Danfoss APP series User manual

© Danfoss | 2023.03 180R9346 | AQ240486503020en-001702 | 1hpp.danfoss.com
Operation guide
APP pumps with FDA approved seals
APP 53 / APP 65 / APP 78 / APP 86 / APP 92
Installation, Operation and
Maintenance Manual

2 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03
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 specic 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 dierent equipment ........................................................11
5.9 Electrics ...............................................................................11
5.10 Instrumentation .......................................................................11
5.11 Connections ...........................................................................12
5.12 Ensure free ow .......................................................................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 lter condition...............................................................12
5.19 Instruct operator and maintenance personnel ..........................................12

180R9346 | AQ240486503020en-001702 | 3© Danfoss | 2023.03
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) ...........................19
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

4 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03
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:
Type Serial no.
APP 53 XXXXXX08-XXX
APP 65 XXXXXX08-XXX
APP 78 XXXXXX08-XXX
APP 86 XXXXXX08-XXX
APP 92 XXXXXX08-XXX
The serial number is referring to the Serial no. on the
product label. The digits shown (08) indicate the
version number of the pump.
PUMP
Type APP 78
Code no. 180BXXXX
Serial no. XXXXXX08-XXX
MADE IN DENMARK
Danfoss A/S, 6430 Nordborg, Denmark

180R9346 | AQ240486503020en-001702 | 5© Danfoss | 2023.03
Operation guide Installation, Operation and Maintenance APP 53-92 pumps
1.1 General
The APP pumps and pump units are manufac-
tured by Danfoss A/S, and are sold and marketed
by a net of authorized distributors world wide.
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 certied, the
additional ATEX instruction must also be read.
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 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:
• 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 instru-
mentation
• 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 ocer 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’ opera-
tional 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 specications
requires a written approval from Danfoss
High Pressure Pumps.
• If any changes are made without written
approval the warranty will automatically
become void.
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 high-
voltage warning
Safety glasses required
Hearing protection required
Safety shoes required
Safety helmet required
!Protective
garments
must be worn
Protective garments
must be worn
Danger HOT.
Do not touch
1. Introduction
If the recommendations in the manual are
not followed, Danfoss reserves the right to
void the warranty.

6 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03
Operation guide Installation, Operation and Maintenance APP 53-92 pumps
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
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 certied, the
additional ATEX instruction must also be read.
!Protective
garments
must be worn
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.
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.
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.
Danger
Installation and maintenance must always
take place during complete shutdown in an
unpressurised condition.
The drive unit must be secured against inadvertent
switching-on (with signs, switching o 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 veried and free ow from safety
valves must be ensured.
All pipe and hose connections must be stress-
free 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 responsibil-
ity of applying good judgment when operating
and maintaining the pump and its compo-
nents.
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.
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: [phone]
Fax: [phone]
Email: [email protected]
Homepage: hpp.danfoss.com
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 specic information
1.4.1 United Kingdom
UK importer:
Danfoss Ltd.
22 Wycombe End
HP9 1NB Beaconseld
United Kingdom

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.

8 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03
Operation guide Installation, Operation and Maintenance APP 53-92 pumps
4. Arrival inspection,
transportation,
handling, lifting and
storage
3.7 Space requirement
When doing service or replacing the complete
pump unit, it is recommended to have sucient
space available around the pump in order to
ensure easy access. Sucient 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 [ß10 ≥ 5000])
Requirements are specied in appendix 1, Data
sheet and in appendix 2, Instruction.
Danfoss recommends not to build a lter bypass
function or to use lters with an integrated
bypass. If the above recommendation is not
followed the warranty for the pump will auto-
matically become void.
It should be possible to monitor the condition of
the lter via the dierential/delta pressure across
the lter.
Using insucient ltration or a lter 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 low-
pressure and high-pressure side before the RO
system is pressurised. Special consideration
should be given in order to minimize air bubbles
in the feed ow. 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.
4.1 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!

180R9346 | AQ240486503020en-001702 | 9© Danfoss | 2023.03
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.
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 position-
ing 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:
Wrong lifting:
Some motors and pumps have specic 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.

10 | 180R9346 | AQ240486503020en-001702 © Danfoss | 2023.03
Operation guide Installation, Operation and Maintenance APP 53-92 pumps
5.1 Important dimensions
Physical dimensions and connections of the
pump unit are described in appendix 1, Data
sheet.
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 uid and pump housing
temperature must be within the specied
temperature range listed see 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.
5.5 Local regulations
Commissioning must always be done in
accordance with valid regulations and local
standards.
5. Installation and
commissioning
Media filter
M
Brine
Permeate
Feed
PI PI PI PT
PI
PI
PI
Fresh water
permeat flush
Schematic 1: Recommended system design