Danfoss APP series, APP 16/1200, APP 19/1500, APP 19/1200, APP 21/1200 User Manual
...
APP 16-22
User manual
Installation, Operation and
Maintenance Manual
APP pumps (APP 16-22)
MAKING MODERN LIVING POSSIBLE
Lenntech
LQIR#OHQQWHFKFRP Tel. +31-152-610-900
ZZZOHQQWHFKFRP Fax. +31-152-616-289
LQIR#OHQQWHFKFRP Tel. +31-152-610-900
ZZZOHQQWHFKFRP Fax. +31-152-616-289
Lenntech
User manual Installation, Operation and Maintenance APP Pumps (APP 16-22)
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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 dierent 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
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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)
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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
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EU Declaration of Conform-
ity
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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
specied 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:
tTransportation of the motor pump unit
tLifting the unit
tInstalling the pump unit
t
Connecting the motor pump unit to the
water system
t
Connecting the electric motor and instrumentation
tCommissioning the unit
t
Servicing the motor pump unit, mechanic
and electric parts
tDecommissioning 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 ocer 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 specications
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
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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:
tDeath or fatal injuries
tCostly 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 veried 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 specic 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
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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
specied 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 dierent 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
sucient 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 reect the
required safety requirements.
3.7 Filtration
(10µm absolute [ß10 =5000])
Requirements are specied in Data sheet,
appendix 1 and APP pump instruction, appendix
2.
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 dierential/delta pressure across
the lter.
Using insucient 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.
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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
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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 specic
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
dierent 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
2.
The pumps are NOT delivered frost protected
from the factory.
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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
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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 dierent 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.
tPrevent 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 specied.
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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
tClose all the bleeding and draining plugs.
tOpen the pressure valve at the brine site.
t Switch the safety circuit breaker on for both
motor(s) and VFD(s).
tStart the feed pump.
tStart 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 specied 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 oers commissioning and service at
system manufacturer’s location. Rate quotes are
oered upon request.
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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 specied 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 oers service of the pump at the system
manufacturer’s location as well as training in
servicing the pump. Quotes are oered 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
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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 oers service of the pump at the system
manufacturer’s location and training in servicing
the pump. Quotes are oered 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 dierent 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
4.
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)
16
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)
17
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 :
t5IFQVNQJTSVOOJOHESZ
t5IFJOMFUQSFTTVSFJTUPPIJHI
t5IFJOMFUQSFTTVSFJTUPPMPX
t5IFWJTDPTJUZPGUIFøVJEJTUPPIJHI
t5IFUFNQFSBUVSFPGUIFøVJECFJOH
pumped is too high.
t5IFBNCJFOUUFNQFSBUVSFJTUPPIJHI
t5IFQVNQJTSVOOJOHBHBJOTUBCMPDLFE
port/closed manual valve.
t5IFQVNQJTPQFSBUJOHBUBQSFTTVSFBCPWF
the operational specication.
t5IFQVNQJTSVOOJOHXJUIBOPOTQFDJöFE
approved uid.
t5IFQVNQJTSVOOJOHJOUIFXSPOH
direction.
t5IFöMUSBUJPOJTJOTVóDJFOU
t5IFQVNQJTOPUCFJOHTFSWJDFEBDDPSEJOH
to Danfoss specications (end of life).
t5IFSFJTFYDFTTJWFNFDIBOJDBMMPBEPOUIF
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)
18
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
A
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
B
Bleed
. . . . . . . . . . . . . . . . . . . 7, 8, 13, 15
C
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
D
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
E
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
F
Fail ure
. . . . . . . . . . . . . . . . . . . . . .8, 17
Filter condition . . . . . . . . . . . . . . . . . . 13
Filtration . . . . . . . . . . . . . . . . . . 8, 12, 17
Flow
. . . . . . . . . . . . . . . . . . . 7, 8, 13, 14
Fluid
. . . . . . . . . . . . . . . . . . .11, 12, 15, 17
Flush
. . . . . . . . . . . . . . . . . . . . . . 11, 13
G
General information
. . . . . . . . . . . . . . . 7
Guideline . . . . . . . . . . . . . . . . . . . . . 17
H
Handling. . . . . . . . . . . . . . . 7, 9, 12, 15, 16
I
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
M
Maintenance
. . . . . . . . . .6, 7, 10, 13, 14, 15
Mechanical failure. . . . . . . . . . . . . . . . 17
Mounting
. . . . . . . . . . . . . . . . . . . . . 16
N
Name plate
. . . . . . . . . . . . . . 9, 11, 12, 13
Noise
. . . . . . . . . . . . . . . . . . . . . . . . 14
L
Leaking. . . . . . . . . . . . . . . . . . . . . . . 17
Lifting
. . . . . . . . . . . . . 6, 9, 10, 12, 15, 16
Local regulations . . . . . . . . . 6, 7, 11, 12, 17
O
Operation
. . . . . . . . .6, 7, 8, 9, 13, 14, 16, 17
Operational conditions . . . . . . . . . . .7, 17
P
Piping. . . . . . . . . . . . . . . . . . 8, 11, 12, 17
Positioning
. . . . . . . . . . . . . . . . . . . . 12
Preferred system design
. . . . . . . . . . . 7, 11
Pre mounting . . . . . . . . . . . . . . . . . . . 11
Protection . . . . . . . . . . . . . . . . . . 6, 7, 10
R
Relief valve
. . . . . . . . . . . . . . . .12, 13, 14
Responsibility . . . . . . . . . . . . . . . 6, 7, 17
Return
. . . . . . . . . . . . . . . . . . . . . 10, 15
Rotation
. . . . . . . . . . . . . . . . . . . . . . 13
S
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
T
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
V
Valve
. . . . . . . . . . . . 7, 11, 12, 13, 14, 15, 17
W
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)
2
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
Data sheet
APP 16-22
MAKING MODERN LIVING POSSIBLE
4
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. Benets
3. Technical data
4. Variants
5. Flow at dierent 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
5
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 insignicant pulsations in the
pressure line.
tNo oil lubricant required
tIntegrated 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
tHigh eciency
2. Benets
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
1)
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
2)
bar 30 30 30 30 30 30 30 30
psi 435 435 435 435 435 435 435 435
Outlet max. Pressure,
continuous
3)
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
1)
Typical average ow at 60 bar (870 psi)
2)
For lower pressure, please contact Danfoss
RO Sales Organization
3)
For higher pressure, please contact Danfoss
RO Sales Organization
The pump is designed according to EN809.
All parts included in the pumps are designed to
provide long service life, i.e. long service life with
a constantly high eciency 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.
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