Danfoss APP W HC Series User manual

ro-solutions.com
APP W HC 21-43
User manual
Installation, Operation and
Maintenance Manual
APP W HC pumps (APP W HC 21-43)
Operation guide
APP W HC pumps
APP W HC 15 - 30
Installation, Operation and
Maintenance Manual
hpp.danfoss.com

Operation guide | Installation, Operation and Maintenance APP W HC 15 - 30 pumps
2180R9410 | AQ282628894589en-000801 | IOM APP W HC 15-30 Pumps | 01.2022
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 specific 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 Noise and vibration .....................................................................7
3.5 Dimension drawings ....................................................................7
3.6 Space requirement......................................................................7
3.7 Filtration................................................................................8
3.8 Properties of water......................................................................8
3.9 Air bubbles .............................................................................8
3.10 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 different equipment ........................................................11
5.9 Electrics ...............................................................................11
5.10 Instrumentation .......................................................................11
5.11 Connections ...........................................................................11
5.12 Ensure free flow .......................................................................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 filter condition...............................................................12
5.19 Instruct operator and maintenance personnel ..........................................12
6. Operation of pump unit ...............................................................13
6.1 General safety information .............................................................13
6.2 What to listen and look for .............................................................13

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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 scrAPP W HCing 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 ScrAPP W HCing criteria ................................................................15
Appendices .......................................................................................17
1. Data sheet for APP W HC pumps 15-30 (AI283147317727en-000601) .....................19
2. Instruction for APP W HC pumps 15-30 (AN283148361728en-000402)....................33
3. IOM Electric motors (180R9230)..........................................................43
4. Recommended service intervals (AX283334052821en-000301) ..........................49
5. Parts lists APP W HC pumps 15-30 (AX283149261730en-000301) . . . . . . . . . . . . . . . . . . . . . . . . .53
6. Trouble shooting guide (521B1447) .....................................................61
7. Right and wrong (180R9042) ...........................................................73

Operation guide | Installation, Operation and Maintenance APP W HC 15 - 30 pumps
4180R9410 | AQ282628894589en-000801 | IOM APP W HC 15-30 Pumps | 01.2022
This manual is valid for APP W HC pumps.Validity
Non ATEX
APP W HC 15/750 Code no. 180B5000
Serial no. XXXXXX02-XXX
APP W HC 21/1000 Code no. 180B5001
Serial no. XXXXXX02-XXX
APP W HC 24/1200 Code no. 180B5002
Serial no. XXXXXX02-XXX
APP W HC 30/1200 Code no. 180B5003
Serial no. XXXXXX06-XXX
The serial number is referring to the Serial no. on
the product label. The digits shown (06) indicate
the version number of the pump.
This documentation is compatible with previous
pump versions.
PUMP
Type APP W HC 30
Code no. 180B5003
Serial no. XXXXXX06-XXX
MADE IN DENMARK
Danfoss A/S, 6430 Nordborg, Denmark

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1.1 General
The APP W HC pumps and pump units are
manufactured 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 water based high pressure RO
or zero liquid dischrge (ZLD) or minimal liquid
discharge (MLD) system.
The APP W HC pumps must not be used for other
purposes than those recommended and
specified without first consulting your local
pump distributor.
Use of the pump in other APP W HC 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 officer 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 specifications
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

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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 equip-
ment from overloads with suitable equipment.
!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.
Before start-up, the settings for all protective
devices, such as sensors/switches and safety
valves must be verified and free flow 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 APP W HC applying good judgment when
operating and maintaining the pump and its
components.
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: [e-mail]
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 specific information
1.4.1 United Kingdom
UK importer:
Danfoss Ltd.
22 Wycombe End
HP9 1NB Beaconsfield
United Kingdom

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3.1 Approved applications and operational
limits for the pumps
The pump and the pump units are designed for
the use in a water based high pressure RO or
zero liquid dischrge (ZLD) or minimal liquid
discharge (MLD) system.
The APP W HC pumps must not be used for
other purposes than those recommended and
specified without first 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
See appendix 1, Data sheet.
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 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.
3.5 Dimension drawings
Dimensions of the different pumps can be found
in appendix 1, Data sheet.
3.6 Space requirement
When doing service or replacing the complete
pump unit, it is recommended to have sufficient
space available around the pump in order to
ensure easy access. Sufficient 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.
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 specific 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 flexible 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.

