to

conform to the environment (corrosion and humidity).

See Data sheet for the used equipment.

CP8 Check the factory settings of the safety/relief valves or

pressure relief valves (8 & 9).

See Data sheets for the used valves.

CP9 Check the settings of the pressure transmitter/switch (3) set

at min. inlet pressure.

See Data sheet or Instruction, appendices 1 and 2.

CP10 Check that all pressure indicators (PI) are selected to be able

to measure the system pressure range.

Scaling should at least be 1 Bar or more precise.

CP11 Check coupling distance ( air gab – movement of the spider ) 3 – 5 mm

CP12 Check correct connections on the pump ( in & outlet)

CP13 Check piping for possible air gaps.

5.7 Lifting and positioning

Lift the pump unit onto base (Remember vibration dampers, if needed). Fasten the motor to the base.

See also chapter 4, Arrival inspection, transportation, handling, lifting and storage.

5.8 Mount the dierent equipment

(connections, pipes, tubes, check and safety/relief valves, etc.)

t

The hard piping and exible hoses used must be of proper design and must be installed in accordance with the manufacturer’s recommendations. (see also Data sheet for Hose and hose ttings and Instruction for Assembling Hose kit - both available on www.ro-solutions.danfoss.com).

t Misalignment of the hard pipes may place

stress on the pump port connection and may damage the pump.

tPrevent excessive external pipe load.

t Do not connect piping by applying external

force (use of wrenches, crane, etc.) Piping must be aligned without residual stress.

t Do not mount expansion joints so that their

force applies internal pressure on the pump connections.

5.9 Electrics

All electrical installation work must be carried out by authorized personnel in accordance with EN60204-1 and/or local regulations. (see also Safety, chapter 2)

Mount the safety circuit breaker, turn the circuit o and lock it in the o position.

Mount the power cable on the electric motor.

If a VFD is used, adjust the protective motor switch/VFD to the current limits found on name plate of the electric motor.

5.10 Instrumentation

The pressure switch/sensor should be mounted as close to the pump as possible. It is recommended to test the pressure/sensor switch via an instrumentation manifold.

Mount the pressure switch/sensors according to the manufacturer’s instructions.

5.11 Connections

Mount connections and maybe check valve(s). Mount and tighten as specied.

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

5.12 Ensure free ow

Ensure that the ow from safety/relief valves 8 and 9 is completely unhindered. A blocked safety/relief valve can cause excessive build-up of pressure and thereby cause dangerous situations and damage to the whole system.

5.13 Verify setting of safety/relief valves

Make sure, the safety/relief valves 8 and 9 are placed correctly.

Check the pressure settings on the name plates of the safety/relief valves. If they are OK, continue. Otherwise replace the safety/relief valves.

5.14 Flush the pump

Fully open the pressure valve at the brine site.

Close all the bleeding and draining plugs on the high pressure pump.

Start the feed pump and ensure that the ow from the feed pump to the high pressure pump is unhindered.

5.15 Bleed and remove air from the pump

Open bleeding plugs. Keep the plugs open until only water leaves the high pressure pump.

5.16 Verify direction of rotation

An arrow can be found on the pump or pump unit. The direction of rotation must always follow the arrow.

Unlock the safety circuit breaker. Start the motor for 1 second and observe the direction of rotation either looking on the fan of the motor or on the coupling true the hole in the bell housing (not available on all bell houses). If the motor is turning the wrong direction, switch two phases in the connection box of the motor or reprogram the direction in VFD.

5.17 Commissioning

tClose all the bleeding and draining plugs.

tOpen the pressure valve at the brine site.

t Switch the safety circuit breaker on for both

motor(s) and VFD(s).

tStart the feed pump.

tStart the high pressure pump.

t If a VFD or a soft starter is used a ramp up

time of minimum 10 second is required to avoid damage of internal pump parts.

t Monitor the inlet pressure and outlet

pressure of the high pressure pump and look for leakages.

t Check the pressure indicator function by

slowly closing the valves. The pump unit should stop when the minimum inlet pressure and maximum outlet pressure has been reached.

t Adjust the pressures to the specied inlet

and outlet pressure for the system and let the pump unit run until the electric motor and pump temperature is stable.

t If the system is running within the system

design limits, the system is released for operation.

5.18 Check the lter condition

Evaluate dirt found in lter, replace lter elements, if necessary.

5.19 Instruct operator and maintenance personnel

Before using the pump/pump unit, the personnel must be instructed in using the pump/pump unit, its function, components, documentation and safety.

Danfoss oers commissioning and service at system manufacturer’s location. Rate quotes are oered upon request.

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

6.1 General safety information

Before inspecting the pump unit, read the Safety chapter 2 in this user manual.

6.2 What to listen and look for

If the following is observed, please act as indicated:

A) Re-check all bolts and, if necessary, contact

the maintenance department in order to have all bolts tighten to the specied levels.

B) Leakage – if a small leak dripping from the

bell housing is observed, contact the maintenance department.

C) Leakage – if there is a large leak, the unit

should be stopped as soon as possible. Contact the maintenance department.

D) High frequency tones – safety/relief valves

are either damaged or running very close to their cracking pressure, stop the unit immediately. Contact the maintenance department.

E) Non-standard noise or vibration from the

pump requires the unit to be stopped immediately. Contact the maintenance department.

F) Very high temperatures – can indicate one

or more damaged parts inside the pump. The pump then needs to be stopped immediately and inspected before running again. Contact the maintenance department.

G) Drop in ow and/or pressure - can indicate

wear on one or more parts inside the pump. The pump needs to be stopped immediately and inspected before running again. Contact the maintenance department.

H) Other observations or troubles, please see

appendix 7, Right and Wrong or the Trouble shooting guide, appendix 6. Both appendices give good advises on design, installation, wiring and troubleshooting.

If the pump is not stopped for inspection, it can lead to damage of the pump. See also service and warranty section in the Data sheet, appendix 1; APP pump instruction or Instruction for recommended service intervals in appendix 2 and 4.

Danfoss oers service of the pump at the system manufacturer’s location as well as training in servicing the pump. Quotes are oered upon request.

Danfoss recommends at the same time also to check the lter and membrane condition and evaluate dirt found, replace lter and membrane elements if necessary.

6. Operation of motor pump unit

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

7. Maintenance and service of the pump unit

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 cleanness level of the water, hydraulic load and temperature of the pump unit. The most important parameter is the cleanness of the water.

See the section Service and warranty in the Data sheet, appendix 1, APP pump instruction and Instruction for recommended service intervals in appendix 2 and 4.

For spare parts and service tools, please see Parts list, appendix 5.

Danfoss oers service of the pump at the system manufacturer’s location and training in servicing the pump. Quotes are oered 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.

D) Turn on the motor safety circuit breaker for

both the high pressure pump, the feed pump and the VDF if used and lock them. Only the employees servicing the pump unit should be able to unlock/activate the switch again.

E) Open bleeding and drain plugs. Wait until

the pump and system are emptied for water.

F) Slowly unscrew and remove the bolts and

gaskets from the in/out hoses or pipes, be careful about jets of water. Be aware that there still can be pressure in the system, which will be released when unscrewing and removing the bolts and gaskets.

G) Attach the lifting equipment to the pump

unit. For instructions on lifting the complete pump unit, see chapter 4, Arrival inspection, transportation, handling, lifting and storage.

H) For the small pumps unscrew the bolts

holding the pump to the bell housing and for the bigger pumps, unscrew the bolts holding the pump and bell housing to the

motor and afterwards unscrew the bolts/ nuts holding the pump and bell housing together.

I) Carefully pull the pump out of the bell

housing by using lifting equipment, if necessary.

J) Hold the pump in dierent positions above

a drip tray; this should allow most of the left-over water trapped in the pump to drip out. Clean and dry the pump surface and plug the bleeding and draining plugs.

K) Move the pump to a clean and safe location

where the pump can be inspected/ serviced.

7. 4 Disassembling and assembling the pump unit

A) Remove all connections from the pump.

B) Disassemble the pump according to the

Disassembling and Assembling Instruction (availabl e at w ww.ro-solutions.danfoss.com At the website you can also nd the Changing pistons instructions for APP 11-13 and APP 16-22 as well as for APP 21-38). Clean all the parts and surfaces with a uid compatible with the materials found in the pump. Wipe the parts clean and dry with a dry and lint-free cloth.

C) Inspect all parts including shaft seal and if

necessary, replace them; see Parts list, appendix 5 and APP pump instruction, appendix 2 or general instruction for Recommended service intervals, appendix

D) If the pump is going to be returned to

Danfoss for repair or a warranty claim, it is important that Danfoss, besides your contact information and reason for returning, gets the below information before shipping.

After Danfoss has been informed about the return, you will receive a return number and a template to ll out. One copy should be attached to the shipment and one copy should be sent to the E-mail address on the template.

Returns without a return number will be

rejected !!!

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

7. 5 Assembling the pump unit

Assemble the pump according to the Disassembling and Assembling Instruction (availabl e at w ww.ro-solutions.danfoss.com).

7. 6 Procedure for mounting pump back onto electric motor

Do always follow the procedure delivered with the instructions from the coupling manufacturer!

Mount the exible coupling and bell housing according to the Data sheet, appendix 1 and APP pump instruction, appendix 2.

