Danfoss APP 53, APP 65, APP 78, APP 86, APP 92 Operating guide

Operation guide

APP pumps APP 53 / APP 65 / APP 78 / APP 86 / APP 92

Installation, Operation and Maintenance Manual

hpp.danfoss.com

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Table of Contents Contents

Table of Contents ..................................................................................2

Validity .........................................................................................4

1. Introduction ............................................................................5

1.1 General.................................................................................5

1.2 Symbols ................................................................................5

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

1.4 Country speciﬁc information ............................................................6

1.4.1 United Kingdom ........................................................................6

2. Safety ..................................................................................6

2.1 General information.....................................................................6

2.2 Preferred system design.................................................................6

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

3.1 Approved applications and operational limits for the pumps .............................7

3.2 Application range .......................................................................7

3.3 Electric motor data......................................................................7

3.4 VFD and Direct on line ..................................................................7

3.5 Noise and vibration .....................................................................7

3.6 Dimension drawings ....................................................................7

3.7 Space requirement......................................................................8

3.8 Filtration................................................................................8

3.9 Properties of water ......................................................................8

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

3.11 Chemicals...............................................................................8

4. Arrival inspection, transportation, handling, lifting and storage ..........................8

4.1 Arrival inspection .......................................................................8

4.2 Warning ................................................................................8

4.3 General safety information ..............................................................8

4.4 Transport and handling .................................................................8

4.5 Return to supplier .......................................................................9

4.6 Storage .................................................................................9

5. Installation and commissioning.........................................................10

5.1 Important dimensions .................................................................10

5.2 Cleanliness.............................................................................10

5.3 Fluid temperature......................................................................10

5.4 Electrical data..........................................................................10

5.5 Local regulations.......................................................................10

5.6 Pre mounting checklist, based on Danfoss preferred system design .....................11

5.7 Lifting and positioning.................................................................11

5.8 Mount the diﬀerent equipment ........................................................11

5.9 Electrics ...............................................................................11

5.10 Instrumentation .......................................................................11

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

5.12 Ensure free ﬂow .......................................................................12

5.13 Verify setting of safety/relief valves .....................................................12

5.14 Flush the pump ........................................................................12

5.15 Bleed and remove air from the pump...................................................12

5.16 Verify direction of rotation .............................................................12

5.17 Commissioning ........................................................................12

5.18 Check the ﬁlter condition...............................................................12

5.19 Instruct operator and maintenance personnel ..........................................12

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

6. Operation of pump unit ...............................................................13

6.1 General safety information.............................................................13

6.2 What to listen and look for .............................................................13

7. Maintenance and service of the pump unit .............................................13

7.1 General safety information .............................................................13

7.2 Service and inspection interval for the pump ...........................................13

7.3 Shut down of the system ...............................................................13

7.4 Disassembling and assembling the pump unit ..........................................14

7.5 Assembling the pump unit .............................................................14

7.6 Procedure for mounting the pump onto the electric motor..............................14

7.7 Getting the pump unit back into operation .............................................14

7.8 Storage of the pump ...................................................................14

8. Troubleshooting and scrapping criteria .................................................15

8.1 General safety information .............................................................15

8.2 Operational conditions which can cause pump failures..................................15

8.3 Mechanical failure......................................................................15

8.4 Electrical failure........................................................................15

8.5 Responsibility..........................................................................15

8.6 Scrapping criteria ......................................................................15

Appendices .......................................................................................17

1. Data sheet for APP pumps 53-92 AI167386503010en-001301) ...................

2. Instruction for APP pumps 53-92 (180R9368) ............................................43

3. Electric motors (180R9230) ..............................................................55

4. Bowex coupling manual .................................................................61

5. Recommended service intervals (AX281930801330en-000401) ..........................85

6. Parts list (AX191786502906en-001101) ...................................................89

7. Trouble shooting (521B1447) ...........................................................101

8. Right and wrong (180R9042) ..........................................................113

........19

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 3

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Validity

This manual is valid for APP pumps with the following type an serial number or higher:

Typ e Serial no.

APP 53 XXXXXX08-XXX

APP 65 XXXXXX08-XXX

APP 78 XXXXXX08-XXX

APP 86 XXXXXX08-XXX

APP 92 XXXXXX08-XXX

PUMP

Type APP 78 Code no. 180BXXXX

Serial no. XXXXXX08-XXX

MADE IN DENMARK

Danfoss A/S, 6430 Nordborg, Denmark

The serial number is referring to the Serial no. on the product label. The digits shown (08) indicate the version number of the pump.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

1. Introduction

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.