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4. Arrival inspection,
transportation,
handling, lifting and
storage
3.7 Filtration
(10µm absolute [ß10 ≥ 5000])
Requirements are specified in appendix 1, Data
sheet and in appendix 2, Instruction.
Danfoss recommends not to build a filter bypass
function or to use filters with an integrated
bypass. If the above recommendation is not
followed the warranty for the pump will
automatically become void.
It should be possible to monitor the condition of
the filter via the differential/delta pressure across
the filter.
Using insufficient filtration or a filter bypass
can cause a failure or decreased service life of
the pump.
3.8 Properties of water
Check Data sheet section 8, for TDS limits and
recommendations to avoid or reduce crevice
corrosion.
3.9 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 flow. Air bubbles can cause cavitation.
3.10 Chemicals
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 Recom-
mended Service Intervals, which are based on
water.
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
(weight can be found in appendix 1, Data sheet).
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.

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When lifting the pump unit, one sling must be
attached to the electric motor and one sling
around the pump.
Some motors and pumps have specific 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.
Pumps which have a weight above 20 kilos (see
appendix 1, Data sheet) must be handled by
using lifting eyes and slings.
When the pump is mounted together with an
electric motor, the pump unit always weigh more
than 20 kilos and must be handled by using
slings around the pump unit.
See below examples of where to/not to attach
the lifting slings on the pump unit:
Correct lifting with 2 separate slings:
Wrong lifting:

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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 fluid and pump housing
temperature must be within the specified
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

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Table 1: Check points when assembling and commissioning system
Check points Comment OK ?
CP1 Ensure that the environmental conditions are safe. See Arrival inspection,
transportation, handling,
lifting and storage, chapter 4.
CP2 Minimum and maximum start-up temperature for fluid and
pump.
See Data sheet or Instruction,
appendices 1 and 2.
CP3 Filtration condition (10 µm absolute (ß10 ≥ 5000) See Danfoss requirements in
Data sheet and Instruction,
appendices 1 and 2
CP4 Power supply for electric motor and VFD. See Data sheet for the used
motor and VFD.
CP5 Safety circuit / breaker must be sized for the motor and
environment (corrosion and humidity)
See Data sheet for the used
safety circuit.
CP6 Bolts and screws must conform to environmental conditions
as well as fluid and torque requirements.
CP7 Instrumentation, pressure switch should be designed to
conform to the environment (corrosion and humidity).
See Data sheet for the used
equipment.
CP8 Check the factory settings of the safety/relief valves or
pressure relief valves (page 11).
See Data sheets for the used
valves.
CP9 Check the settings of the pressure transmitter/switch (3) set
at min. inlet pressure (page 11).
See Data sheet or Instruction,
appendices 1 and 2.
CP10 Check that all pressure indicators (PI) are selected to be able
to measure the system pressure range (page 11).
Scaling should at least be 1 bar
or more precise.
CP11 Check coupling distance ( air gab – movement of the spider ) 3-5 mm
CP12 Check correct connections on the pump ( in & outlet)
CP13 Check piping for possible air gaps.
5.7 Lifting and positioning
Lift the pump unit onto base (Remember
vibration dampeners, if needed). Fasten the
motor to the base.
See also chapter 4, Arrival inspection, transporta-
tion, handling, lifting and storage.
5.8 Mount the different equipment
(connections, pipes, tubes, check and safety/relief
valves, etc.)
• The hard piping and flexible hoses used,
must be of proper design and must be
installed in accordance with the manufactur-
er’s recommendations. ).
• Misalignment of the hard pipes may give
unintended stress on the pump port
connections and may damage the pump.
• Prevent excessive external pipe load.
• Do not connect piping by applying external
force (use of wrenches, crane, etc.) Piping
must be aligned without residual stress.
• Do not mount expansion joints so that their
force applies internal pressure on the pump
connections.
5.9 Electrics
All electrical installation work must be carried
out by authorized personnel in accordance with
EN60204-1 and/or local regulations. (see also
Safety, chapter 2)
Turn off the safety circuit breaker and lock it.
Mount the power cable on the electric motor.
If a VFD is used, adjust the protective motor
switch/VFD to the current limits found on the
name plate of the electric motor.
5.10 Instrumentation
The pressure switch/sensor should be mounted
as close to the pump as possible. It is recom-
mended to test the pressure/sensor switch via an
instrumentation manifold.
Mount the pressure switch/sensors according to
the manufacturer’s instructions.
5.11 Connections
Mount and tighten connections and check
valve(s) as specified.
5.6 Pre mounting checklist, based on Danfoss preferred system design

