Instruction
Instruction
APP W HC pump instruction
APP W HC pumps
APP W HC 15 - 30
APP W HC 21-43
hpp.danfoss.com
ro-solutions.com
Instruction | APP W HC 15-30 pumps
Table of Contents
1. Identification ...........................................................................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 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. Identification
PUMP
Type APP W HC 15
Code no. 180B5000
Serial no. XXXXXX02-XXX
MADE IN DENMARK
Danfoss A/S, 6430 Nordborg, Denmark
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Instruction | APP W HC 15 - 30 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 W HC 15-30 must be at
least 2 barg (29 psig).
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 system design and P&ID
1. Dimension the inlet line to obtain minimum pressure loss (large flow, minimum
pipe length, minimum number of bends/
connections, and fittings with small
pressure losses).
2. Place an inlet filter (1) in front of the
APP W HC pump (2). Please consult Danfoss
filter data sheet for guidance on how to
select the right filter. Thoroughly clean
pipes and flush system prior to start-up.
3. Place a monitoring pressure switch (3) set
at min. inlet pressure between filter and
pump inlet. The monitoring switch must
stop the pump at pressures lower than
minimum pressure.
4. Use flexible 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 flushing, a
bypass non-return valve (6) is integrated in
the APP W HC 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 flow 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 W HC pump
creates pressure and flow immediately after
start-up, 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.
Feed
Media filter
PI
PI
PI PI
1 1
Fresh water
permeat flush
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M
9
3
PT
2
7
5
6
8
PI
Permeate
4
PI
Brine
3
Instruction | APP W HC 15-30 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 W HC 15-30 must be min.
2 barg (29 psig).
The inlet line connection must be properly
tightened, as possible entrance of air will cause
cavitation.
2.4 General comments
Filtrat ion
A good filtration is vital to ensure a long and
trouble-free life of the pump.
As water has very low viscosity, the APP W HC
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
filtered properly to minimize the wear of the
pump.
The main filter must have a filtration efficiency of
99.98% at 10 μm. We recommend to use
precision depth filter cartridges rated 10 μm abs.
β10 ≥ 5000 (equivalent to a filtration efficiency of
99.98%). Bag filters and string wounded filter
cartridges typically have only 50% filtration
efficiency. This means that for each 100,000 particles reaching the filter, 50,000 particles pass
through it compared to only 20 particles in a
filter with an efficiency of 99.98%.
For more information on the importance of
proper filtration, please consult our publication
“Filtration” (code number 521B1009), which also
will provide you with an explanation of filtration
definitions and a guidance on how to select the
right filter.
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 flange
3.1 Mounting
1. Mount the coupling flush or maximum
1 mm offset 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 flange are not in
contact with each other.
5. Measure from motor flange 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 W HC 15 - 30 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
flange 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 W HC 15
Code no. 180B5000
Serial no. XXXXXX02-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.
MADE IN DENMARK
Danfoss A/S, 6430 Nordborg, Denmark
M5 M6 M8 M10
2 4.8 10 17
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.
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 132 barg
(1914 psig).
We recommend the use of flexible soft hoses
both in the inlet and in the outlet lines.
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Instruction | APP W HC 15-30 pumps
The valve outlet must not be connected directly to the pump suction line.
It must be connected directly to the drain.
Inlet
3.5 Connections
I: Inlet
O: Outlet
C: Bleeding
D: Parallel key
Outlet
Inlet
Outlet
C
I
O
C
C
D
Description APP W HC 15 - 30
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 flange 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 - 2m (79”) 3” Victaulic 180Z014 4
2½” outlet high pressure hose 120 bar
2½” outlet high pressure hose 120 bar
3” inlet connector M60 - 3” Victaulic
Non-return valve (outlet) Super Duplex M60 - 2 ½” Victaulic
1)
The installation instuction for Style 77DX is located in the Victaulic document
2 ½” Victaulic 1 m
Style 77DX
2 ½” Victaulic 1.78 m
Style 77DX
Style 77DX
1)
1)
1)
I-100 Field Installation Handbook (htpp://static.victaulic.com)
180Z100 9
180Z100 8
180B3208
180H0055
Instruction | APP W HC 15 - 30 pumps
4. Initial start-up
5. Operation 5.1 Tempe ratu re
1. Flush inlet line before connecting the
pump, to remove possible impurities from
pipes, hoses etc.
2. Connect pump inlet to inlet line and flush
the pump for 5 min. by means of the
internal flushing 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 APP W HC 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
flushing
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 different types of stainless steel
related to NaCl concentration and temperature.
The APP W HC water pump is made of Duplex
and Super Duplex.
If the water pump is operated above the Super
Duplex line, always flush water pump with fresh
water at operation stop in order to minimize the
risk of crevice corrosion.
Super Duplex
20
100
160 1600
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1000
10 000
16000
100 000
160000
CI
ppm
NaCI
ppm
-
7
Instruction | APP W HC 15-30 pumps
5.2 Pressure
The inlet pressure for APP W HC 15-30 must be
min. 2 barg (29 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 120 barg (1750 psig) continuously,
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
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,
flush the pump with an anti-freeze medium type
monopropylene glycol to prevent internal
corrosion or frost in the pump.
For further information on anti-freeze media,
please contact 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 flow 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 of pump that have been in operation:
For shorter periods of storage flush 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 surfaces. Store the
pump dry without water inside.
6. Service
8
6.1 Warranty
Danfoss APP W HC pumps are designed for long
operation, low maintenance and reduced
lifecycle costs.
Provided that the pump has been running
according to the Danfoss specifications, Danfoss
guarantees 8,000 hours service-free operation,
however, max 18 months from date of production.
All pumps comes with NBR seals and shaft seal,
ideal for water. When pumping water mixed with
chemicals, we recommend assessing or testing
the impact from the chemicals on the pump
materials (see Part List for full overview of
materials). Danfoss product warranty doesn´t
cover cases where chemicals are the root cause
of the failure or claim. Additionally, use of certain
chemicals may lead to increase wear and require
part replacement more often than the Recommended Service Intervals, which are based on
water.
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If Danfoss recommendations concerning
system-design are not followed, it will strongly
influence the life of the APP W HC pumps.
Other factors that affect pump performance and
lifetime include:
- Running the pump at speed outside
specifications.
- Supplying the pump with water at
temperature higher than recommended.
- Running the pump at inlet pressure outside
specifications.
- Running the pump at outlet pressure
outside the specifications.
Instruction | APP W HC 15 - 30 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 W HC pumps are made of Duplex/Super
Duplex materials with excellent corrosion
properties. It is however, always recommended
to flush the pump with fresh water when the
system is shut down.
When stopping the pump for more than 1 day
flush the ppump with permeate be rotating the
pump for 10 sec. Flushing through the flashing
valve of the pump without rotating the pump is
not enought for cleaning the inside of the pump.
The pump can be flushed with biocicde 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 W HC,
please contact Danfoss High Pressure Pumps
sales organisation.
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9
Danfoss A/S
High Pressure Pumps
Nordborgvej 81
DK-6430 Nordborg
Denmark
© Danfoss | DCS (im) | 2019.10
AN283148361728en-000402 | 10
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