Danfoss PP W HC High Energy Efficiency Pumps Instructions

System Design
Review the system design options provided in the manual for open-ended systems with direct water supply, reversible pumps, and general comments.

Building Up the Pump Unit
Follow the steps for mounting, direction of rotation, orientation, protection from high pressures, and proper connections.

Initial Start-Up
Before starting the pump, ensure all connections are secure and follow the recommended start-up procedure.

Operation
Monitor temperature and pressure levels during operation, avoid dry running, follow proper disconnection procedures, and store the pump correctly when not in use.

Identiﬁcation

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.

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 low- pressure relief valve on the inlet line.

Preferred system design and P&ID

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).

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

Use ﬂexible hoses (4) to minimize vibrations and noise.
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.It is recommended to install a safety valve or a pressure relief valve (9) to avoid high-pressure peaks in case the pump stops momentarily or spins backward.

For easy system bleeding and ﬂushing, a bypass non-return valve (6) is integrated in the APP W HC pump.
A non-return valve (7) in outlet can be installed in order to avoid backspin of the pump. The volume of water in the mem-brane vessel works as an accumulator and will send ﬂow backwards in case of the pump stops momentarily.

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.

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 non-return 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.

General comments

Filtration

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 using precision depth ﬁlter cartridges rated 10 μm abs. β10 ≥ 5000 (equivalent to a ﬁltration eﬃciency of 99.98%). Bag ﬁlters and string-wound 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 guidance on how to select the right ﬁlter.

Monitoring
It is recommended to continuously monitor the following conditions:

Filter clogging
Pressure (inlet and outlet sides of the pump)

Building up the pump unit

Mounting

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).
Mount the bell housing on the pump. Secure nuts with the right torque.
Measure the longest distance “A” from the top of the bell housing to the bottom of the coupling claw.
Mount the coupling on motor shaft. Ensure the coupling and motor ﬂange are not in contact with each other.

Measure from the 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.)
Adjust respectively, verify the measure-ment, and secure both couplings with the right torques on the locking screws (see coupling operation & mounting instruction).
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) axially “C”. The check can be done through the inspection hole of the bell housing. Secure ﬂange bolts with the right torque.

If alternative mounting is desired, please contact Danfoss High Pressure Pumps.

Choose proper tolerances to ensure an easy mounting of the elastic coupling without the 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).

Direction of rotation
It is indicated by an arrow on the pump label.

Orientation
The pump can be mounted/orientated in any horizontal direction with the inlet and the outlet pointing upwards, downwards, or to either side.

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.

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.

Connections

Description			APP W HC 15 – 30
E	Parallel key, DIN 6885	mm	12 × 8 × 70
		in	0.47 × 0.31 × 2.76
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

For more details on the accessories, please contact Danfoss High Pressure Pumps. Possible extension, see next page.

Accessories	Type	Code no.
3” inlet hose kit – 2m (79”)	3” Victaulic	180Z0144
2½” outlet high-pressure hose 120 bar	2 ½” Victaulic 1 m Style 77DX¹⁾	180Z1009
2½” outlet high-pressure hose 120 bar	2 ½” Victaulic 1.78 m Style 77DX¹⁾	180Z1008
3” inlet connector	M60 – 3” Victaulic	180B3208
Non-return valve (outlet) Super Duplex	M60 – 2 ½” Victaulic Style 77DX¹⁾	180H0055

The installation instruction for Style 77DX is located in the Victaulic document I-100 Field Installation Handbook (htpp://static.victaulic.com)

Initial start-up

Flush the inlet line before connecting the pump to remove possible impurities from pipes, hoses, etc.
Connect the pump inlet to the inlet line and ﬂush the pump for 5 min. Use the internal ﬂushing valve to remove possible impurities from pipes, hoses, etc.
Loosen top bleeding plug “C” (see item 3.5) using an Allen key (only plugs with internal hexagon sockets). Retighten the plug when water APP W HC appears from the bleeding plug.

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

Operation

Temperature

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.

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 the water pump with fresh water at the operation stop to minimize the risk of crevice corrosion.

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 to 120 barg (1750 psig) continuously,

Note: The pump unit should include a pressure gauge on the high-pressure side.

Dry running
When running, the pump must always be connected to the water supply in order to avoid damage if it should run dry.

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.

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 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:

Disconnect the water supply to the pump.

Through the lower bleeding plug, empty the pump housing of water and close it again.
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.
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 pumps 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 recom-mends servicing the product and clean any biological growth of the surfaces. Store the pump dry without water inside.

Service

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 come with NBR seals and shaft seals, ideal for water. When pumping water mixed with chemicals, we recommend assessing or testing the impact of 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 Recom-mended Service Intervals, which are based on water.

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 a temperature higher than recommended.
Running the pump at an inlet pressure outside speciﬁcations.
Running the pump at outlet pressure outside the speciﬁcations.

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 recom-mended 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 pump with permeate by rotating the pump for 10 seconds. Flushing through the ﬂashing valve of the pump without rotating the pump is not enough for cleaning the inside of the pump.
The pump can be ﬂushed 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.

Repair
In case of irregular function of the APP W HC, please contact the Danfoss High Pressure Pumps sales organisation.

Danfoss A/S

High Pressure Pumps Nordborgvej 81

DK-6430 Nordborg Denmark
Danfoss can accept no responsibility for possible errors in catalogues, brochures, and other printed material. Danfoss reserves the right to alter its products without This also applies to products
already on order, provided that such alterations can be made without subsequent changes being necessary in specifications already agreed

Danfoss I DCS (im) | 2019.10
AN283148361728en-000402 | 10

FAQS

Q: What should I do if the pump is not working?
A: Check the power supply, connections, and ensure the pump is primed before starting.

Q: Can the pump be used for continuous operation?
A: The pump is designed for intermittent duty cycles; continuous operation may lead to overheating.

Documents / Resources

Danfoss PP W HC High Energy Efficiency Pumps [pdf] Instructions
15-30, 21-43, PP W HC High Energy Efficiency Pumps, PP W HC, High Energy Efficiency Pumps, Energy Efficiency Pumps, Efficiency Pumps

References

User Manual

Danfoss PP W HC High Energy Efficiency Pumps

Specifications

Product Information

Product Usage Instructions