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5.12 Ensure free flow
Ensure free flow from the safety/relief valves 8
and 9 (schematic1, page 11). A blocked safety/
relief valve can cause excessive build-up of
pressure and thereby cause dangerous situations
and damage to the whole system.
5.13 Verify setting of safety/relief valves
Make sure, the safety/relief valves 8 and 9 are
placed correctly.
Check the pressure settings on the name plates
of the safety/relief valves. If they are within
specifications, you can continue.
5.14 Flush the pump
Fully open the pressure valve at the brine outlet.
Close all the bleeding and draining plugs on the
high-pressure pump.
Start the feed pump and ensure free flow to the
high-pressure pump.
5.15 Bleed and remove air from the pump
Open the bleeding plugs. Keep the plugs open
until the high-pressure pump is bleeded.
5.16 Verify direction of rotation
The direction of rotation must always follow the
arrow. The arrow is placed on the pump or pump
unit.
Check the direction of rotation before mounting
the pump.
Unlock the safety circuit breaker. Start the motor
for 1 second and observe the direction of
rotation either looking at the fan of the motor or
the coupling through the inspection hole in the
bell housings (not available on all bell housings).
If the motor is turning the wrong direction,
switch two phases in the connection box of the
motor or reprogram the direction in VFD.
When the motor is turning in the right direction,
the pump can be mounted.
5.17 Commissioning
• Close all the bleeding and draining plugs.
• Open the pressure valve at the brine site.
• Switch the safety circuit breaker on for both
motor(s) and VFD(s).
• Start the feed pump.
• Start the high-pressure pump.
• If a VFD or a soft starter is used, a ramp up
time of minimum 10 seconds is required to
avoid damage of the pump.
• Monitor the inlet and outlet pressure of the
high-pressure pump and look for leakages.
• Check the function of the pressure
indicators by slowly closing the valves. The
pump unit should stop when the minimum
inlet pressure and maximum outlet
pressure has been reached.
• Adjust the pressures to the specified inlet
and outlet pressure for the system and let
the pump unit run until the electric motor
and pump temperature is stable.
• If the system is running within the system
design limits, the system is released for
operation.
5.18 Check the filter condition
Evaluate contamination found in filter, replace
filter elements, if necessary.
5.19 Instruct operator and maintenance
personnel
Before using the pump/pump unit, the personnel
must be instructed in using the pump/pump
unit, its function, components, documentation
and safety.
Danfoss offers commissioning and service at
system manufacturer’s location. Rate quotes are
offered upon request.

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6.1 General safety information
Before inspecting the pump unit, read the Safety
chapter 2 in this user manual.
6.2 What to listen and look for
If one or more of the following examples are
observed, please act as indicated:
A) Loose bolts – check all bolts and, if
necessary, contact the maintenance
department in order to have all bolts
tightened to the specified torque(s).
B) Leakage – if a small leakage from the bell
housing is observed. Contact the mainte-
nance department.
C) Leakage – if there is a large leak, the unit
should be stopped immediately. Contact
the maintenance department.
D) High frequency tones – safety/relief valves
are either damaged or running very close
to their design pressure, stop the unit
immediately. Contact the maintenance
department.
E) Increased noise or vibration – requires the
unit to be stopped immediately. Contact
the maintenance department.
F) Very high temperatures – may indicate that
one or more parts are damaged inside the
pump. The pump must be stopped
immediately and inspected before it is
restarted. Contact the maintenance
department.
G) Drop in flow and/or pressure – may indicate
wear on one or more parts inside the
pump. The pump must be stopped
immediately and inspected before it is
restarted. Contact the maintenance
department.
H) Other observations or troubles, please see
appendix 7, Right and Wrong or appendix
6, the Trouble shooting guide.
Both appendices give good advises
regarding design, installation, wiring and
troubleshooting.
See also service and warranty section in
appendix 1, Data sheet and appendix 2,
Instruction.
If the pump is not stopped for inspection as
recommended, it can lead to damage of the
pump or break-down. See also service and
warranty section in the appendix 1, Data sheet,
in appendix 2, Instruction or appendix 4,
Instruction for recommended service intervals.
Danfoss offers service of the pump at the system
manufacturer’s location as well as we offer
training in how to service the pump. Quotes are
offered upon request.
Danfoss recommends simultaneously to check
the filter and membrane condition and to
evaluate contamination; filter and membrane
elements must be replaced if necessary.
6. Operation of pump
unit
7. Maintenance and
service of the pump
unit 7.1 General safety information
Before servicing the pump unit, it is necessary to
read and understand this user manual, especially
the Safety, chapter 2. Remember to wear suitable
safety equipment according to Safety, chapter 2.
7.2 Service and inspection interval for the
pump
Maintenance and service intervals are depending
on the cleanliness level of the water, hydraulic
load and temperature of the pump unit. The
most important parameter is the filtration of the
water.
See the section Service and warranty in the
appendix 1, Data sheet, in appendix 2, Instruc-
tion and appendix 4, Instruction for recom-
mended service intervals.
For spare parts and service tools, please see
appendix 3, Parts list.
Danfoss offers service of the pump at the system
manufacturer’s location and training in how to
service the pump. Quotes are offered upon
request.
7.3 Shut down of the system
A) Open the pressure valves at the brine site
to release the pressure.
B) Stop the high-pressure pump.
C) Stop the feed pump.
D) Switch off the safety circuit breaker for
both the high-pressure pump, feed pump
and VFD and lock them. Only personnel
servicing the pump unit should be able to
unlock/activate the switch again.
E) Open bleeding and drain plugs. Wait until
the pump and system are emptied for
water.