• If any changes are made without written approval the warranty will automatically become void.

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

In case the pump delivered is ATEX certiﬁed, the additional ATEX instruction must also be read.

The APP pumps must not be used for other purposes than those recommended and speciﬁed without ﬁrst consulting your local pump distributor.

Use of the pump in other applications that are 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:

It is important that these instructions are always available to the 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 highvoltage warning

Safety glasses required

• Transportation of the pump unit

• Lifting the unit

• Installing the pump unit

• Connecting the pump unit to the water system

• Connecting the electric motor and instrumentation

• Commissioning the unit

• Servicing the pump unit, mechanical and electrical parts

• Decommissioning the 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 oﬃcer or the chief operator to assure compliance with all local regulations that are not taken into account in this manual.

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

• Changes to the delivered pump or motor pump unit may only be done with a written approval from Danfoss High Pressure Pumps.

• Operation outside the Danfoss speciﬁcations requires a written approval from Danfoss High Pressure Pumps.

Hearing protection required

Safety shoes required

Safety helmet required

Protective garments must be wor n

Protective garments must be worn

Danger HOT. Do not touch

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Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

2. Safety

1.3 Manufacturer and customer service address

Danfoss A/S

Danfoss High Pressure Pumps

RO Solutions

Nordborgvej 81, DK-6430 Nordborg Denmark

Telephone: +45 7488 4024 Fax: +45 7445 3831 Email: highpressurepumpss@danfoss.com Homepage: hpp.danfoss.com

2.1 General information

Dangers that can arise from not following the instructions:

When the pump or pump unit is managed by untrained personnel, there is a danger of:

• Death or fatal injuries

• Costly damages and claims

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

Data sheets and instructions on all accessories are available on hpp.danfoss.com

1.4 Country speciﬁc information

1.4.1 United Kingdom

UK importer:

Danfoss Ltd. 22 Wycombe End HP9 1NB Beaconsﬁeld United Kingdom

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 a VFD.

VFD operation may increase the temperature inside the electric motor if the motor is not designed for VFD operation. This can damage the motor and cause unintended breakdown.

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

It is recommended to install a lockable circuit breaker to avoid inadvertent starting and/or electrical hazard. The lockable circuit breaker must be used during installation, operation and maintenance.

It is recommended to place a local safety switch nearby the pump, enabling service personnel to cut power for the electric motor.

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

In case the pump delivered is ATEX certiﬁed, the additional ATEX instruction must also be read.

Protective garments

must be wor n

Always wear suitable safety clothing when handling the pump.

When working near the pump system, safety shoes, safety glasses, hearing protection and safety helmet must always be worn.

Danger

Installation and maintenance must always take place during complete shutdown in an unpressurised condition. The drive unit must be secured against switching-on (with signs, switching oﬀ electricity power supply) in order to avoid serious injuries due to rotating parts. Do not reach inside the working area during the operation of the coupling. For protection against accidental contact appropriate security must be installed.

Before start-up, the settings for all protective devices, such as sensors/switches and safety valves must be veriﬁed and free ﬂow from safety valves must be ensured.

All pipe and hose connections must be stressfree mounted, securely fastened to the pump and well supported. Improper installation will or can 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 good judgment when operating and maintaining the pump and its components.

inadvertent

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.

2.2 Preferred system design

Danfoss recommends to build systems with a high degree of safety. Danfoss preferred system design and P&ID are found in appendix 1, Data sheet, and appendix 2, Instruction.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

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

Proper installation, proper start up and shutdown devices as well as high-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.

• Do not try to lift the pump unit manually; most of the pumps weigh more than 20 kilos, see speciﬁc weight for the pump in the appendix 1, Data sheet.

• Always bleed the pump prior to initial start-up.

• Do not mount the pump without the bell housing and a ﬂexible coupling.

• Do not try to start the unit before the system components are mounted, bleeded and adjusted.

• Flush the system throughly before connecting the pump or pump unit.

• Check rotation direction of the motor before mounting the pump.

3. Technical data

2.4 Adhere to the following important points

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

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 speciﬁed without ﬁrst 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.

2.5 In case of doubt

Please contact Danfoss A/S in case of doubt. Contact information is listed in section 1.3, Manufacturer and customer service address.

3.2 Application range

The Danfoss range of APP high-pressure pumps is designed according to EN 809 for use in RO applications with low viscosity and corrosive ﬂuids such as sea water.

