Danfoss APP series User Manual

180R9346 | AQ240486503020en-001702 | 7© Danfoss | 2023.03
Operation guide Installation, Operation and Maintenance APP 53-92 pumps
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
specied without rst 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.
For system integration of the pump, please see
appendix 1, Data sheet and appendix 2,
Instruction.
3. Technical data
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
uids 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
53
APP
65
APP
78
APP
86
APP
92
MAWT 878 1,118 1,257 1,112 1,112
MAST 1,700 1,700 1,700 1,700 1,700
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.
3.6 Dimension drawings
Dimensions of the dierent pumps can be found
in appendix 1, Data sheet.
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 shut-
down 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.
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.
• Do not try to lift the pump unit manually;
most of the pumps weigh more than
20 kilos, see specic 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 exible 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.
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.

Danfoss APP series Specifications

General

Brand	Danfoss
Model	APP series
Category	Water Pump
Language	English

Summary

Pump Unit Operation

What to Listen and Look For

Pump Unit Maintenance and Service

Troubleshooting and Scrapping Criteria

General Safety Information

Operational Conditions Causing Failures

Lists operational conditions that can lead to pump failures.

Mechanical and Electrical Failures

Information on potential mechanical and electrical failures and associated risks.

Safety Precautions

General Safety Information

Dangers arising from not following instructions and general safety precautions.

Technical Data

Approved Applications and Limits

Specifies approved uses and operational boundaries for the APP pumps.

Arrival, Transportation, Handling, Lifting, and Storage

Arrival Inspection Procedure

General Safety for Handling

Installation and Commissioning

Lifting, Positioning, and Mounting Equipment

Cleanliness Requirements

Emphasizes the importance of cleanliness for pump and system integrity.

Electrics and Instrumentation

Pump Commissioning and Instruction

Step-by-step guide for commissioning the pump unit and instructing personnel.

Pump Unit Maintenance

Disassembling and Assembling the Pump Unit

Instructions for disassembling and reassembling the pump unit.

Mounting Pump to Electric Motor

APP 53-92 Technical Data

Pump Specifications

Detailed technical specifications for APP 53-92 pump sizes.

Performance Curves

Temperature and Corrosion

Installation Guidance

Filtration Requirements

Importance of proper filtration for pump performance, maintenance, and warranty.

RO System Inlet Design

Service and Warranty

Warranty Information and Conditions

Long-Term Storage and Warranty

Pump Shutdown and Maintenance

Recommended procedures for shutting down, flushing, and maintaining the pump.

System Design

Preferred RO System Design

Building Up Pump Unit with BoWex Coupling

Coupling Assembly and Alignment

Overall Assembly with HEW Compact Coupling

Mounting Procedures for Coupling Components

Building Up Pump Unit with Jaw Coupling

Mounting Instructions for Jaw Coupling

Initial Start-up Procedures

Cleaning and Flushing Procedures

Pump Operation

Pressure Limits and Dry Running Warning

Hoyer Motors: General Information

Electrical Connections and Maintenance

Safety for electrical connections and regular motor inspection and maintenance.

Hoyer Motors: Special ATEX Notes

ATEX Motor Maintenance and Repairs

BoWex-ELASTIC® Coupling Technical Data

BoWex-ELASTIC® Coupling Advice

BoWex-ELASTIC® Coupling Safety

BoWex-ELASTIC® Coupling Assembly

Assembly of the Coupling Components

Displacements and Alignment of Couplings

Displacement and Alignment Notes

BoWex-ELASTIC® Coupling Start-up

Pre-Start-up Checks and Adjustments

BoWex-ELASTIC® Coupling Breakdowns

Causes and Elimination of Failures

Identifies common failures, their causes, and elimination steps.

BoWex-ELASTIC® Coupling Enclosure A

Intended Use in Hazardous Locations

Specific conditions of operation for couplings in potentially explosive atmospheres.

Inspection Intervals for Explosive Atmospheres

Inspection schedules for couplings used in potentially explosive atmospheres.

Torsional Backlash Inspection

Procedure for inspecting torsional backlash to ensure coupling integrity.

Marking for Potentially Explosive Atmospheres

Details of ATEX marking for couplings used in potentially explosive atmospheres.

Standard Wear Values

Information on wear limits for elastomer parts and torsional backlash.

Appendix 1: Piston Wear

Evaluating Piston Wear

Guidance on evaluating piston wear and determining replacement needs.

Exploded View: APP 53-92 (Serial No. 07+)

Exploded View: APP 53-86 (Serial No. up to 06)

Troubleshooting Guide Overview

Trouble Shooting Fish Bone Chart

Visual representation of potential pump issues and their causes.

Troubleshooting Open-Ended Water Systems

No Flow/No Pressure Issues

Troubleshooting steps for pumps with no flow or no pressure output.

Dry Running and Pump Reversing Diagnosis

Troubleshooting steps for dry running and pump reversing due to incorrect motor rotation.

Pump Wear and Low Inlet Pressure

Troubleshooting steps for pump wear and low inlet pressure issues.

No Water Supply Diagnosis

Troubleshooting steps for systems with no water supply.

Reduced Flow/Pressure Issues

Troubleshooting steps for pumps with reduced flow or pressure.

Motor and Pump Rotation Issues

Troubleshooting steps for issues where the motor or pump does not rotate.

Rotation Speed (RPM) Issues

Troubleshooting steps related to incorrect rotation speed affecting pump performance.

Motor Rotation and Filter Clogging Checks

High Torque on Electric Motor

Troubleshooting steps for issues causing high torque on the electric motor.

Axial Load and Pump Damage

Troubleshooting steps for axial load issues and internal pump damage.

Troubleshooting High Torque on Electric Motor

High Outlet Pressure and Pressure Start Issues

Troubleshooting steps for high outlet pressure and pump start issues.

Troubleshooting Pump Noise

Water Pump Damage and Air in Fluid Noise

Troubleshooting steps for noise caused by pump damage or air in the fluid.

Bleeding, Inlet Pressure, and Reversing Noise

Troubleshooting steps for noise related to bleeding, inlet pressure, and pump reversing.

High RPM, Outlet Pressure, and Soft Start Noise

Troubleshooting steps for noise related to high RPM, outlet pressure, and soft start/stop.

Troubleshooting Installation Noise

Typical Signs of Wear

Valve Plate Wear Identification

Visual guide to identifying wear on the valve plate.

Port Plate Wear Identification

Swash Plate Wear and Filtration Issues

Design Considerations for Water Hydraulic Systems

Material Choice and Filter Selection

Installation Procedures for Water Hydraulic Systems

System Start-up Procedures

Pump Bleeding and Cleaning/Flushing

Troubleshooting Closed Water Systems

System Not Working Diagnosis

General troubleshooting steps for when the closed system is not functioning.

Tank Water Level and Motor Rotation Checks

Filter Clogging Check