Operation guide | Installation, Operation and Maintenance APP W HC 15 - 30 pumps
14 180R9410 | AQ282628894589en-000801 | IOM APP W HC 15-30 Pumps | 01.2022
F) Slowly unscrew and remove the bolts and
gaskets from the inlet/outlet hoses or
pipes, be careful about jets of water.
Beware that the system can be pressurized!
G) Attach the lifting equipment to the pump
unit. For instructions on lifting the
complete pump unit, see chapter 4, Arrival
inspection, transportation, handling, lifting
and storage.
H) For the small pumps, unscrew the bolts
holding the pump to the bell housing. For
the bigger pumps, unscrew the bolts/nuts
from the pump and bell housing to the
motor. Afterwards unscrew the bolts/nuts
holding the pump and bell housing.
I) Carefully pull the pump out of the bell
housing by using lifting equipment, if
necessary.
J) Hold the pump in different positions above
a drip tray; this should allow most of the
water trapped in the pump to drain. Clean
and dry the pump surface and plug the
bleeding and draining plugs.
K) Move the pump to a clean and safe location
where the pump can be inspected/
serviced.
7.4 Disassembling and assembling the
pump unit
A) Remove all connections from the pump.
B) Disassemble the pump according to the
Disassembling and Assembling Instruction
(available at www.hpp.danfoss.com)
Clean all parts and surfaces with a fluid
compatible with the materials found in the
pump. Wipe the parts clean and dry with a
lint-free clothing.
C) Inspect all parts including shaft seal and if
necessary, replace them; see appendix 3,
Parts list.
D) If the pump is going to be returned to
Danfoss for repair or a warranty claim, it is
important to contact Danfoss in order to
receive a return number and a form to fill
out with product information. A copy of the
form together with contact information
and reason for returning should be sent to
the email address on the form. The same
documents should be attached to the
shipment.
Returns without a return number will be
rejected !!!
7.5 Assembling the pump unit
Assemble the pump according to the Dis-
assembling and Assembling Instruction
(available at www.hpp.danfoss.com).
7.6 Procedure for mounting the pump onto
the electric motor
Mount the flexible coupling and bell housing
according to appendix 2, Instruction.
7.7 Getting the pump unit back into
operation
Find instructions of how to put the pump unit
back into operation in chapter 4, Arrival inspec-
tion, transportation, handling, lifting and storage
and Installation and commissioning, chapter 5.
7.8 Storage of the pump
If the pump has to be shut down for a longer
period, instructions can be found in appendix 2,
Instruction.