3.3 Electric motor data

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

3.4 VFD and Direct on line

Danfoss APP pumps can be used with VFD and direct on line. Torque limits can be found in the table below:

Nm APP 53APP 65APP 78APP 86APP

MAWT 878 1,118 1,257 1,112 1,112

MAST 1,700 1,70 0 1,70 0 1,70 0 1,70 0

MAWT: Maximum allowable working torque MAST: Maximum allowable starting torque

3.5 Noise and vibration

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

For system integration of the pump, please see appendix 1, Data sheet and appendix 2, Instruction.

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3.6 Dimension drawings

Dimensions of the diﬀerent pumps can be found in appendix 1, Data sheet.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

3.7 Space requirement

When doing service or replacing the complete pump unit, it is recommended to have suﬃcient space available around the pump in order to ensure easy access. Suﬃcient space means at least 1 meter/40 inches around the pump. When working with high pressures, it is important to have the right space available around the pump as stated in the safety requirements.

3.8 Filtration

(10µm absolute [ß Requirements are speciﬁed in appendix 1, Data

≥ 5000])

sheet and in appendix 2, Instruction.

Danfoss recommends not to build a ﬁlter bypass function or to use ﬁlters 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 ﬁlter via the diﬀerential/delta pressure across the ﬁlter.

Using insuﬃcient ﬁltration or a ﬁlter bypass can cause a failure or decreased service life of the pump.

3.9 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.

3.10 Air bubbles

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

All air must be bleeded from both the lowpressure and high-pressure side before the RO system is pressurised. Special consideration should be given in order to minimize air bubbles in the feed ﬂow. Air bubbles can cause cavitation.

3.11 Chemicals

The pump should not be exposed to any chemicals as it can result in damage to piping, equipment and internal parts in the pump.

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

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.

When the shipment has arrived it is important to check the pump for any damages. The name plate/type designation must be in accordance with the delivery note and your order.

In case of damage and/or missing parts, a report should be documented 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 in safety procedures for 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 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.

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

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Pumps which have a weight above 20 kilos must be handled by using lifting eyes and slings.

Wrong lifting:

When the pump is mounted together with a bell housing, the pump can be rotated and in that case the lifting eye cannot be used in all positions. When lifting a pump with bell housing, a sling can be used to lift the pump by positioning it on the drive end of the pump outlet.

When the pump is mounted together with an electric motor, it must not be lifted in the lifting eye. A pump unit with motor must be handled by using two slings around the pump unit. One sling must be attached to the electric motor and one sling around the pump. Make sure that the unit/load is balanced before lifting. The centre of the mass varies from pump/ pump unit size to pump(pump unit).

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

Correct lifting with 2 separate slings:

Some motors and pumps have speciﬁc lifting eyes.

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

Make sure that the unit/load is balanced before lifting. The centre of the mass varies from pump/ pump unit size to pump/pump unit.

How to mount the pump and the electric motor correctly, see appendix 1, Data sheet or appendix 2, Instruction.

Incorrect lifting can result in personal injury and/or damage to the pump unit, see appendix 2, Instruction.

Once the lifting is done the lifting eye must be removed from the pump.

4.5 Return to supplier

Please see maintenance chapter 7.

4.6 Storage

Each pump is tested before shipment, and will therefore contain water. For storage temperature and frost protection see appendix 2, Instruction.

The pumps are NOT delivered frost protected from the factory.

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Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

5. Installation and commissioning

5.1 Important dimensions

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

5.4 Electrical data

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

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. In worst case the pump can be damaged beyond repair!

5.3 Fluid temperature

Before start-up, the ﬂuid and pump housing temperature must be within the speciﬁed temperature range listed see appendix 1, Data sheet.

Schematic 1: Recommended system design

Media filter

Feed

PI PI

5.5 Local regulations

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

Permeate

Fresh water

permeat flush

Brine

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

5.6 Pre mounting checklist, based on Danfoss preferred system design

Table 1: Check points when assembling and commissioning system

Check points Comment OK ?

Ensure that the environmental conditions are safe. See Arrival inspection,

CP1

Minimum and maximum start-up temperature for ﬂuid and

CP2

pump.

Filtration condition (10 µm absolute (ß

CP3

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

CP4

Safety circuit / breaker must be sized for the motor and

CP5

environment (corrosion and humidity)

Bolts and screws must conform to environmental conditions

CP6

as well as ﬂuid and torque requirements.

Instrumentation, pressure switch should be designed to

CP7

conform to the environment (corrosion and humidity).

Check the factory settings of the safety/relief valves or

CP8

pressure relief valves (page 11).

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

CP9

at min. inlet pressure (page 11).