7.7 Getting the pump unit back into operation

Find instructions of how to put the pump unit back into operation in chapter 4, Arrival inspection, transportation, handling, lifting and storage and Installation and commissioning, chapter 5.

7. 8 Storage of the pump

If the pump has to be shut down for a longer period or put on the shelf, instructions can be found in Storage-chapter in Data Sheet, appendix 1 or APP pump instruction, appendix 2.

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

8. Troubleshooting and scrapping criteria

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 :

t5IFQVNQJTSVOOJOHESZ

t5IFJOMFUQSFTTVSFJTUPPIJHI

t5IFJOMFUQSFTTVSFJTUPPMPX

t5IFWJTDPTJUZPGUIFøVJEJTUPPIJHI

t5IFUFNQFSBUVSFPGUIFøVJECFJOH

pumped is too high.

t5IFBNCJFOUUFNQFSBUVSFJTUPPIJHI

t5IFQVNQJTSVOOJOHBHBJOTUBCMPDLFE

port/closed manual valve.

t5IFQVNQJTPQFSBUJOHBUBQSFTTVSFBCPWF

the operational specication.

t5IFQVNQJTSVOOJOHXJUIBOPOTQFDJöFE

approved uid.

t5IFQVNQJTSVOOJOHJOUIFXSPOH

direction.

t5IFöMUSBUJPOJTJOTVóDJFOU

t5IFQVNQJTOPUCFJOHTFSWJDFEBDDPSEJOH

to Danfoss specications (end of life).

t5IFSFJTFYDFTTJWFNFDIBOJDBMMPBEPOUIF

shaft coupling and piping.

8.3 Mechanical failure

If the pump is running dry, the temperature will quickly increase which can be dangerous, depending on how long time the pump is running dry.

If there is any leaking at start up or leaking arises during operation, the high pressure can lead to eye or skin damage.

Leaking can result in ooding, which again can cause a risk of slipping, tripping or falling.

If water is dripping into the electric motor; it can lead to electric shock, re, short of circuit or even death. In order to avoid water dripping into the electric motor, see Installation and commissioning, chapter 5 and Operation, chapter 6.

Electrical

hazard

8.4 Electrical failure

If the wiring/connection of the electric motor is not correct or the earth connection is missing, it can lead to electric shock, burn damages, re or even death.

If a VFD is used and wrongly programmed, it can damage the pump and lead to high temperatures or other dangers.

Therefore all electrical installation work must only be carried out by authorized personnel in accordance with EN60204-1 and/or local regulations.

8.5 Responsibility

Danfoss takes no responsibility for any other abnormal injuries, risks or damages that could arise caused by abnormal conditions, vibrations, corrosion, abrasives, foreign objects or excessive temperatures and shall not be liable for any consequential or incidental damages.

8.6 Scrapping criteria

Whether the pump can be repaired or need to be scrapped depends on how damaged the internal parts are or how damaged the whole unit is. Please use appendix 6, Trouble shooting guide as guideline or send the pump to Danfoss headquarter in Denmark for evaluation.

For other observations or troubles, please see appendix 7, Right and Wrong which gives good advises in design, installation, wiring and troubleshooting.

User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)

180R9265 / IOM APP Pumps - v01 / 01.2013

Danfoss ca n accept no responsi bility for pos sible errors in ca talogues, bro chures and other pr inted material. D anfoss reserve s the right to alter it s products wit hout notice. This also ap plies to produc ts already on orde r provided that su ch alterations ca n be made without su bsequential cha nges being nece ssary in speci cations alread y agreed. All trade marks in this mater ial are proper ty of the respec tive companies . Danfoss and the Danf oss logotyp e are trademark s of Danfoss A/S. Al l rights reser ved.

Danfoss A/S

High Pressure Pumps

DK-6430 Nordborg

Denmark

Address

. . . . . . . . . . . . . . . . . . . 6, 7, 15

Air bubbles . . . . . . . . . . . . . . . . . . . . . 8

Appendix

. . . .7, 8, 9, 10, 11, 12, 14, 15, 16, 17

Application range

. . . . . . . . . . . . . . . . . 8

Approval . . . . . . . . . . . . . . . . . . . . . . . 6

Arrival

. . . . . . . . . . . . . . . . . 9, 12, 15, 16

Assembling

. . . . . . . . . . . . . . . . 12, 15, 16

Bleed

. . . . . . . . . . . . . . . . . . . 7, 8, 13, 15

Checklist . . . . . . . . . . . . . . . . . . . . . . 11

Check points

. . . . . . . . . . . . . . . . . . . 12

Chemicals . . . . . . . . . . . . . . . . . . . . . . 8

Cleanliness

. . . . . . . . . . . . . . . . . . . . 11

Commissioning . . . . . .6, 7, 11, 12, 13, 16, 17

Connections

. . . . . . . . . . 7, 9, 10, 11, 12, 15

Coupling . . . . . . . . . . . . . . 7, 12, 13, 16, 17

Danger

. . . . . . . . . . . . . . . . . . . .7, 13, 17

Data sheet . . . . . . 7, 8, 9, 10, 11, 12, 14, 15, 16

Declaration of Conformity

. . . . . . . . . 5, 6

Design

. . . . . . . . . . . . 7, 8, 9, 11, 12, 14, 17

Distributor. . . . . . . . . . . . . . . . . . . . 6, 8

Dimensions

. . . . . . . . . . . . . . . . . . . 8, 11

Disassembling . . . . . . . . . . . . . . . . 15, 16

Electric motor

. 6, 7, 8, 9, 10, 11, 12, 13, 16, 17

Electrical failure

. . . . . . . . . . . . . . . . . 17

Electrical hazard . . . . . . . . . . . . . . . . . . 6

Electrics

. . . . . . . . . . . . . . . . . . . . . . 12

EU Declaration of Conformity

. . . . . . . . . 5

Fail ure

. . . . . . . . . . . . . . . . . . . . . .8, 17

Filter condition . . . . . . . . . . . . . . . . . . 13

Filtration . . . . . . . . . . . . . . . . . . 8, 12, 17

Flow

. . . . . . . . . . . . . . . . . . . 7, 8, 13, 14

Fluid

. . . . . . . . . . . . . . . . . . .11, 12, 15, 17

Flush

. . . . . . . . . . . . . . . . . . . . . . 11, 13

General information

. . . . . . . . . . . . . . . 7

Guideline . . . . . . . . . . . . . . . . . . . . . 17

Handling. . . . . . . . . . . . . . . 7, 9, 12, 15, 16

Inspection. . . . . . . . . . . . . 9, 12, 14, 15, 16

Installation

. . . . . . . . .6, 7, 11, 12, 14, 16, 17

Instruction. . . . . . . . 6, 7, 8, 10, 12, 14, 15, 16

Instrumentation

. . . . . . . . . . . . . . . .6, 12

Introduction . . . . . . . . . . . . . . . . . . . .6

Maintenance

. . . . . . . . . .6, 7, 10, 13, 14, 15

Mechanical failure. . . . . . . . . . . . . . . . 17

Mounting

. . . . . . . . . . . . . . . . . . . . . 16

Name plate

. . . . . . . . . . . . . . 9, 11, 12, 13

Noise

. . . . . . . . . . . . . . . . . . . . . . . . 14

Leaking. . . . . . . . . . . . . . . . . . . . . . . 17

Lifting

. . . . . . . . . . . . . 6, 9, 10, 12, 15, 16

Local regulations . . . . . . . . . 6, 7, 11, 12, 17

Operation

. . . . . . . . .6, 7, 8, 9, 13, 14, 16, 17

Operational conditions . . . . . . . . . . .7, 17

Piping. . . . . . . . . . . . . . . . . . 8, 11, 12, 17

Positioning

. . . . . . . . . . . . . . . . . . . . 12

Preferred system design

. . . . . . . . . . . 7, 11

Pre mounting . . . . . . . . . . . . . . . . . . . 11

Protection . . . . . . . . . . . . . . . . . . 6, 7, 10

Relief valve

. . . . . . . . . . . . . . . .12, 13, 14

Responsibility . . . . . . . . . . . . . . . 6, 7, 17

Return

. . . . . . . . . . . . . . . . . . . . . 10, 15

Rotation

. . . . . . . . . . . . . . . . . . . . . . 13

Safety

. . . . . . . . . .6, 7, 8, 9, 12, 13, 14, 15, 17

Safety valve . . . . . . . . . . . . . . . . . . . . .7

Scrapping criteria

. . . . . . . . . . . . . . . . 17

Serial number

. . . . . . . . . . . . . . . . . . . 4

Servicing. . . . . . . . . . . . . . . . . 6, 7, 14, 15

Shut down. . . . . . . . . . . . . . . . . . . 15, 16

Space requirement

. . . . . . . . . . . . . . . . 8

Spare part . . . . . . . . . . . . . . . . . . . . . 15

Start up

. . . . . . . . . . . . . . . . . . . . . . 7, 17

Storage . . . . . . . . . . . . . . . 9, 10, 12, 15, 16

Symbols

. . . . . . . . . . . . . . . . . . . . . . . 6

System . . . . . . . . . . 6, 7, 8, 11, 12, 13, 14, 15

Systems

. . . . . . . . . . . . . . . . . . . . . 7, 8

Table of content

. . . . . . . . . . . . . . . . . . 2

Technical data . . . . . . . . . . . . . . . . . . . 8

Tem pe rat ure

. . . . .7, 10, 11, 12, 13, 14, 15, 17

Transportation

. . . . . . . . . . . 6, 9, 12, 15, 16

Trouble shooting . . . . . . . . . . . . . . 14, 17

Valve

. . . . . . . . . . . . 7, 11, 12, 13, 14, 15, 17

Warning

. . . . . . . . . . . . . . . . . . . . . 6, 9

Subject index

Front page for Appendices

APP 16-22

User manual

Appendices for Installation, Operation and Maintenance Manual

APP pumps (APP 16-22)

