High-pressure pumps by Danfoss, world leading manufacturer | Danfoss
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Instructions for Danfoss models including: 15-30, 21-43, PP W HC High Energy Efficiency Pumps, PP W HC, High Energy Efficiency Pumps, Energy Efficiency Pumps, Efficiency Pumps
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DocumentDocumentInstruction
Instruction
AAPPPP WWHCHpuCmppsump instruction AAPPPPWWHCH15C- 3021-43
ro-hspop.lduatnifoosns.sco.cmom
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.
Inlet Outlet
2.2 Preferred system design and P&ID 1. Dimension the inlet line to obtain mini-
mum 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.
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 1 PI 1
93
PI
PT
5
Fresh water permeat flush
M
8
2
PI
7
4
6
PI Brine
Permeate
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Instruction | APP W HC 15-30 pumps
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 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 m. We recommend to use precision depth filter cartridges rated 10 m abs. 10 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
3-5 mm 0.12-0.20 inch
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 measure-
If alternative mounting is desired, please contact
ment, and secure both couplings with the Danfoss High Pressure Pumps.
right torques on the locking screws (see
coupling operation & mounting instruction). Choose proper tolerances to ensure an easy
mounting of the elastic coupling without use of
7. Mount the elastic gear ring and mount the tools.
bell housing/pump on the motor. After
mounting it must be possible to move the Please take care to observe the recommended
elastic gear ring 3-5 mm (0.12 - 0.2 inch)
length tolerances of the chosen coupling, as an
axial "C". The check can be done through axial force on the pump will damage the pump.
the inspection hole of bell housing. Secure
flange bolts with the right torque.
("C" can be found on the drawing below).
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
Thread size
Torque (Nm)
M5 M6 M8 M10 2 4.8 10 17
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
MADE IN DENMARK Danfoss A/S, 6430 Nordborg, Denmark
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.
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 Inlet
Outlet
Outlet
3.5 Connections
I: Inlet O: Outlet C: Bleeding D: Parallel key
C C C
I O
D
C
Description
E Parallel key, mm DIN 6885 in
APP W HC 15 - 30 12 × 8 × 70
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 3" inlet hose kit - 2m (79") 2½" outlet high pressure hose 120 bar
2½" outlet high pressure hose 120 bar 3" inlet connector
Type
3" Victaulic
2 ½" Victaulic 1 m Style 77DX1)
2 ½" Victaulic 1.78 m Style 77DX1)
M60 - 3" Victaulic
Non-return valve (outlet) Super Duplex M60 - 2 ½" Victaulic Style 77DX1)
Code no. 180Z0144 180Z1009 180Z1008 180B3208
180H0055
1) The installation instuction for Style 77DX is located in the Victaulic document I-100 Field Installation Handbook (htpp://static.victaulic.com)
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Instruction | APP W HC 15 - 30 pumps
4. Initial start-up
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
5. Operation
5.1 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 water pump with fresh water at operation stop in order to minimize the risk of crevice corrosion.
NaCl vs. temperature
80 º C 70 60 50 40 30
20 100 160
316L
Duplex
Super Duplex
1000 1600
10 000 16000
100 000
CI ppm
160000
NaCI ppm
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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.
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.
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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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Danfoss A/S High Pressure Pumps Nordborgvej 81 DK-6430 Nordborg Denmark
© Danfoss | DCS (im) | 2019.10
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