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

CP10

to measure the system pressure range (page 11).

Check that the coupling is installed according to manufac-

CP 11

turers instruction

Ensure all pipings have been ﬂushed and are correct installed

CP12

Check piping for possible air gaps.

CP13

transportation, handling, lifting and storage, chapter 4.

See Data sheet or Instruction, appendices 1 and 2.

≥ 5000) See Danfoss requirements in

Data sheet and Instruction, appendices 1 and 2

motor and VFD.

See Data sheet for the used safety circuit.

See Data sheet for the used equipment.

See Data sheets for the used valves.

See Data sheet or Instruction, appendices 1 and 2.

Scaling should at least be 1 bar or more precise.

5.7 Lifting and positioning

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

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

5.8 Mount the diﬀerent equipment

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

• The hard piping and ﬂexible hoses used, must be of proper design and must be installed in accordance with the manufacturer’s recommendations. (see also Design guides 180R9084 and 180R9367 - both available on hpp.danfoss.com).

• Misalignment of the hard pipes may give unintended stress on the pump port connections and may damage the pump.

• Prevent excessive external pipe load.

• Do not connect piping by applying external force (use of wrenches, crane, etc.) Piping must be aligned without residual stress.

• 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)

Turn oﬀ the safety circuit breaker and lock it.

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 the 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.

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Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

5.11 Connections

Mount and tighten connections and check valve(s) as speciﬁed. Danfoss check valve VCM 92 comes with a ﬂange connection that is easily mounted directly on the outlet port (outlet connection is not required). Note: Bolts (ref. 11) must be tightened with torque 95Nm ± 9.5 Nm. Use only Style 77DX coupling or equivalent for the 3” victaulic OSG outlet on the VCM 92.

95 Nm ± 9.5 Nm

5.12 Ensure free ﬂow

Ensure free ﬂow from the safety/relief valves 8 and 9 (schematic1, page 10). 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 within speciﬁcations, you can continue.

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

When the motor is turning in the right direction, the pump can be mounted.

5.17 Commissioning

• Close all the bleeding and draining plugs.

• Open the pressure valve at the brine site.

• Switch the safety circuit breaker on for both motor(s) and VFD(s).

• Start the feed pump.

• Start the high-pressure pump.

• If a VFD or a soft starter is used, a ramp up time of minimum 10 seconds is required to avoid damage of the pump.

• Monitor the inlet and outlet pressure of the high-pressure pump and look for leakages.

• Check the function of the pressure indicators by slowly closing the valves. The pump unit should stop when the minimum inlet pressure and maximum outlet pressure has been reached.

• Adjust the pressures to the speciﬁed inlet and outlet pressure for the system and let the pump unit run until the electric motor and pump temperature is stable.

• If the system is running within the system design limits, the system is released for operation.

5.14 Flush the pump

Fully open the pressure valve at the brine outlet.

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

Start the feed pump and ensure free ﬂow to the high-pressure pump.

5.15 Bleed and remove air from the pump

Open the bleeding plugs. Keep the plugs open until the high-pressure pump is bleeded.

5.16 Verify direction of rotation

The direction of rotation must always follow the arrow. The arrow is placed on the pump or pump unit.

Check the direction of rotation before mounting the pump.

5.18 Check the ﬁlter condition

Evaluate contamination found in ﬁlter, replace ﬁlter 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 oﬀers commissioning and service at system manufacturer’s location. Rate quotes are oﬀered upon request.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

6. Operation of pump unit

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 one or more of the following examples are observed, please act as indicated:

A) Loose bolts – check all bolts and, if

necessary, contact the maintenance department in order to have all bolts tightened to the speciﬁed torque(s).

B) Leakage – if a small leakage from the bell

housing is observed. Contact the maintenance department.

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

should be stopped immediately. Contact the maintenance department.

D) High frequency tones – safety/relief valves

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

E) Increased noise or vibration – requires the

unit to be stopped immediately. Contact the maintenance department.

F) Very high temperatures – may indicate that

one or more parts are damaged inside the pump. The pump must be stopped immediately and inspected before it is restarted. Contact the maintenance department.

G) Drop in ﬂow and/or pressure – may indicate

wear on one or more parts inside the pump. The pump must be stopped immediately and inspected before it is restarted. Contact the maintenance department.

H) Other observations or troubles, please see

appendix 7, Right and Wrong or appendix 6, the Trouble shooting guide. Both appendices give good advises regarding design, installation, wiring and troubleshooting. See also service and warranty section in appendix 1, Data sheet and appendix 2, Instruction.