MAKING MODERN LIVING POSSIBLE

User manual Appendices for IOM Manual for APP Pumps (APP 16-22)

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Table of Contents 1. Data sheet for APP 16-22 pumps (521B1183)..............................................3

2. APP pump instruction APP 11-13 and APP 16-22 (180R9223) .............................15

3. IOM Electric motors (180R9230)..........................................................27

4. Recommended service intervals for APP pumps (180R9199) . . .. . . . . . .. . . . .. . . . . . .. . . . .. .31

5. APP parts list (521B0941)................................................................35

6. Trouble shooting guide .. ... .. ... .. ..... ..... .. ... .. ..... ..... .. ... .. ..... ..... .. ... .. .41

7. Right and wrong (180R9042) ...........................................................51

1. Data sheet for APP 16-22 pumps (521B1183)

ro-solutions.com

Data sheet

APP 16-22

MAKING MODERN LIVING POSSIBLE

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Data sheet APP 16-22

APP 16-22 pumps are designed to supply low viscosity and corrosive uids under high pressure, e.g. in seawater reverse osmosis ltration applications and for high pressure salt water pumping.

The pumps are based on the positive displacement principle (axial piston design) which enables a very light and compact design, and

they are designed so that the lubrication of the moving parts in the pumps is provided by the uid itself. No oil lubrication is thus required.

The pumps are supplied with an integrated ushing valve that allows the salt water to ow from inlet to the outlet, when the pump is not running.

1. General information

1: Shaf t Sealing 2: Bolts for bell housing 3: Flushing valve 4: Port plate 5: Bleeding plug 6: Valve/thrust plate 7: Piston/shoe 8: Cylinder barrel 9: Retainer ring 10: Swash plate with bearing 11: Port ange with bearing 12: Drain plug 13: Housing 14: Springs

1. General information

2. Benets

3. Technical data

4. Variants

5. Flow at dierent rpm

6. Flushing valve

7. Power requirements

8. Temperature and corrosion

8.1 Operation

8.2 Storage

9. Noise level

10. Filtration

11. Dimensions

12. Dimensions, complete unit

13. Installation

13.1 Mounting

13. 2 Open-ended system with direct water supply

13. 3 RO system with APP pump

14. Service

14.1 Warranty

14. 2 Maintenance

14. 3 Repair

Data sheet for APP 16-22 pumps (521B1183)

Table of Contents

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Data sheet APP 16-22

t One of the smallest and lightest pumps on

the market

t Can be powered by a combustion engine

provided that a special coupling is used.

t Long service life / No preventive mainte-

nance required in the warranty period.

t Generates insignicant pulsations in the

pressure line.

tNo oil lubricant required

tIntegrated ushing valve

t All parts of the pump are made of non-

corrosive materials, e.g. Duplex (EN1.4462/ UNS S31803-S32205) and Super Duplex (EN1.4410/UNS S32750) stainless steel and carbon reinforced PEEK

tHigh eciency

2. Benets

3. Technical data

APP Pumps APP 16

120 0

APP 16 150 0

APP 17 120 0

APP 17 150 0

APP 19 120 0

APP 19 150 0

APP 22 120 0

APP 22 150 0

Code number 180 B325 4 18 0B325 0 18 0B32 55 180 B3251 180B 3256 18 0B32 52 180 B3257 180B 3253

Geometric displacement cm³/rpm 235 18 5 252 19 8 272 220 311 252

in³/rpm 14. 3 11 . 3 15. 4 12 .1 16 .6 13. 4 19 .0 15. 4

Rated ow at max speed

m³/h 16 15. 8 17. 2 16 .9 18. 8 18. 8 21.5 21.7

gpm 70.4 69.6 75.7 74 .4 82.8 82.8 94.7 95.5

Outlet min. Pressure

bar 30 30 30 30 30 30 30 30

psi 435 435 435 435 435 435 435 435

Outlet max. Pressure, continuous

bar 80 70 80 70 80 70 80 70

psi 116 0 1015 116 0 1015 1160 1015 116 0 1015

Inlet min. Pressure bar 2 2 2 2 2 2 2 2

psi 29 29 29 29 29 29 29 29

Inlet max. Pressure, continuous bar 5 5 5 5 5 5 5 5

psi 72.5 72.5 72.5 72.5 72.5 72.5 72.5 72.5

Inlet max. Pressure, peak bar 10 10 10 10 10 10 10 10

psi 145 145 145 145 145 145 145 145

Max. Speed continuous rpm 120 0 15 00 1200 150 0 120 0 15 00 1200 150 0

Min. Speed continuous rpm 700 70 0 700 700 700 700 700 700

Power requirement at max. speed and 60 bar outlet pressure

kW 32 31 35 33 38 37 43 43

hp 42 .9 41.6 46.9 44.3 51.0 49.6 57.7 57.7

Torque at 60 bar outlet pressure

Nm 258 196 276 210 299 236 341 273

lbf-ft 190 .3 14 4.6 203.6 15 4.9 220.5 174.1 251.5 201.4

Weight kg 78 78 78 78 78 78 78 78

lb 172 17 2 17 2 17 2 172 17 2 17 2 172

Integrated ushing valve Yes Yes Ye s Yes Yes Yes Ye s Yes

Typical average ow 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.

All parts included in the pumps are designed to provide long service life, i.e. long service life with a constantly high eciency and minimum service required.

The pumps are xed displacement pumps in which the ow is proportional to the number of revolutions of the input shaft and the pump displacement.

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Data sheet APP 16-22

t Available as ATEX certied. Category 2,

zone 1 and category 3, zone 2.

t Available with material certicates on

wetted parts

For more details on the variants, please contact the Danfoss RO Solutions Sales Organisation

4. Variants

5. Flow at dierent rpm When using the diagrams shown below, it is easy

to select the pump which ts the application best if the ow required and the rotation speed (rpm) of the pump are known.

5,00

8,00

11,00

14,00

17,00

20,00

23,00

700 800 900 1000 1100 1200

m3/h

rpm

1200 rpm version

APP 22

APP 19 APP 17 APP 16

5,00

8,00

11,00

14,00

17,00

20,00

23,00

700 800 900 1000 1100 1200 1300 1400 1500

m3/h

rpm

1500 rpm version

APP 22

APP 19 APP 17

APP 16

Furthermore, these diagrams shows that the ow can be changed by changing the rotation speed of the pump. The ow/rpm ratio is constant, and the “required “ ow can be obtained by changing the rotation speed to a corresponding value. Thus, the required rpm can be determined as:

Required ow × Rated rpm Required rpm = Rated ow

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Data sheet APP 16-22

6. Flushing valve

0,5

1,5

2,5

0 50 100 150 200 250 300 350 400

Pressure drop [bar]

Flow [l/min]

Flushing Valve characteristic

7. Power requirements

Pump model

Flow Pressure rpm Calc.

factor

60 bar 70 bar 80 bar

l/min m

/h gpm 870 psi 1015 psi 1160 psi

APP 16 1200

267 16.0 70.5 32 kW 38 kW 43 kW 1180 496

APP 16 1500

263 15.8 69.5 31 kW 36 kW 41 kW 1480 511

APP 17 1200

287 17.2 75.8 35 kW 40 kW 46 kW 1180 498

APP 17 1500

281 16.9 74.2 33 kW 38 kW 44 kW 1480 513

APP 19 1200

314 18.8 82.9 38 kW 44 kW 50 kW 1180 499

APP 19 1500

313 18.8 82.7 37 kW 43 kW 49 kW 1480 509

APP 22 1200

358 21.5 94.6 43 kW 50 kW 57 kW 1180 501

APP 22 1500

362 21.7 95.6 43 kW 50 kW 57 kW 1480 507

The power requirements can be determined using one of the following guiding equations:

l/min × bar 16.7 × m

/h × bar 0.26 × gpm × psi Required power = [kW] or [kW] or [kW] Calc. factor Calc. factor Calc. factor

1 hp = 0.75 kW 1 kW = 1.34 hp 1 gpm = 3.79 l/min 1 l/min = 0.26 gpm 1 m

/h = 4.40 gpm

1 gpm = 0.23 m

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Data sheet APP 16-22

8.1 Operation

The chart on the next page illustrates the corrosive resistance of dierent types of stainless steel related to NaCl concentration and temperature.

All critical parts of the APP water pump are made of Super Duplex.

If the water pump is operated at high salinity, always ush the water pump with fresh water at operation stop in order to minimize the risk of crevice corrosion.

8.2 Storage

Frost protection is required at temperatures below 2°C. Danfoss recommends to use DOWFROST from DOW Chemical Company or Chilsafe mono propylene glycol from Arco Chemical Company.

8. Temperature and corrosion

316L

Super Duplex

100

160 1600

1000

16000

10 000

160000

100 000

ppm

NaCI ppm

Duplex

NaCl vs. temperature

9. Noise level 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 exible 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.

