Instruction
Instruction
APP pump instruction
APP pumps
APP 21–46
APP 21-43
hpp.danfoss.com
ro-solutions.com
Instruction | APP 21-46 pumps
Table of Contents
Table of Contents
1. Identication ...........................................................................2
2. System design ..........................................................................3
2.1 Open-ended systems with direct water supply...........................................3
2.2 Preferred RO system design and P&ID ...................................................3
2.3 Reversible pumps .......................................................................4
2.4 General comments......................................................................4
3. Building up the pump unit ..............................................................4
3.1 Mounting...............................................................................4
3.2 Direction of rotation ....................................................................5
3.3 Orientation .............................................................................5
3.4 Protection from too high pressures ......................................................5
3.5 Grounding ..............................................................................5
3.6 Connections ............................................................................6
4. Initial start-up ...........................................................................7
5. Operation...............................................................................7
5.1 Temperature............................................................................7
5.2 Pressure ................................................................................8
5.3 Dry running.............................................................................8
5.4 Disconnection ..........................................................................8
5.5 Storage .................................................................................8
6. Service..................................................................................8
6.1 Warranty................................................................................8
6.2 Maintenance............................................................................8
6.3 Repair ..................................................................................8
1. Identication
PUMP
Type APP 38
Code no. 180BXXXX
Serial no. XXXXXXXX-XXX
MADE IN DENMARK
Danfoss A/S, 6430 Nordborg, Denmark
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Instruction | APP 21-46 pumps
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 directly from a
feed pump.
The inlet pressure for APP 21-38 must be at least
2 barg (29 psig) and 3.5 barg (50.8 psig) for the
APP 46, depending on speed. It must not exceed
5 barg (72.5 psig) continuous.
To protect the pump from being damaged by
peaks of high-pressure in case the pump stops
momentarily, it is required to mount a lowpressure relief valve on the inlet line.
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 Danfoss lter data
sheet 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.
Inlet
Outlet
It is recommend to install safety valve or a
pressure relief valve (9) in order to avoid
high-pressure peaks in case the pump stops
momentarilly or is spinning backwards.
6. For easy system bleeding and ushing, a
bypass non-return valve (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 startup, regardless of any counter pressure.
Note: If a non-return valve is mounted in the
inlet line, a low-pressure relief valve is also
required between non-return valve and pump
as protection against high-pressure peaks.
Media filter
PI
Feed
180R9405 | AN274337709031en-000302 | 11.2019
1
PI
1
PI PI
Fresh water
permeat flush
9 3
5
M
PT
2
7
4
6
PI
Brine
Permeate
PI
3
Instruction | APP 21-46 pumps
3-5 mm
[0.12-0.20 inch]
2.3 Reversible pumps
If exposed to high-pressure in the outlet while
the electric motor is not energized, the pumps
will start spinning backwards. This will not harm
the pumps as long as the pressure in the inlet
does not exceed the max. pressure peak of
10 barg(145 psig).
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 barg (145 psig), when a nonreturn valve is mounted in the inlet.
In order to avoid the risk of cavitation, the
inlet pressure for APP 21-38 must be min.
2 barg (29 psig) and 3.5 barg (50.8 psig) for
APP 46, depending on speed. The inlet line
connection must be properly tightened, as
possible entrance of air will cause cavitation.
2.4 General comments
Filtration
A good ltration is vital to ensure a long and
trouble-free life of the pump.
As water has very low viscosity, the APP pumps
have been designed with very narrow clearance
in order to control internal leakage rates and
improve component performance. Therefore it is
important that the inlet water is ltered properly
to minimize the wear of the pump.
The main lter must have a ltration eciency of
99.98% at 10 μm. We recommend to use
precision depth lter cartridges rated 10 μm abs.
β10 ≥ 5000 (equivalent to a ltration eciency of
99.98%). Bag lters and string wounded lter
cartridges typically have only 50% ltration
eciency. 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 eciency 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
denitions and a guidance on how to select the
right lter.
Monitoring
It is recommended to continuously monitor the
following conditions:
• Filter clogging
• Pressure (inlet- and outlet side of the
pump)
3. Building up the
pump unit
D
A: Elastic coupling
B: Bell housing
C: Motor shaft
D: Pump ange
3.1 Mounting
1. Mount the coupling ush or maximum
1 mm oset from the pump shaft end.
Ensure an air gap between coupling parts
of 3-5 mm (0.12-0.2 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”.
(“A” and “B” can be found on the next
page).
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Instruction | APP 21-46 pumps
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.
1: Bolts: torque 100 Nm ±10 Nm
2: Nuts: torque 40 Nm ±4 Nm
3: Torque see table below
1
3
2
2
C
1
If alternative mounting is desired, please contact
Danfoss High Pressure Pumps.
Choose proper tolerances to ensure an easy
mounting of the elastic coupling without use of
tools.
Please take care to observe the recommended
length tolerances of the chosen coupling, as an
axial force on the pump will damage the pump.
(“C” can be found on the drawing below).
Thread
size
Torque
(Nm)
3.2 Direction of rotation
Is indicated by an arrow on the pump label.
PUMP
Type APP 38
Code no. 180BXXXX
Serial no. XXXXXXXX-XXX
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.