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

Danfoss oﬀers service of the pump at the system manufacturer’s location as well as we oﬀer training in how to service the pump. Quotes are oﬀered upon request.

Danfoss recommends simultaneously to check the ﬁlter and membrane condition and to evaluate contamination; ﬁlter and membrane elements must be replaced if necessary.

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

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

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

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 13

Danfoss oﬀers service of the pump at the system manufacturer’s location and training in how to service the pump. Quotes are oﬀered upon request.

7.3 Shut down of the system

A) Stop the high-pressure pump.

B) Open the pressure valves at the brine site

to release the pressure.

C) Stop the feed pump.

D) Switch oﬀ the safety circuit breaker for

both the high-pressure pump, feed pump and VFD and lock them. Only personnel 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.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

F) Make sure the system is not pressuized! Slowly unscrew and remove the bolts and

gaskets from the inlet/outlet hoses or pipes, be careful about jets of water. Beware that the system can be pressurized!

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. For the bigger pumps, unscrew the bolts/nuts from the pump and bell housing to the motor. Afterwards unscrew the bolts/nuts holding the pump and bell housing.

I) Carefully pull the pump out of the bell

housing by using lifting equipment, if necessar y.

J) Hold the pump in diﬀerent positions above

a drip tray; this should allow most of the water trapped in the pump to drain. 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.

Returns without a return number will be

rejected !!!

7.5 Assembling the pump unit

Assemble the pump according to the Disassembling and Assembling Instruction (available at hpp.danfoss.com).

7.6 Procedure for mounting the pump onto the electric motor

Mount the ﬂexible coupling and bell housing according to appendix 2, Instruction.

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.

B) Disassemble the pump according to the

Disassembling and Assembling Instruction (available at hpp.danfoss.com)

Clean all parts and surfaces with a ﬂuid

compatible with the materials found in the pump. Wipe the parts clean and dry with a lint-free clothing.

C) Inspect all parts including shaft seal and if

necessary, replace them; see appendix 5, Parts list.

D) If the pump is going to be returned to

Danfoss for repair or a warranty claim, it is important to contact Danfoss in order to receive a return number and a form to ﬁll out with product information. A copy of the form together with contact information and reason for returning should be sent to the email address on the form. The same documents should be attached to the shipment.

7.8 Storage of the pump

If the pump has to be shut down for a longer period, instructions can be found in appendix 2, Instruction.

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

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.

If water is leaking into the electric motor; it can cause electric shock, ﬁre, short circuit or even death. When mounting the pump vertically always mount the motor above the pump to avoid water leaking into the electric motor.

8.2 Operational conditions which can cause pump failures

The following conditions can cause a pump failure :

• The pump is running dry.

• The inlet pressure is too high.

• The inlet pressure is too low.

• The temperature of the ﬂuid is too high.

• The ambient temperature is too high.

• The pump is running against a blocked port/closed manual valve.

• The pump is operating at a pressure out of speciﬁcation.

• The pump is running with a non-speciﬁed/ approved ﬂuid.

• The pump is running in the wrong direction.

• The ﬁltration is insuﬃcient.

• The pump is not being serviced according to Danfoss speciﬁcations (end of life).

• There is excessive mechanical load on the shaft coupling and piping.

8.3 Mechanical failure

If the pump is running dry, the temperature will quickly increase which can cause burns.

If there is any leakage at start-up or during operation, a high-pressure jet can cause eye or skin damage.

Leakage can result in ﬂooding, which can cause slipping, tripping or falling.

8.4 Electrical failure

If the wiring of the electric motor is incorrect or the ground connection is missing, it can cause electric shock, burn damages, ﬁre or even death.

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

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

8.5 Responsibility

Danfoss takes no responsibility for any 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 in which conditions 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 regarding design, installation, wiring and troubleshooting.

In case the pump needs to be scrapped, please follow your local environmental rules.