The noise level is inuenced by:

t The speed of the pump, high rpm create

more noise than low rpm

t Rigid mounting of the pump generates

more noise than exible mounting

t Pipe mounting direct to the pump

increases the noise level compared to a exible hose

t If using a VFD the motors can produce

higher noise values depending on the operation point.

t

*) 1 meter from the pump unit surfaces (reference box) acc. to EN ISO 20361 section 6.2. Deviation σTOT = ± 1,6 dB(A)

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)

Storage temperature:

-40° C to +70° C (-40° F to 158° F) – provided that the pump is drained of uid and stored ”plugged”.

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Data sheet 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 ltered properly to minimize the wear of the pump.

The main lter must have a ltration eciency of

99.98% at 10 μm. We recommend to use precision depth lter cartridges rated 10μm abs. ß10>5000 (equivalent to a ltration eciency of

99.98%). Bag lters and string wound lter cartridges typically have only 50% ltration

eciency. This means that for each 100,000 particles reaching the lter, 50,000 particles pass through it compared to only 20 particles in a lter with an eciency of 99.98%.

For more information on the importance of proper ltration, please consult our publication “Filtration” (code number 521B1009), which also will provide you with an explanation of ltration denitions and a guidance on how to select the right lter.

10. Filtrat ion

11. Dimensions

Outlet

O I

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Data sheet APP 16-22

12. Dimensions, complete unit

Description APP 16 – APP 22

Parallel key, DIN 6885

12 × 8 × 70

In 0.47 × 0.31 × 2.76

Bleeding G ¼”, Hexagon AF

= 6 mm

Inlet port M52 x 1.5; depth 21 mm

Outlet port M52 x 1.5; depth 21 mm

Pump mounting  ange 125 B 4

Accessories Ty pe Code no.

2” inlet hose kit 2 m/79”

2” Victaulic 18 0Z02 98

2” inlet Vic. Super Duplex

2” Victaulic 18 0Z0165

Non-return valve (outlet) Super Duplex

2” Victaulic (OD 63 mm)

180 H025 6

For more details on the accessories, please contact the Danfoss RO Solutions Sales Organisation.

Accessories

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Data sheet APP 16-22

13. Installation 13.1 Mounting

The gure below illustrates how to mount the pump and connect it to the electric motor/ combustion engine.

If alternative mounting is required, please contact Danfoss RO Sales Organization for further information.

To ensure easy mounting of the exible coupling without using tools, the tolerances must be dimensioned accordingly.

Note: Any axial and radial loads on the pump shaft must be avoided.

Pump A (mm)

(P)

B (mm) (HD)

C (mm) (H)

D (mm) (A)

E (mm) (B)

F (mm) (LB)

G (mm) IEC Electric motor

APP 16 450 560 225 356 286 675 262 37 kW, IEC 225 S4

APP 17 450 560 225 356 311 705 262 45 kW, IEC 225 M4

APP 19 55 0 615 250 406 349 775 265 55 kW, IEC 250 M4

APP 22 55 0 680 280 457 368 835 265 75 kW, IEC 280 S4

Note: Examples of dierent pump/motor sizes and drawing dimensions are only for IEC motors and couplings. Please always check required motor power and dimensions.

13. 2 Open-ended system with direct water supply

In order to eliminate the risk of cavitation, a positive inlet pressure is always to be maintained. Please see technical data (section 3.) for specic pressure values.

1. Place the lter (1) in the water supply line in front of the pump.

2. Place a monitoring pressure switch (2) - set at min. inlet pressure - between lter and pump inlet. The monitoring switch must stop the pump at pressures lower than min. inlet pressure. Please see technical data (section 3.) for specic pressure values

3. Install a low pressure safety valve or a pressure relief valve (3) in order to avoid system or pump damage in case the pump stops momentarilly or spinning backwards.

Note: If a non return valve is mounted in the inlet line, a low pressure relief valve is also required between non return valve and pump as protection against high pressure peaks.

A: Flexible coupling B: Bell housing C: Motor shaf t

Ensure 3-5 mm (0.12-0.2 inches) air gap between coupling parts.

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Data sheet APP 16-22

13. 3 RO system with APP pump

1. Dimension the inlet line to obtain minimum pressure loss (large ow, minimum pipe length, minimum number of bends/ connections, and ttings with small pressure losses).

2. Place an inlet lter (1) in front of the APP pump (2). Please consult section 10, “Filtration” for guidance on how to select the right lter. Thoroughly clean pipes and ush system prior to start-up.

3. Place a monitoring pressure switch (3) set at min. inlet pressure between lter and pump inlet. The monitoring switch must stop the pump at pressures lower than minimum pressure.

4. Use exible hoses (4) to minimize vibrations and noise.

5. In order to eliminate the risk of damage and cavitation, a positive pressure at the inlet (5) is always to be maintained at min. inlet pressure and max. inlet pressure. Recommend to install safety valve or a pressure relief valve (9) in order to avoid

high pressure peaks in case the pump stops momen tarilly or spinning backwards.

6. For easy system bleeding and ushing, 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 membrane vessel works as an accumulator and will send ow 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 ow immediately after start-up, regardless of any counterpressure.

Note: If a non return valve is mounted in the inlet line, a low pressure relief valve is also required between non return valve and pump as protection against high pressure peaks.

14. Service 14.1 Warranty

Danfoss APP pumps are designed for long operation, low maintenance and reduced lifecycle costs.

Provided that the pump has been running according to the Danfoss specications, Danfoss guarantees 8,000 hours service-free operation, however, max. 18 months from date of production.

If Danfoss recommendations concerning system-design are not followed, it will strongly

inuence the life of the APP pumps.

14. 2 Maintenance

After 8,000 hours of operation it is strongly recommended to inspect the pump and change any worn parts, e.g. pistons and shaft seal. This is done in order to prevent a potential

breakdown of the pump.

If the parts are not replaced, more frequent inspection is recommended according to our guidelines.

Pump shutdown:

The APP pumps are made of Duplex/Super Duplex materials with excellent corrosion properties. It is, however, always recommended

to ush the pump with freshwater when the system is shut down.

14. 3 Repair

In case of irregular function of the APP, please contact the Danfoss RO Solutions Sales Organisation.

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Data sheet APP 16-22

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Data sheet APP 16-22

Danfoss A/S

High Pressure Pumps

DK-6430 Nordborg

Denmark

2. APP pump instruction APP 11-13 and APP 16-22 (180 R922 3)

www.ro-solutions.com

Instruction

APP pump instruction

APP 11-13 and APP 16-22

MAKING MODERN LIVING POSSIBLE

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction APP pump instruction APP 11-13 and APP 16-22

1. Identication

Pump

Type APP Serial no.

Code no.

NESSIE

MADE IN DEN MARK

APP pump instruction

APP 11-13 and APP 16-22

(180 R922 3)

Table of Contents

1. Identication

2. System design

2.1 Open-ended systems with direct water supply

2.2 Preferred RO system design and P&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

5.1 Te mpe ra tur e

5.2 Pressure

5.3 Dry running

5.4 Disconnection

5.5 Storage

5.5.1 Recommended procedure

6. Service

6.1 Warrant y

6.2 Maintenance

6.3 Repair

7. EC Declaration of Conformity

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

2. System design The design of the system must ensure that self-emptying of the pump during standstill is avoided. The inlet pressure of the pump must never exceed the outlet pressure. This may typically occur in boosted or open-ended systems with direct water supply.

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 lter (1) in the water supply line in

front of the pump.

2. Place a monitoring pressure switch (3) between lter 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.

Inlet

Outle t

Instruction APP pump instruction APP 11-13 and APP 16-22

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

2.2 Preferred RO system design and P&ID

1. Dimension the inlet line to obtain minimum pressure loss (large ow, minimum pipe length, minimum number of bends/ connections, and ttings with small pressure losses).

2. Place an inlet lter (1) in front of the APP pump (2). Please consult the Danfoss lter data sheet for guidance (521B1009) on how to select the right lter. Thoroughly clean pipes and ush system prior to start-up.

3. Place a monitoring pressure switch (3) set at min. inlet pressure between lter and pump inlet. The monitoring switch must stop the pump at pressures lower than minimum pressure.

4. Use exible hoses (4) to minimize vibrations and noise.

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 ushing, a bypass non-return vavle (6) is integrated in the APP pump.

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.

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 cavitation, the inlet 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.

2.4 General comments on

Filtration

A good ltration is vital to ensure a long and trouble free life of the pump.

The main lter must have a ltration eciency of

99.98% at 10 µm. We recommend to use

precision depth lter cartridges rated 10µm abs. ß10>5000 (equivalent to a ltration eciency of

99.98%). Bag lters and string wound lter

cartridges typically have only 50% ltration eciency. This means that for each 100,000 particles reaching the lter, 50,000 particles pass through it compared to only 20 particles in a lter with an eciency of 99.98%.

Instruction APP pump instruction APP 11-13 and APP 16-22

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

For more information on the importance of proper ltration, please consult our data sheet “Filtration” (521B1009), which also will provide you with an explanation of ltration denitions and a guidance on how to select the right lter.

Monitoring

It is recommended to continuously monitor the following conditions:

tlter clogging

tpressure (inlet- and outlet side of the pump)

3. Building up the pump unit

3.1 Mounting

1. Mount the coupling ush or maximum 1 mm oset from the pump shaft end. Ensure an air gap between coupling and pump ange of min. 4 mm (0.16 inch).