Operation guide | Installation, Operation and Maintenance APP W HC 15 - 30 pumps
15
180R9410 | AQ282628894589en-000801 | IOM APP W HC 15-30 Pumps | 01.2022
8. Troubleshooting and
scrapping criteria
8.1 General safety information
Before inspecting the pump unit, it is necessary
to read and understand this user manual,
especially the Safety chapter 2.
Remember to wear suitable safety equipment
according to Safety chapter 2.
8.2 Operational conditions which can cause
pump failures
The following conditions can cause a pump
failure :
• The pump is running dry.
• The inlet pressure is too high.
• The inlet pressure is too low.
• The temperature of the fluid is too high.
• The ambient temperature is too high.
• The pump is running against a blocked
port/closed manual valve.
• The pump is operating at a pressure out of
specification.
• The pump is running with a non-specified/
approved fluid.
• The pump is running in the wrong
direction.
• The filtration is insufficient.
• The pump is not being serviced according
to Danfoss specifications (end of life).
• There is excessive mechanical load on the
shaft coupling and piping.
8.3 Mechanical failure
If the pump is running dry, the temperature will
quickly increase which can cause burns.
If there is any leakage at start-up or during
operation, a high-pressure jet can cause eye or
skin damage.
Leakage can result in flooding, which can cause
slipping, tripping or falling.
If water is leaking into the electric motor; it can
cause electric shock, fire, short circuit or even
death. When mounting the pump vertically
always mount the motor above the pump to
avoid water leaking into the electric motor.
8.4 Electrical failure
If the wiring of the electric motor is incorrect or
the ground connection is missing, it can cause
electric shock, burn damages, fire or even death.
If a VFD is used and wrongly programmed, it can
damage the pump and lead to high tempera-
tures or other dangers.
All electrical installation must be carried out by
authorized personnel in accordance with
EN60204-1 and/or local regulations.
8.5 Responsibility
Danfoss takes no responsibility for any abnormal
injuries, risks or damages that could arise caused
by abnormal conditions, vibrations, corrosion,
abrasives, foreign objects or excessive tempera-
tures and shall not be liable for any consequen-
tial or incidental damages.
8.6 Scrapping criteria
Whether the pump can be repaired or need to be
scrapped, depends on in which conditions the
internal parts are, or how damaged the whole
unit is. Please use appendix 6, Trouble shooting
guide as guideline or send the pump to Danfoss
headquarter in Denmark for evaluation.
For other observations or troubles, please see
appendix 7, Right and Wrong which gives good
advises regarding design, installation, wiring and
troubleshooting.
In case the pump needs to be scrapped, please
follow your local environmental rules.

Operation guide | Installation, Operation and Maintenance APP W HC 15 - 30 pumps
16 180R9410 | AQ282628894589en-000801 | IOM APP W HC 15-30 Pumps | 01.2022

Operation guide
APP W HC pumps
APP W HC 15 - 30
Appendices for Installation, Operation
and Maintenance Manual
hpp.danfoss.com

Operation guide | Installation, Operation and Maintenance APP W HC 15 - 30 pumps
18 180R9410 | AQ282628894589en-000801 | IOM APP W HC 15-30 Pumps | 01.2022
Table of Contents
1. Data sheet for APP W HC pumps 15-30 (AI283147317727en-000601) .....................19
2. Instruction for APP W HC pumps 15-30 (AN283148361728en-000402)....................33
3. IOM Electric motors (180R9230)..........................................................43
4. Recommended service intervals (AX283334052821en-000301) ..........................49
5. Parts lists APP W HC pumps 15-30 (AX283149261730en-000301) . . . . . . . . . . . . . . . . . . . . . . . . .53
6. Trouble shooting guide (521B1447) .....................................................61
7. Right and wrong (180R9042) ...........................................................73
Contents

ro-solutions.com
Data sheet
APP pumps
APP 0.6-1.0 / APP 1.5-3.5 / APP (W) 5.1-10.2 /
APP 11-13 / APP 16-22 / APP 21-43
Data sheet
APP W HC Pumps
APP W HC 15 - 30
hpp.danfoss.com.

Data sheet | APP W HC 15 -30
20 180R9410 | AQ282628894589en-000801 | IOM APP W HC 15-30 Pumps | 01.2022
Table of Contents 1. Introduction ...........................................................................21
2. Benefits................................................................................21
3. Application examples ..................................................................21
4 Technical data .........................................................................22
4.1 APP W HC 15 - 30.......................................................................22
5. Flow at different rpm...................................................................23
5.1 APP W HC 15 - 24 flow curves measured at 120 barg ( 1740 psig ) ........................23
5.2 APP W HC 30 flow curves measured at 110 barg ( 1595 psig ) ............................24
6 Flushing valve curves ..................................................................25
6.1 APP W HC 15 - 30 integrated flushing valve .............................................25
7. Motor requirements....................................................................25
7.1 Calculation factor for APP W HC 15 - 30 @ 110 barg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
8. Temperature and corrosion.............................................................26
8.1 Temperature ...........................................................................26
9. Installation.............................................................................26
9.1 Filtration...............................................................................27
9.2 System with direct supply: .............................................................27
10. Dimensions and connections...........................................................29
10.1 APP W HC 15 - 30.......................................................................29
11. Dimensions with motor unit............................................................30
11.1 APP W HC 15 -30 .......................................................................30
12. Accessories ............................................................................31
12.1 Accessories for APP W HC 15 - 30 .......................................................31
13. Service.................................................................................31