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 15

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Operation guide

APP pumps APP 53 / APP 65 / APP 78 / APP 86 / APP 92

Appendices for Installation, Operation and Maintenance Manual

hpp.danfoss.com

Operation guide | Installation, Operation and Maintenance APP 53-92 pumps

Table of Contents

Appendices .......................................................................................17

1. Data sheet for APP pumps 53-92 AI167386503010en-0013

2. Instruction for APP pumps 53-92 (180R9368) ............................................43

3. Electric motors (180R9230) ..............................................................55

4. Bowex coupling manual .................................................................61

5. Recommended service intervals (AX281930801330en-000401) ..........................85

6. Parts list (AX191786502906en-001101) ...................................................89

7. Trouble shooting (521B1447) ...........................................................101

8. Right and wrong (180R9042) ..........................................................113

01) ...........................19

Data sheet

APP Pumps

APP pumps

APP 53 / APP 65 / APP 78 / APP 86 / APP 92

APP 53-86

hpp.danfoss.com

ro-solutions.com

Data sheet | APP 53-92 Pumps

Table of Contents

1. Introduction ...........................................................................21

2. Beneﬁts................................................................................21

3. Application examples ..................................................................21

4 Technical data .........................................................................22

4.1 APP 53-92..............................................................................22

5. Performance curves....................................................................24

5.1 APP 53 ﬂow at diﬀerent rpm............................................................24

5.2 APP 65 ﬂow at diﬀerent rpm............................................................25

5.3 APP 78 ﬂow at diﬀerent rpm............................................................26

5.3 APP 86 ﬂow at diﬀerent rpm............................................................27

5.4 APP 92 ﬂow at diﬀerent rpm............................................................28

6. Flushing valve curves ..................................................................29

6.1 APP 53-92 integrated ﬂushing valve ....................................................29

7. Motor requirements....................................................................29

7.1 Calculation factor at 60 barg / 870 psig for APP 53-92 ...................................29

8. Temperature and corrosion.............................................................30

8.1 Operation..............................................................................30

9. Installation.............................................................................30

9.1 Filtration...............................................................................31

9.2 RO system with direct supply: ..........................................................31

10. Dimensions and connections...........................................................33

10.1 APP 53.................................................................................33

10.2 APP 65 - 92.............................................................................34

10.3 APP 53-92 with IE3 motor, IEC 315S - 4 ..................................................36

10.4 APP 53-92 with IE3 motor, IEC 315M - 4..................................................36

10.5 APP 53-92 with IE3 motor, IEC 315L 1-4 .................................................37

10.6 APP 53-92 with IE3 motor, IEC 315L 2 - 4 ................................................37

11. Pump connections .....................................................................38

11.1 APP 53 - 92.............................................................................38

12. VCM 3” Victaulic........................................................................39

12.1 Technical data .........................................................................39

12.2 Flow versus pressure ...................................................................40

13. Accessories ............................................................................41

14. Service and warranty...................................................................41

20 | © Danfoss | DCS (im) | 2021.12

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Data sheet | APP 53-92 Pumps

1. Introduction

The Danfoss range of APP high-pressure pumps is designed according to EN 809 for use in RO applications with low viscosity and corrosive ﬂuids such as sea water. Danfoss APP pumps are positive displacement pumps with axial pistons that move a ﬁxed amount of water in each cycle. Flow is proportional to the number of input shaft revolutions (rpm).

1 Housing 2 Shaft 3 Swash plate (non drive end) 4 Retainer plate 5 Piston 6 Cylinder barrel 7 Bleeding / drain plug 8 Valve plate 9 Port plate (non drive end)

Unlike centrifugal pumps, they produce the same ﬂow at a given speed no matter what the discharge pressure. The sectional drawing below illustrates the main components of the APP 53-92 pump range.

10 Center ﬂange 11 Spring cartridge 12 Eye bolt 13 Port plate (drive end) 14 Swash plate (drive end) 15 Shaft seal 16 Motor ﬂange 17 Flushing valve 18 Tail stock screws

2. Beneﬁts

3. Application examples Danfoss APP pumps are built into a broad range

• Zero risk of lubricant contamination:

- Oil lubricants are replaced with the pumped medium, water, so there is no contamination risk from the pump.

• Low maintenance costs:

- Eﬃcient design and all-stainless steel

construction ensure exceptionally long life. When Danfoss speciﬁcations are met, service intervals of 8,000 hours can be expected. Service is easy, and can be carried out on-site due to the simple design and few parts.

• Low energy costs:

- The highly eﬃcient axial piston design provides the lowest energy consumption of any comparable pump on the market.

• Easy installation:

- The most compact and lightest design

available.

- The pump can be installed horizon-

tally in diﬀerent positions rotating it around the shaft (see section 10 for example).

of RO desalination plants around the world:

• Containerized solutions for hotels, resorts and residences on islands and in coastal regions

No pulsation dampeners necessary due to extremely low pressure pulsation.

- Powered directly by electric motors or combustion engines (with special coupling).

- All pumps are supplied with an integrated ﬂushing valve that allows the ﬂuid to ﬂow from inlet to the outlet, when the pump is not running.