2. Mount the bell housing on pump. Secure nuts with the right torque.

3. Measure the longest distance “A” from top of bell housing to the button of coupling claw.

4. Mount the coupling on motor shaft. Ensure the coupling and motor ange are not in contact with each other.

5. Measure from motor ange to the top of the coupling. That measurement “B” shall be 3-5 mm (0.12 - 0.2 inch) shorter than the measurement “A”.

6. Adjust respectively, verify the measurement, and secure both couplings with the right torques on the locking screws (see coupling operation & mounting instruction).

7. Mount the elastic gear ring and mount the bell housing/pump on the motor. After mounting it must be possible to move the elastic gear ring 3-5 mm (0.12 - 0.2 inch) axial “C”. The check can be done through the inspection hole of bell housing. Secure ange bolts with the right torque.

A: Elastic coupling B: Bell housing C: Motor shaft D: Pump ange

1: Bolts and nuts: torque 75 Nm ±5 Nm 2: Bolts and nuts: torque 40 Nm ±4 Nm 3: Torque see table below

Thread size

M4 M5 M6 M8 M10 M12 M16

Torque (Nm)

1,5 2 4,8 10 17 40 80

Instruction APP pump instruction APP 11-13 and APP 16-22

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

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.

3.2 Direction of rotation

Is indicated by means of an arrow on the pump label.

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

Instruction APP pump instruction APP 11-13 and APP 16-22

Pump

Type APP Serial no.

Code no.

NESSIE

MADE IN DEN MARK

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

3.5 Connections

3.4 Protection against too high outlet pressure

The pump should be protected against too high outlet pressure by means of a safety valve or a pressure relief valve. The valve should be placed as close to the pump as possible. The opening characteristics of the valve must not result in peak pressures higher than 80 bar (1,160 psi).

Both the inlet and outlet lines must be exible soft hoses.

The valve outlet must not be connected directly to the pump suction line. It must be connected directly to the drain.

Inlet

Outlet

Inlet

I : Inlet O : Outlet C : Bleeding D : Parallel key

Instruction APP pump instruction APP 11-13 and APP 16-22

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction APP pump instruction APP 11-13 and APP 16-22

Description APP 11 - APP 13

Parallel key, DIN 6885

10 × 8 × 45

inch

0.39 × 0.31 × 1.77

Bleeding

G ¼”, Hexagon AF = 6 mm

Inlet port

M42 x 1.5; depth 17 mm

Outlet port

M42 x 1.5; depth 17 mm

Pump mounting ange

125 B 4

Accessories Ty pe Code no.

2” inlet hose kit 2 m / 79”

2” Victaulic 180Z0298

2” inlet Vic. Super Duplex

2” Victaulic 180Z0166

Non-return valve (outlet) Super Duplex

1,5” Victaulic (OD 48,3 mm)

180 H0053

For more details on the accessories, please contact the Danfoss RO Solutions Sales Organisation.

Description APP 16 – APP 22

Parallel key, DIN 6885

12 × 8 × 70

0.47 × 0.31 × 2.76

Bleeding

G ¼”, Hexagon AF = 6 mm

Inlet port

M52 x 1.5; depth 21 mm

Outlet port

M52 x 1.5; depth 21 mm

Pump mounting ange

125 B 4

Accessories Ty pe Code no.

2” inlet hose kit 2 m/79”

2” Victaulic 180Z 0298

2” inlet Vic. Super Duplex

2” Victaulic 180Z 0165

Non-return valve (outlet) Super Duplex

2” Victaulic (OD 63 mm)

180 H02 56

For more details on the accessories, please contact the Danfoss RO Solutions Sales Organisation.

APP 11 - APP 13

APP 16 – APP 22

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction APP pump instruction APP 11-13 and APP 16-22

4. Initial start-up 1. Flush inlet line before connecting the pump, to remove possible impurities from pipes, hoses etc.

2. Connect pump inlet to inlet line and ush the pump for 5 min. by means of the internal ushing valve, to remove possible impurities from pipes, hoses etc.

3. Loosen top bleeding plug “C” (see item 3.3) using an allen key (only plugs with internal hexagan sockets). Retighten the plug, when water appears from the bleeding plug.

4. Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump (see label on pump).

5. Now the pump is ready for start-up.

Warning: Make sure that the direction of rotation of the electric motor corresponds to the direction of rotation of the pump (see label on pump).

Otherwise the pump will be damaged if a check valve is placed between pump and feed pump.

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction APP pump instruction APP 11-13 and APP 16-22

5. Operation

In case of lower operating temperatures, please contact the Danfoss RO Solutions Sales Organisation.

5.1 Te mp er at ur e

316L

Super Duplex

100

160 1600

1000

16000

10 000

160000

100 000

ppm

NaCI ppm

Duplex

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 pro cedure described under section 4: Initial start up.

5.5 Storage

When preparing the pump for long-term storage or for temperatures below the freezing point, ush 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 ow 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.

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)

The chart below illustrates the corrosive resistance of dierent 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 ush water pump with fresh water at operation stop in order to minimise the risk of crevice corrosion.

Storage temperature: Min. -40°C to max. +70°C (Min. -40°F to max. +158°F)

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction APP pump instruction APP 11-13 and APP 16-22

6. Service 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 specications, Danfoss guarantees 8,000 hours service-free operation, however, max 18 months from date of production.

If Danfoss recommendations concerning system-design are not followed, it will strongly inuence 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

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 ush 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.

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction APP pump instruction APP 11-13 and APP 16-22

Danfoss A/S

High Pressure Pumps

DK-6430 Nordborg

Denmark

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

3. IOM Electric motors (180 R923 0)

Electric Motors

Motor Manual

hoyermotors.com

Manual

180R9230

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

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 ≤1000 m above sea level. Low-voltage motors are components for installation in machinery. They are CE marked according to the Low Voltage Directive 2006/95/EC

2. Transport and storage

Check the motor for external damage immediately upon receipt and, if found, inform the forwarding agent right away. Check all rating plate data, and compare it with the requirement of the motor. Turn the shaft by hand to check free rotation, remove transport locking if used. Transport locking must be used again for internal transport also. It is also important that transport locking is used when motors are transported mounted on equipment. All motors should be stored indoors, in dry, vibration- and dust-free conditions.

Lifting eyebolts must be tightened before use. Damaged eyebolts must not be used, check before use. Lifting eyes at motor must not be used to lift the motor when it is attached to other equipment.

Before commissioning, measure the insulation impedance. If values are ≤ 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 foundation.

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.

Correct alignment is essential to avoid bearing, vibration and shaft failure. Use appropriate methods for alignment. Re-check the alignment after the ﬁnal tightening of the bolts or studs. Check that drain holes and plugs face downwards. We recommend opening the drain hole for motors placed outdoors and not running 24 hours / day, so that the motor can breathe, thus ensuring a dry motor.

4. Electrical connection

Work is only permitted to be carried out by qualiﬁed specialists and must to be carried out in accordance with local regulations. Before work commences, ensure that all power is switched off and 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:

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.

Thread M5 M6 M8 M10 M12 M16 M20

T.(Nm) 2.5 3.5 7 12 18 35 55

Motor Manual

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

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 ≤225. Motor types MS and Y2E is as standard with lifetime greased bearing with motor size ≤160.

Typical duty hours for lifetime lubricated bearings.

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.

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.

The table values are 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: Ex II 3D T125°C, IP55.

The dust hazardous 3-phase asynchronous motors are in accordance with European standard EN 50281-1-1. Combustible dust areas will be found in agricultural areas and in industrial environments. Only one electrical installation may be installed in one speciﬁed area (zone).

Only certiﬁcated cable glands for category 2D may be used. Unused glands must be closed. Connections must be made in such a way as to ensure that a permanently safe electrical connection is maintained, both for the main supply and earth connection. Installations must be in accordance with actual standards for installation in the Zone 22 area.

It is recommended that EN 50281-2 is followed according temperature and dust on the motor surface. The use of motors with so much surface dust that the motor temperature increases is not permitted. Regularly cleaning is recommended. The radial shaft sealing ring is part of the ATEX certiﬁcation. It is important that the ring is always intact. The shaft sealing must be regularly checked, and if dry it must be lubricated. It is recommended that the seal is re-lubricated regularly. Always use the original seal ring when replaced. Replacing bearings also means replacing the seals.

All machines must be inspected regularly for mechanical damage. The 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.