3.4 Protection from too high pressures
The pump should be protected against too high
pressure by means of a safety valve or a pressure
relief valve.
MADE IN DENMARK
Danfoss A/S, 6430 Nordborg, Denmark
M5 M6 M8 M10
2 4.8 10 17
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 100 barg
(1450 psig).
We recommend the use of exible soft hoses
both in the inlet and in the outlet lines.
3.5 Grounding
To prevent stray current corrosion we recommend grounding of the pump and all other parts
in the system. All parts in the system must be
electrical potential equalized to a single
reference point (grounding point). It is recommended that the electrical resistance in the
grounding cable is equal to or below 0.25 Ω
toards the grounding point.
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Instruction | APP 21-46 pumps
The valve outlet must not be connected directly to the pump suction line.
It must be connected directly to the drain.
Inlet
3.6 Connections
I: Inlet
O: Outlet
C: Bleeding
D: Parallel key
Outlet
Inlet
Outlet
C
I
O
C
C
D
Description APP 21 - APP 46
E Parallel key,
DIN 6885
F Bleeding G ¼”, Hexagon AF = 6 mm
I Inlet port M60 x 1.5; depth 24 mm
O Outlet port M60 x 1.5; depth 24 mm
Mounting ange ISO 3019-2 180B4TW
mm 12 × 8 × 70
in 0.47 × 0.31 × 2.76
For more details on the accessories,
please contact Danfoss High Pressure Pumps.
Possible extension see next page.
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C
Accessories Typ e Code no.
3” inlet hose kit 3” Victaulic 180Z0144 2.00 m [79”]
2” outlet hose kit
APP 21-38
2½” outlet hose kit
APP 46
2½” inlet connector
APP 21-24
3” inlet connector
APP 21-46
Non-return valve (outlet) Super Duplex
APP 21-46
2½” Victaulic 180Z0263 1.78 m [70”]
2½”Victaulic 180Z0618 1.00 m [39.4”]
2½” Victaulic 180B3206
3” Victaulic 180B3208
2½” Victaulic
(OD 73 mm)
180Z0280 1.00 m [39.4”]
180Z0619 1.78 m [70”]
180H0055
Instruction | APP 21-46 pumps
4. Initial start-up
5. Operation 5.1 Temperature
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 3.5)
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.
O
I
Internal
ushing
valve
Fluid temperature:
Min. +2°C to max. +50°C
(Min. +35.6°F to max. +122°F)
Ambient temperature:
Min. +2°C to max. +50°C
(Min. +35.6°F to max. +122°F)
In case of lower operating temperatures, please
contact Danfoss High Pressure Pumps.
NaCl vs. temperature
º
80
C
Duplex
70
60
50
316L
40
30
The chart below illustrates the corrosive
resistance of dierent 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 minimize the
risk of crevice corrosion.
Super Duplex
20
100
1000
160 1600
180R9405 | AN274337709031en-000302 | 11.2019
10 000
16000
100 000
160000
CI
ppm
NaCI
ppm
-
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Instruction | APP 21-46 pumps
5.2 Pressure
The inlet pressure for APP 21-46 must be min.
2 barg (30 psig) and max. 5 barg (72.5 psig). 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 barg (145 psig) are
acceptable.
Max. pressure on the pump’s outlet line should
be limited at 80 barg (1160 psig) continuously,
70 barg for APP 46.
Note: 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
procedure described under section 4: Initial
start up.
5.5 Storage
monopropylene glycol to prevent internal
corrosion or frost in the pump.
For further information on anti-freeze media,
please contact Danfoss High Pressure Pumps.
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 antifreeze 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.
Storage:
Storage of pump that have been in operation:
For shorter periods of storage ush the pump
with permeate rotating the pump for 10 sec.,
empty permeate and store.
For long term storage (more than 2 months)
Danfoss recommends servicing the product and
clean any biological growth of the surface. Store
the pump dry without water inside.
6. Service
Storage temperature:
Min. -40°C to max. +70°C
(Min. -40°F to max. +158°F)
When preparing the pump for long-term storage
or for temperatures below the freezing point,
ush the pump with an anti-freeze medium type
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 specications, 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
inuence 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.
Standstill:
The APP pumps are made of Duplex/Super
Duplex materials with excellent corrosion
properties. It is however, always recommended
to ush the pump with fresh water when the
system is shut down.
When stopping the pump for more than 1 day
ush the pump with permeate by rotating the
pump for 10 sec. Flushing through the ushing
valve of the pump without rotating the pump is
not enough for cleaning the inside of the pump.
The pump can be ushed with biocide like the
membranes. The biocide must be compatible
with the materials used in our pump (materials
can be found in the parts list in the Operating
guide.
6.3 Repair
In case of irregular function of the APP, please
contact Danfoss High Pressure Pumps sales
organisation.
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180R9405 | AN274337709031en-000302 | 11.2019
Instruction | APP 21-46 pumps
180R9405 | AN274337709031en-000302 | 11.2019
9
Danfoss A/S
High Pressure Pumps
Nordborgvej 81
DK-6430 Nordborg
Denmark
© Danfoss | DCS (im) | 2019.11
180R9405 | AN274337709031en-000302 | 10
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