• High reliability:

- All parts are made of high corrosion resistant materials e.g. Duplex (EN1.4462/ UNS S31803) and Super Duplex (EN1.4410/UNS S32750) stainless steel and carbon reinforced PEEK.

• Certiﬁed quality:

- Available with positive material idenﬁcation (PMI) certiﬁcation on request.

- ISO 9001, ISO 14001, IAFT 16949

- ATEX certiﬁcation available for APP S (all Super Duplex) and APP S 674 (API). Please see relevant data sheets.

• Mobile systems for humanitarian and military organizations

• Onboard systems for ships and yachts

• Oﬀshore platforms for the oil and gas industry

• Municipal and regional waterworks

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 21

Data sheet | APP 53-92 Pumps

4.1 APP 53-924 Technical data

Pump size APP 53/1500 APP 65/1500 APP78 /1500 A PP 8 6/1700 APP 92 /178 0

Code number 180B7806 180B7807 180B7808 180B7809 180B7810

Geometric displacement

Pressure

Max. outlet pressure (MAWP)

Min. inlet operating pressure

Max. inlet operating pressure

Max. inlet pressure peak

Min. outlet pressure

Speed

Min. speed continuous

Max. speed continuous

Flow

Min. ﬂow

700 rpm at max. pressure

1000 rpm at max. pressure

1200 rpm at max. pressure

1500 rpm at max. pressure

1700 rpm at max. pressure

1780 rpm at max. pressure

Eﬃciency

1000 rpm

1200 rpm

1500 rpm

170 0 rp m

178 0 rp m

cm³/rev. 617 778 888 888 888 in³/rev. 37. 7 47. 3 54.2 54.2 54.2

barg 83 83 83 70 70

psig 1,200 1,200 1,200 1,015 1,015

barg 2 2 2 2.5 3.5

psig 29 29 29 36 50

barg 5 5 5 5 5

psig 73 73 73 73 73

barg 10 10 10 10 10

psig 145 145 145 145 145

barg 30 30 30 30 30

psig 435 435 435 435 435

rpm 700 700 700 700 700

rpm 1,500 1,500 1, 500 1,700 1,780

m³/h 24 32 36 36 36

gpm 106 141 158 158 15 8

m³/h 24 32 36 36 36

gpm 106 141 158 158 15 8

m³/h 35 45 52 52 52

gpm 15 4 198 228 228 228

m³/h 42 54 62 62 62

gpm 187 238 275 275 275

m³/h 53 68 78 78 78

gpm 235 299 345 345 345

m³/h 88 88

gpm 387 387

m³/h 92

gpm 405

% 88 88 89 89 89

% 89 89 90 89 89

% 88 89 89 88 88

% 88 88

% 87

22 | © Danfoss | DCS (im) | 2021.12

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Data sheet | APP 53-92 Pumps

Pump size APP 53/150 0 APP 65/15 00 APP 78/1500 APP 86/1700 APP 92 /1780

Code number 180B7806 180B7807 180B7808 180B7809 18 0B7810

Technical speciﬁcations

Media temperature

Ambient temperature

Weight (dry)

Weight (operation)

°C 2–50 2-50 2–50 2-50 2-50

°F 36–122 36-122 3 6–122 36-122 36-12 2

°C 0–50 0-50 0–50 0-50 0-50

°F 32–122 32-12 2 32–122 32-12 2 32-122

kg 196 196 196 19 6 196

lb 432 432 432 432 432

kg 204 204 204 204 204

lb 450 450 450 450 450

Sound pressure level

Footprint with IE3 motor

db(A) 84-95 84-95 84-93 84-96 84-96

m² 1.49 1.49 1. 50 1.50 1.50

Foot² 16.0 17. 0 16.1 16.1 16.1

Typical motor size

Max.speed at max. pres-

sure

Max. allowable working pressure at continuous operation. The pump is designed according to EN809, i.e. to

withstand hydrostatic test pressure (HTP) of 1.3 x MAWP. For lower and higher pressure, please contact Danfoss.

Dependent on the NaCI concentration.

Typical eﬃciency at max. pressure after a system has been commissioned and run in.

Maximum area covered with recommended IE3 motor conﬁgurations (excl. of space to service pump)

IE3 and NEMA motors, 4-pole, current insulated ND non drive end bearing

Operating with water

kW 132 16 0 160 200 200

HP 200 250 250 300 300

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 23

Data sheet | APP 53-92 Pumps

100,00

120,00

140,00

160,00

180,00

200,00

220,00

240,00

260,00

280,00

300,00

320,00

340,00

360,00

380,00

400,00

Flow [gpm]

Speed [RPM]

5. Performance curves

If the ﬂow required and the rotation speed (rpm) of the pump is known, it is easy to select the pump, ﬁtting the application best, by using the diagram below.