Frame size Poles Typical lifetime

56 – 160 2 – 8 40.000h

180 2 35.000h

200 2 27.000h

225 2 23.000h

180 – 225 4 – 8 40.000h

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 35 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

Motor Manual

4. Recommended service intervals for APP pumps (180 R9199)

Instruction

Recommended service intervals

for APP pumps

MAKING MODERN LIVING POSSIBLE

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Recommended service intervals for APP pumps

Nr. Qty. Description Material Service interval

11Housing, main bearing Duplex, PEEK No need for service

11, 125, 211*

1 Mounting ange/

end ange

Wetted part: Duplex Dry part: AISI 316L

No wear part

121, 181* 1 Port ange Duplex No wear part

31 1 Swash plate Super Duplex 40,000 hours

66 5/7/9 Piston Super Duplex and PEEK Recommended inspection

on a yearly basis and evaluated acc. to app. 1

92 1 Valve plated Super Duplex 24,000 hours

91 1 Port plate Super Duplex, PEEK 24,000 hours

61 1 Cylinder barrel Super Duplex 40,000 hours

65 1 Retaining plate Super Duplex 24,000 hours

64 1 Retaining ball Super Duplex 40,000 hours

71 1 Retaining guide Super Duplex 40,000 hours

62 1/4 Spring Duplex 40,000 hours

63 1 Spring guiede Duplex or PP 40,000 hours

142 1 Stop for shaft seal PP No wear part

124, 215* 1 Shaft seal Hasteloy and NBR It is good practice to

change the seal af ter each disassembly of the pump

125 1 Cover/ange for

shaft seal

Super Duplex No wear part

93 5/7/9 Back-up ring Te on 24,000 hours

* O-ring (overall) NBR 24,000 hours

* Screw (overall) AISI 316 No wear part

* Pin (overall) AISI 316, Duplex or PEEK No wear part

152 1 Valve cone (ushing valve) Duplex or PEEK 40,000 hours

3, 129* 2 Bleeding screw Duplex No wear part

67 1 Parallel key AISI 302 40,000 hours

1. General information This guideline provides information on the recommended service intervals. The recommendation is based upon good engineering practice and on experience gained from operation even under extreme conditions.

The recommendation is for guidance only.

2. Design/features

Danfoss APP pumps are designed for long operation and low maintenance and life cycle costs.

Danfoss guarantees 8,000 hours service free operation, however max. 18 months from date of production. After 8,000 operation hours it is recommended to inspect the pump and replace worn parts, if any.

If the Danfoss recommendations concerning system-design (see our data sheet) are not followed, the service life of the APP pumps might be aected.

The recommended service intervals on the dierent parts in the APP pumps appear from the table below:

1. General information

2. Design/features

3. Appendix 1

Recommended service intervals for APP pumps (180 R9199)

Table of Contents

* depends on pump size

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Recommended service intervals for APP pumps

3. Appendix 1 Pistons:

The pistons are the heart of the pump regarding service.

If the pistons break down, the pump will suer a breakdown.

In case of doubt - the pistons must be replaced.

The pictures below is ment as a guideline for evaluating the wear of the sliding surface.

Cavitation of the piston shoes. New inspection is required in 3,000-4,000 hours.

Cavitation of the piston shoes. All pistons must be replaced within the next 500-1,000 hours.

Cavitation of the piston shoes. All pistons must be replaced within the next 100-200 hours.

Cavitation of the piston shoes. All pistons must be replaced immediately.

Abrasive wear of the piston shoes. All pistons must be replaced immediately.

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Recommended service intervals for APP pumps

Danfoss A/S

High Pressure Pumps

DK-6430 Nordborg

Denmark

5. APP parts list (521B0941)

Parts list

APP Pumps

APP 0.6-38 / APM 0.8-2.9 / APPW 5.1- 10.2

MAKING MODERN LIVING POSSIBLE

APP 16-22

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2

15. APP 16 - 19

Note:

The parts listed are not sold

separately, only in various kits

Exploded view, see next page.

180B4206 – Seal set

(APP 16-19)

180B4205 – Cylinder barrel set

(APP 16-19)

180B4204 – Valve plate set

(APP 16-19)

180B4201 – Retainer set

(APP 16-19)

180B4221 – Piston set

(APP 16-19)

180B4219 – Swash plate

(APP 16 / 1200 rpm)

180B4215 – Swash plate

(APP 16 / 1500 rpm )

180B4218 – Swash plate

(APP 17 / 1200 rpm)

180B4216 – Swash plate

(APP 17 / 1500 rpm)

180B4220 – Swash plate

(APP 19 / 1200 rpm)

180B4217 – Swash plate

(APP 19 / 1500 rpm)

180B4203 – Flushing valve set

(APP 16-19)

Pos. Qnt. Designation Material

11Housing Dup lex / PEEK

2 1 Pin (Ø6 x 10) AISI 316 x

2 2 Pin (Ø6 x 10) AISI 316 x x

32Bleeding plug Super Duplex x

4 2 O-ring, (Ø11.0 x 2.0 ) NBR

5 12 Screw (M 8 x 30) AISI 316 x

9 1 O-ring, (Ø182 x 4.0 ) NBR x xxxxxx

10 2 O-ri ng, (Ø9.19 x 2.62) NBR x

11 1 End ange Duplex

12 1 Lifting eye AISI 316 xxxxxx

31 1 Swash plate Super Duplex / PEEK x

34 2 Pin ( Ø10.5 x 20) Duplex x xxxxxx

61 1 Cylinder barrel Super Duplex /

Duplex / PEEK

62 7 Spring Duplex x

63 1 Spring guide PP x

64 1 Retainer ball Super D uplex x

65 1 Re tainer plate Super Duplex x

66 7 Piston Super Duplex / PEEK x

67 1 Key (12x8x70) AISI 316

81 3 Pin (Ø6,4 x 40) Super Duplex x

91 1 Port plate Sup er Duplex / PEEK x

92 1 Valve plate Super Duplex x

93 7 Back-up ring PTFE x x

94 7 O-ring, (Ø30.2 x 3.0) NBR x x

121 1 Por t ange Duplex / PEEK

122 1 O -ring, (Ø68 x 2.0) NBR x

123 1 O -ring, (Ø182 x 4.0) NBR x

124 1 Shaft seal (Ø45) Hastelloy/NBR x

125 1 Cover for shaft seal Super Duplex

126 2 Pin (Ø10.5 x 20) Duplex x x

127 4 Screw (M6 x 16.0) AISI 316 x

128 10 Screw (M8 x 75) AISI 316 x

129 1 Lif ting eye AISI 316

142 1 Stop for shaft seal PP x

144 4 Tailstock screw (M12 x 60) AISI 316

145 4 Check nut M12 AISI 316

151 1 O-ring, (Ø35 x 3) FPM 75 x x

152 1 Valve cone Sup er Duplex x

153 1 Spring (Ø1.9 x Ø25.0 x 33.7) Duplex x

154 1 Plug/guide Supe r Duplex x

155 1 O-ring, (Ø47.22 x 3.53) NBR x x

Instruction xxxxxxxxxxxx

APP 16 - 19

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2

16. Exploded view APP 16 - 19

Exploded view APP 16 - 19

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2

17. APP 22

180B4206 – Seal set

(APP 22)

180B4205 – Cylinder barrel set

(APP 22)

180B4204 – Valve plate set

(APP 22)

180B4201 – Retainer set

(APP 22)

180B4200 – Piston set

(APP 22)

180B4202 – Swash plate

(APP 22 / 1200 rpm)

180B4218 – Swash plate

(APP 22 / 1500 rpm)

180B4203 – Flushing valve set

(APP 22)

Pos. Qnt. Designation Material

11Housing Duplex / PEEK

2 2 Pin (Ø6 x 10) AISI 316 x

2 2 Pin (Ø6 x 10) AISI 316 xxx

32Bleeding plug Super Duplex x

4 2 O-ring, (Ø11.0 x 2.0 ) NBR x

5 12 Screw (M8 x 30) AISI 316 x

9 1 O-ring, (Ø182 x 4.0 ) NBR x xx

10 2 O-ring, (Ø9.19 x 2.62) NBR x

11 1 End ange Duplex

12 1 Lifting eye AISI 316 xx

31 1 Swash plate Super Duplex / PEEK x

34 2 Pin (Ø10.5 x 20) Duplex x xx

61 1 Cylinder barrel Super Duplex / Duplex / PEEK x

62 7 Spring Duplex x

63 1 Spring guide PP x

64 1 Retainer ball Super Duplex x

65 1 Retainer plate Super Duplex x

66 7 Piston Super Duplex / PEEK x

67 1 Key (12 x 8 x 70) AISI 316

81 3 Pin (Ø6,4 x 40) Super Duplex x

91 1 Port plate Super Duplex / PEEK x

92 1 Valve plate Super Duplex x

93 7 Back-up ring PTFE x x

94 7 O-ring, (Ø30.2 x 3.0) NBR x x

121 1 Port ange Duplex / PEEK

122 1 O-ring, (Ø68 x 2.0) NBR x

123 1 O-ring, (Ø182 x 4.0) NBR x

124 1 Shaft seal Hastelloy/NBR x

125 1 Cover for shaft seal Super Duplex

126 2 Pin (Ø10.5 x 20) Duplex x x

127 4 Screw (M6 x 16.0) AISI 316 x

128 10 Screw (M8 x 75) AISI 316 x

129 1 Lifting eye AISI 316

142 1 Stop for shaft seal PP x

144 4 Tail stock screw (M12 X 60) AISI 316

145 4 Check nut M12 AISI 316

151 1 O-ring, (Ø35 x 3) FPM 75 x x

152 1 Valve cone Super Duplex x

153 1 Spring (Ø1.9 x Ø25.0 x 33.7) Duplex x

154 1 Plug/guide Super Duplex x

155 1 O-ring, (Ø47.22 x 3.53) NBR x x

Instruction xxxxxxxx

Note: The parts listed are not sold separately, only in various kits

Exploded view, see next page.

APP 22

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2

18 . Exploded view

APP 22

Exploded view APP 22

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Parts list APP 0.6-38 / APM 0.8-2.9 / APPW 5.1-10.2

23. Tool sets

Danfoss A/S

High Pressure Pumps DK-6430 Nordborg Denmark

Designation

180B4188 – Tool set (APP 0.6-1.0 Compact)

180B4142 – Tool set (APP 0.6-1.0)

180B4148 – Tool set (APP 1.5-3.5)

180B4162 – Tool set (APP 5.1-10.2)

180B4230 - Tool set (APP 11-13)

180B4222 – Tool set (APP 16-22)

180B4172 – Tool set (APP 21-38)

Shaft bush x

Press bush x

Drift x

Torx T30 x

Shaft bush Ø18 xx

Press Bush Ø18 xx

Allen Key 4mm x

Allen Key 5mm x

Allen Key 6mm xxxx

Shaft bush Ø35 x

Shaft seal extractor Ø35 xx

Press bush Ø35 xx

Adjustable pin wrench xxxx

Combination wrench 10mm xxxx

Combination wrench 13mm xxx

Nut M8x6.5x13 xxx

Guide bolt M8x140mm x

Shaft seal extractor Ø45 xx

Press Bush Ø45 xx

Eye bolt M8 xx

Press bush for valve plate xx

Stop for retainer plate x

Screw M8x20 xxx

Screw M8x70 xx

Screw M8x140 x

Lifting eye x

Note: The parts listed are not sold separately, only in various kits.

Tool sets

6. Trouble shooting guide

Guideline

Trouble shooting guide

for APP pumps

MAKING MODERN LIVING POSSIBLE

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Trouble shooting guide for APP pumps

Trouble shooting guide for APP pumps

Table of Contents

Trouble shooting sh bone chart

1. No ow/no pressure

2. Reduced ow/reduced pressure

3. High torque on electric motor

4. Noise from pump

5. Noise from installation

6. Typical signs of wear

6.1 Valve plate

6.2 Port plate

6.3 Swash plate

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Trouble shooting guide for APP pumps

Trouble shooting sh bone chart

1. No ow/pressure

3. High torque on el. motor

4. Noise from pump

5. Noise from installation

2. Reduced ow/pressure

1.1 Dry running

1.2 Pump reversing

1.3 No rotation of el ectric motor

1.4 No rotation of pump

1.5 Axial force on p ump shaft

1.6 Pump damage

2.1.5 Pre-treatment

2.1.8 Main ltration

2.1 Wear in pump

(internal leakag e)

2.1.9 Type of uid

2.1.11 High  uid temperature

4.1 Air in uid

4.2 Bleedi ng conditions of pump

4.3 M in/max nominal

inlet pressure

4.4 Pump reversing

4.5 High rota tion speed (RPM)

4.6 Outlet pre ssure

5.1 Inlet/outlet co nnections

(hoses/pipes)

5.2 Le ngth/dimensions of

inlet/outlet lin e

5.3 Hose stin ess

5.4 Hoses /pipes mounted

directly on f rame

5.5 Vi bration damper under the

electric mo tor

3.1 Too high outlet pressur e

from pump

3.3 Constant tor que

3.4 Water pump damage

4.7 Soft star t/stop

PUMP FAILED

3.2 Pump star ts against pressure

2.2 Low inle t pressure

2.3 RPM

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Trouble shooting guide for APP pumps

1. No ow/no pressure

Cause Remedy Comments

1.1 Dry running

(no water supply to the pump)

If no water comes out of the pump:

1.1.1 Check that inlet valve is open.

1.1.2 Check that booster pump is running.

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 reachedminimuminlet pressure (see Data sheet)

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.

WARN ING:

- The pumpmust not run withoutwater

formore than a few seconds.

- If the pump takes in water from the high-

pressure outlet line, it builds up pressure in pump housing and will eventually break down.

Rotation direction for the APP pump is shown by an arrow on the sticker on the side of the pump.

1.3 No rotation of electric motor 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.

If motor-type relay or the electrical fuse is blown, check that electric motor is sized correctly.

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 oce 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

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.

To ensure easymounting of the exible coupling without using tools, the tolerances must be dimensioned accordingly.

WARN ING: Any axial and/or radial loads on the shaft must be avoided. Any axial or radial load will cause breakdown.

A Flexible coupling B Bell housing C Motor shaft

1.6 Pump damage

(the internal parts may be damaged)

1.6.1 Contact Danfoss sales oce for guidelines in how to troubleshoot internal pump parts.

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 16-22 180 R9121/180 R9139 for AP P 21-3 8 – are available on www.ro-solutions.com.

ABC

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Trouble shooting guide for APP pumps

Cause Remedy Comments

2.1 Wear on pump

Large internal leakage due to:

- Pre-treatment

- Main ltration

- Fluid type

- High uid temperature

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

2.1.3 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

2.1.4 Check cylinder barrel. Liners in cylinder barrel may be scratched or worn. Insert a piston in the liner and check the t. If there is any space (clearance) between liner and piston, liner or piston is worn.

2.1.5 Analyse uid for content of particles.

2.1.6 Check that lters are OK and working correctly.

2.1.7 Install correct pre-lter (1μm nom. string-wound lter).

2.1.8 Check that the correct lter type is used (particles in uidmust not exceed 10 μm). Danfoss RO Solutions supply lters. Please contact Danfoss sales oce.

2.1.9 The APP pump is designed for seawater operation; for any other uid, please contact Danfoss sales oce for further help.

2.1.10 If uid temperature is above 50°C, stop

the pump immediately.

2.1.11 Check internal parts (see above).

See instruction on replacement criteria (521B0925). Are available on www.ro-solutions.com

Typical signs of wear:

Polished surface all over the swash plate. Normally, only half of the swash plate = the pressure side is polished. See index 6.3.

If the ring is missing, the piston is very worn.

The lters can be bypassed, even if they are correctly mounted. Some lters can create channelling where particles can pass trough the lter in tunnels. String wound lters are typically channelling lters. A string wound lter may have a ltration eciency of only 50%, which will cause internal wear and must always be followed by a main lter.

Insucient ltration means that too many or too large hard par ticles can pass the main lter because it is damaged, bypassed or simply too poor. Filtration eciency must be 99.98% (Beta = 5000) at 10 μmto prevent abnormal wear of the pump.

Temperature > 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 uid temperatures > 50° C.

2.2 Low inlet pressure 2. 2.1 Check that booster pump supplies the right pressure/ow.

2.2.2 Check if lters require replacement.

If the pressure drop across the lters is too high, the booster pump does not deliver sucient ow/pressure. No pressure or low pressure results in cavitation and insucient internal lubrication causing wear on internal pump parts.

Mount a low-pressure switch before the pump and check its set point/ function. The lowpressure switch ensures that the pump does not start until the inlet pressure has reached 1 bar.

2.3 Rotation speed (RPM) 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.

Speeds below 700 rpm result in insucient internal lubrication causing wear on the internal pump par ts.

2. Reduced ow/reduced pressure

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Trouble shooting guide for APP pumps

Cause Remedy Comments

3.1 Too high outlet pressure from pump 3.1.1 Check uid salinity.

3.1.2 Check temperature.

3.1.3 Check pressure drop across RO membrane.

Pump conditions may change (more salt, lower water temperature or scaling of RO membrane) causing higher pressure, resulting in higher motor torque.

3.2 Pump starts against pressure 3.2.1 Check that electric motor is correctly sized.

3.2.2 Check internal parts (see item 2.1).

3.2.3 Systems with more than one electric motor installed: Start motors simultaneously.

Pumps run in parallel with cascade start, may switch o the motor relay due to too high torque caused by high outlet pressure.

3.3 Constant torque 3.3.1 Please contact Danfoss sales oce. If the electric motor is too small for the APP pump it cannot provide sucient torque.

3.4 Water pump damage 3.4.1 Dismantle pump and check for wear. Too heavy damage in the pump will increase friction causing a high torque (see item 6, Typical signs of wear).

3. High torque on electric motor

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Trouble shooting guide for APP pumps

4. Noise from pump

Cause Remedy Comments

4.1 Air in uid 4.1.1 Ensure that the entire inlet line is bled

before starting up the system.

4.1.2 Ensure that air cannot enter into the inlet line.

Small air bubbles will accumulate and create large bubbles causing internal cavitation and thus making the pump very noisy.

WARN ING: The pump can only run fewminutes with air in the uidwithout being damaged.

4.2 Bleeding conditions of pump 4.2.1 Follow the instructions “Initial start-up”

supplied with the new pump.

4.2.2 Ensure that the pump is completely bled

before start-up.

The pump and the inlet line must be completely bled before start-up, otherwise the pump will cavitate and make high noise.

WARN ING: The pump can only run few minutes with air in the uid without being damaged.

4.3 Min/max nominal inlet pressure 4.3.1 Ensure that inlet pressure is between 1

and 5 bar.

4.3.2 Check the pump for internal damage.

Too high inlet pressure causes too high pressure inside the pump damaging the pistons and eventually the pump.

Inlet pressure below 1 bar causes cavitation and insucient internal lubrication resulting in wear on internal pump parts.

Mount a low-pressure switch before the pump and check its set point/ function. The low-pressure switch will ensure that the pump does not start until the inlet pressure has reached 1 bar.

4.4 Pump reversing 4.4.1 Dismantle pump and check if anything is broken or worn (See “1. No ow”, item 1.2 Pump reversing”).

WARN ING: The pump must not run without water for more than a few seconds. If the pump takes in water from the high- pressure outlet line, it builds up pressure and will eventually be damaged.