5.1 APP 53 ﬂow at diﬀerent rpm

90,00

85,00

80,00

75,00

70,00

65,00

60,00

55,00

50,00

Flow [m3/h]

45,00

40,00

35,00

30,00

25,00

20,00

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

Required ﬂow x Rated rpm

Required rpm =

Rated ﬂow

Speed [RPM]

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Data sheet | APP 53-92 Pumps

20,00

25,00

30,00

35,00

40,00

45,00

50,00

55,00

60,00

65,00

70,00

75,00

80,00

85,00

90,00

Flow [m3/h]

Speed [RPM]

100,00

120,00

140,00

160,00

180,00

200,00

220,00

240,00

260,00

280,00

300,00

320,00

340,00

360,00

380,00

400,00

Flow [gpm]

Speed [RPM]

5.2 APP 65 ﬂow at diﬀerent rpm

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 25

Data sheet | APP 53-92 Pumps

20,00

25,00

30,00

35,00

40,00

45,00

50,00

55,00

60,00

65,00

70,00

75,00

80,00

85,00

90,00

Flow [m3/h]

Speed [RPM]

5.3 APP 78 ﬂow at diﬀerent rpm

400,00

380,00

360,00

340,00

320,00

300,00

280,00

260,00

240,00

Flow [gpm]

220,00

200,00

180,00

160,00

140,00

120,00

100,00

Speed [RPM]

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Data sheet | APP 53-92 Pumps

100,00

120,00

140,00

160,00

180,00

200,00

220,00

240,00

260,00

280,00

300,00

320,00

340,00

360,00

380,00

400,00

Flow [gpm]

Speed [RPM]

5.3 APP 86 ﬂow at diﬀerent rpm

90,00

85,00

80,00

75,00

70,00

65,00

60,00

55,00

50,00

Flow [m3/h]

45,00

40,00

35,00

30,00

25,00

20,00

Speed [RPM]

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 27

Data sheet | APP 53-92 Pumps

20,00

25,00

30,00

35,00

40,00

45,00

50,00

55,00

60,00

65,00

70,00

75,00

80,00

85,00

90,00

95,00

100,00

Fl ow [m3/h]

Speed [RP M]

100,00

120,00

140,00

160,00

180,00

200,00

220,00

240,00

260,00

280,00

300,00

320,00

340,00

360,00

380,00

400,00

420,00

Fl ow [gpm]

Speed [RPM]

5.4 APP 92 ﬂow at diﬀerent rpm

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

Data sheet | APP 53-92 Pumps

6. Flushing valve curves

6.1 APP 53-92 integrated ﬂushing valve

Pressure [barg]

3.5

3.0

2.5

2.0

1.5

1.0

0.5

100

200

300

400

500

Flow [l/min]

600

The power requirements can be determined using one of the following guiding equations:7. Motor requirements

l/min x barg 16.7 x m

/h x barg 0.35x gpm x psig Required power = [kW] or [kW] or Calc. factor Calc. factor Calc. factor

1 hp = 0.75 kW 1 gpm = 3.79 l/min

1 m

/h = 4.40 gpm 1 kW = 1.34 hp 1 l/min = 0.26 gpm 1 gpm = 0.23 m

7.1 Calculation factor at 60 barg / 870 psig for APP 53-92

Name rpm

APP 53 1500 528

APP 65 150 0 534

APP 78 150 0 534

APP 86 170 0 528

APP 92 178 0 522

Calculation

factor

[Hp]

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701 | 29

Data sheet | APP 53-92 Pumps

8. Temperature and corrosion

8.1 Operation

The chart below illustrates the corrosive resistance of diﬀerent types of stainless steel related to NaCl concentration and temperature.

All wetted parts of the APP pump are made of Duplex or Super Duplex.

Duplex

316L

100

160 1600

1000

10 000

16000

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

NaCI vs. temperature

Super Duplex

100 000

160000

CI ppm

NaCI ppm

9. Installation See example below on how to mount the pump and connect it to an electric motor or combustion engine (special coupling). For further instruction on installation of coupling see APP Pump Instruction 180R9368.

If alternative mounting is required. please contact your Danfoss sales representative for further information.

Note: Do not add any axial or radial loads to the pump shaft.

180R9346 | IOM APP 53-92 pumps | AQ240486503020en-001701

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