If pump rotates in wrong direction, it will take in water fromthe high-pressure outlet line. Pressure will be built up inside the pump and it will eventually be damaged.

4.5 High rotation speed (RPM) 4.5.1 If electric motor RPM is too high, dismantle pump and check for damage.

4.5.2 If the RPM is within the specied range of the pump data sheet and abnormal noise remains, dismantle pump and check for damage.

Higher RPM than specied in the pump data sheet results in wear of the pistons, i.e. pistons may be damaged.

High RPM will also increase pressure pulsations from the pump, and the noise level will increase.

If RPM is changed, noise frequency will also change.

4.6 Outlet pressure 4.6.1 If outlet pressure is too low, check set point of outlet pressure valve.

4.6.2 If outlet pressure is lower than mentioned in the pump data sheet, please contact Danfoss A/S RO Solutions Technical Support.

4.6.3 If outlet pressure has exceeded its maximum, check set point of outlet pressure valve.

4.6.4 Check internal parts for wear/damage.

At too low outlet pressure, the pump will create higher pressure pulsations and thus make noise. Too low pressure also causes insucient internal lubrication and wear on internal parts. Pump may eventually be damaged.

Too high outlet pressure may damage the pump.

4.7 Soft start/stop 4.7.1 Check if noise is normal when the pump is running at operation speed.

4.7.2 If noise is abnormal at operation speed, check internal parts (see above).

Noise frequency changes during soft start-up/ stop.

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Trouble shooting guide for APP pumps

5. Noise from installation

Cause Remedy Comments

5.1 Inlet/outlet connections (hoses/pipes) 5.1.1 Use exible hoses at inlet/outlet connec-

tions. Danfoss A/S can provide exible hoses. Please contact Danfoss sales oce for further information.

5.1.2 Mount the connections to the frame by a vibration damper mounting plate.

Non-exible connectionsmounted directly on the frame will cause even small pressure pulsations from pump and create vibrations in the system/plant.

5.2 Length/dimension of inlet/outlet line 5.2.1 Increase pipe diameter and/or reduce the number of bends.

Too small pipes or too many bends may create too fast ow/turbulence through the pipes and thus increase the noise level.

5.3 Hose stiness 5.3.1 Use amore exible hose. Danfoss A/S can provide exible hoses. Please contact Danfoss sales o ce for further information.

Too sti hoses cannot damp the small pressure pulsations from the pump, and subsequently vibrations occur in the system/plant.

5.4 Hoses/pipes mounted directly on frame 5.4.1 Mount the connections to the frame by a vibration damper mounting plate.

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.

5.5 Vibration damper under the electric motor 5.5.1 Mount a vibration damper below the motor/pump.

When no damper is installed below the electric motor, vibrations from the motor and pump may be transferred to the frame/r est of the system/plant.

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Trouble shooting guide for APP pumps

6. Typical signs of wear

6.1 Valve plate

Picture 1

A normally worn valve plate has no mark s/scratches but only a slightly polished surface.

No scratches or marks should be felt. The surface must be at and level.

Picture 2

Scratches

A worn valve plate has scratches, and/or a polished surface. Even small scratches will give a loss of ow.

Picture 3 A good way to identify a worn valve plate is to hold a straight knife edge

over the valve plate. When holding it up to the light, it will be possible to see any space between the knife edge and the valve plate. See picture 3.

If any light can be seen between the two arrows on the picture, the valve plate is worn.

If any scratches or marks can be felt by running a ngernail over the surface, the valve plate is worn.

The valve plate on picture 3 is highly damaged.

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Instruction Trouble shooting guide for APP pumps

Danfoss A/S

High Pressure Pumps

DK-6430 Nordborg

Denmark

Picture 1

If the port plate has scratches, level dierences or both between the arrows, the port plate must be replaced.

Even small scratches or wear will cause loss of ow.

To check: See item 6.1, picture 3

6.2 Port plate

6.3 Swash plate

Picture 1

If the swash plate is polished 360°, it is an indication of insucient ltration.

The surface of the swash plate must be plane and even at same level all over. To check this, please see item 6.1, picture 3.

If the surface has any marks/scratches it is worn/damaged and a new one is required.

Please contact Danfoss sales oce for further information

Scratches

Level dierences between

dull and shining PEEK

7. Right and wrong (180 R90 42)

MAKING MODERN LIVING POSSIBLE

180R9042

Right and wrong

Trouble shooting guide for water hydraulic systems

Choice of material

Rubber

Plastic

. Stainless steel

Iron

Copper

. Brass . Aluminium

Always use system components made of corrosion proof materials

Non-corrosion proof materials may cause damage

Choice of lter

Install a 10 micron absolute ﬁlter with pressure switch

< 10

mm abs.

> 10

Return ﬁlter with bypass valve and poorer ﬁlterability than 10

m will

damage the system

Filter location

Locate the return ﬁlter in the return line immediately before the tank

Placing the return ﬁlter upstream of the ﬁnal load may damage the pump

Pump location

Pump always to be placed below water surface level

Pump location above water surface level will cause damage

Water supply

System to be ﬁlled via ﬁlter

Filling system with unﬁltered water causes damage

Pressure Relief valve

Pressure relief valve to be mounted vertically or with vertical outlet and connected to return hose or tank

Coupling the pressure relief valve outlet directly to the pump inlet may damage the pump

Suction conditions

System to be dimensioned to provide a suction pressure of the pump inlet of max. 0.1 bar vacuum

Poor suction conditions will cause malfunction and damage the pump

Design

Installation

Impurities

Prior to installation, burrs and chips and other impurities must be removed from pipes and hoses, eg with a felt plug

Chips or other impurities in the system may cause damage

Sealing

Fittings in screwed components to be sealed with O-rings or bonded seals

Using teﬂon tape or packing yarn in joints may cause damage

Grease

10.

Correctly limited quantities of grease prevent seizing

Too much grease may develop bioﬁlm causing operational failures

Water supply

13.

Fill system with water before starting to ensure lubrication and cooling

Starting without water will cause damage

Coupling

12.

Ensure always to have 3 mm distance between coupling ﬂanges

Insuﬃcient distance and/or misalignment between the coupling ﬂanges will damage the pump

= min. 3 mm

0 mm

Assembly of coupling

11.

The coupling must be easy and simple to assemble (see product instruction)

Never use force when assembling the coupling parts, as this will damage the motor/pump

Wiring

Level indicator

14.

Rotation direction

15.

Bleeding

16.

Level and temperature indicators must be ﬁtted. Follow installation instructions

Missing or incorrectly connected level and temperature indicators cause damage

Check pump drive motor rotation direction matches that of the pump prior to installation

Incorrect rotation direction will damage the pump

Bleeding the pump will ensure correct cooling and lubrication

Insuﬃcient bleeding may cause damage (not applicable to Power Packs)

Starting procedure

Observing the starting procedure will ensure problem-free operation

If the system is not cleaned before starting, the ﬁlter will clog

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. Start and bleed the system -without pressure by opening the bypass valve

3. Add the cleaning agent to give 3% agent/water solution

4. Run the system for 60 min. and activate all components as often as possible to ensure eﬀective ﬂushing with the cleaning agent

5. Empty the system of the cleaning agent solution

Flushing procedure

6. Fill cold water through the return ﬁlter and bleed the pump (Power Packs PPH 4 - 6.3 - 10 and 12.5 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

10. Change the return ﬁlter element, ﬁll cold water through the return ﬁlter and bleed the pump during start up

11. The system is now ready for operation

Starting procedure

2-3

days

60 min.

Open ended water systems

Trouble shooting

No water supply

Is the water supply ok?

Is water supplied to the pump?

Is water coming

out of the tap?

Are all taps open?

Is the electric motor of

the pump unit rotating?

Is the water in the tank

very hot? Ie above 50

Lower inlet

temperature or provide better cooling

Is the control light

for “low pump suction pressure” on?

The ﬁlter is clogging

Is the power supply ok?

Are control lights on?

Is the ﬁlter clogged?

Is the ﬁlter control

light on?

Is water coming

through the ﬁlter?

Replace ﬁlter element

Turn on the tap for

water supply

Replace ﬁlter element

A blown fuse / or short

circuit?

. Check power supply

and fuses and contact electrician

Contact serviceman

Stamp

Yes

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Trouble shooting

Closed water systems

The system

does not work

Is there suﬃcient water

in the tank?

Yes

Is the water in the tank

very hot? Ie above 50

Is the power supply ok?

Are control lights on?

Is the ﬁlter clogged?

Is the ﬁlter control

light on?

Replace ﬁlter element

Contact serviceman

Stamp

Fill water into the system

Trace leakage, if any

A blown fuse/or short

circuit?

. Check power supply

and fuses and contact electrician

At temperatures

higher than 50o the pump drive cuts out. Consequently the cooler must be checked/cleaned

Is the electric motor of

the pump unit rotating?

User manual Appendices for IOM Manual for APP Pumps (APP 16-22)

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

Contact information Danfoss A/S

180R9265 / IOM APP 16-22 Append ices - v02 / 01.2013

User manual Appendices for IOM Manual for APP Pumps (APP 16-22)

Lenntech

LQIR#OHQQWHFKFRP Tel. +31-152-610-900 ZZZOHQQWHFKFRP Fax. +31-152-616-289

Lenntech

Danfoss APP series, APP 16/1200, APP 19/1500, APP 19/1200, APP 21/1200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual