MAKING MODERN LIVING POSSIBLE

Instruction

APP S 674 pumps

APP S 674 3.0-3.5 / APP S 674 5.1-9.0

APP S 674 21-38

ro-solutions.com

Instruction

Table of Contents

1. Identification

APP S 674 pumps

1. Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2.

2.1

2.2

2.3

System design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Open system design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

RO system with APP S 674 pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Protection from too high pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

3.

3.1 Mounting

3.2

3.3 Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.4.1

3.4.2

3.4.3

Building up the pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

APP S 674 3.0-3.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

APP S 674 5.1-9.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

APP S 674 21-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.

4.1

4.2

4.3

5.

Initial start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

APP S 674 3.0-3.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

APP S 674 5.1-9.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

APP S 674 21-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

6. Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

7. Long-term shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

8. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

9. Service and warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

9.1 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

9.2 Recommended service intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

10. EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Our CLP RO pumps have changed name as listed below:

CLP674 050-058 RO will now be called APP S 674 3.0-3.5

CLP674 085-152 RO will now be called APP S 674 5.1-9.0

CLP674 365-640 RO will now be called APP S 674 21-38

This is ONLY a name change.

Pump:

Code No:

Serial No: ccm / rpm:

900 ≤rpm≤1800

0.5 bar≤Pin≤5 barg

20 bar≤Pout≤80 barg

4°C≤Tmedia≤95°C

Media:

Warning

Use only 10µm filter with a

β-value>5000. Bleed the pump befor initial startup.

EX II 2 G bc T3

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Instruction

2. System design

APP S 674 pumps

2.1 Open system design

A

Inlet line:

Minimize pressure loss by allowing for maximum flow, minimum pipe length, as few bends/connections as possible, and fittings with small pressure losses.

B

Inlet filter:

Install the inlet filter (1) in front of the

APP S 674 pump (4). Please consult the

Danfoss filter data sheet for guidance on how to select the right filter.

C

Monitoring pressure switch:

Install the monitoring pressure switch (3) between the filter and the pump inlet. Set the minimum inlet pressure according to pump specifications. The monitoring pressure switch stops the pump if inlet pressure is lower than the set minimum pressure.

D Monitoring temperature switch when the

pump operates in a hazardous area:

Install the monitoring temperature switch between the filter and the pump, on either side of the monitoring pressure switch. Set the temperature according to pump specifications. The monitoring temperature

E

F

switch stops the pump if inlet temperature is higher than the set value.

Connections:

Ensure flange loads (5) do not exceed max. allowable loads on process connections according to API 674 3 rd

edition (pipe size).

Inlet pressure:

In order to eliminate the risk of cavitation and other pump damage, inlet pressure must be maintained in-betweens pump specifications.

G

LP relief valve (2):

Can be installed in order to avoid system or pump damage in case the pump stops momentarily or spinning backwards.

H

HP relief valve:

As the Danfoss APP S 674 pump begins to create pressure and flow immediately after start-up and regardless of any counter pressure, a pressure relief valve (6) should be installed to prevent system damage.

Note: If a non-return valve is mounted in the inlet line, a low-pressure relief valve is also required between the non-return valve and the pump to protect against high-pressure peaks.

4 5

6

1

PI

2 3

PS

5

2.2 RO system with APP S 674 pump

The numbers in brackets refer to the drawing on next page.

A Dimension the inlet line to obtain minimum pressure loss (large flow, minimum pipe length, minimum number of bends/ connections, and fittings with small pressure losses).

B Place an inlet filter (1) in front of the

APP S 674 pump (2). Please consult section

10, “Filtration” for guidance on how to select the right filter. Thoroughly clean pipes and flush system prior to start-up.

C 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.

D Ensure flange loads (4) do not exceed max. allowable loads on process connections according to API 674 3 rd

edition (pipe size).

E 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. 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.

F For easy system bleeding and flushing, a bypass non-return valve (6) is integrated in the APP S 674 pump.

G 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 the pump stops momentarily.

H A safety valve or a pressure relief valve (8) can be installed in order to avoid system damage as the Danfoss APP S 674 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.

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Instruction





APP S 674 pumps

  





















 

 

















2.3 Protection of too high pressures

The pump should be protected against too high pressure by using 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 80 bar

(1,160 psi).

The valve outlet must not be connected directly to the pump suction line. It must be connected directly to the drain.

















3. Building up the pump unit

3.1 Mounting

4

D

A: Flexible coupling

B: Bell housing

C: Motor shaft

D: Pump flange

1. Mount the coupling on the pump shaft.

Ensure an air gap between coupling and pump flange of min. 4 mm (0.16 in).

2. Mount the bell housing on the 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 the motor shaft.

Ensure the coupling and motor flange are not in contact with each other.

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Instruction APP S 674 pumps

5. Measure from motor flange to the top of the coupling. The measurement “B” shall be

3-5 mm (0.12 - 0.2 in) shorter than the measurement “A”.

6. Adjust respectively, verify the measurement, and secure both couplings with the right torques on the locking screws (see coupling operation & mounting instruction).

7. Mount the flexible gear ring and mount the bell housing/pump on the motor. After mounting it must be possible to move the flexible gear ring 3-5 mm (0.12 - 0.2 in) axial

“C”. The check can be done through the inspection hole of the bell housing. Secure flange bolts with the right torque.

If alternative mounting is desired, please contact

Danfoss High Pressure Pumps.

Choose proper tolerances to ensure an easy mounting of the flexible coupling without use of tools.

Please take care to observe the recommended length tolerances of the chosen coupling, as an axial force on the pump will damage the pump.

3

1

C

2

B

A

1 = Nuts:

APP S 674 3.0-3.5: 40 ± 4 Nm / 30 ± 3 lbf ft

APP S 674 5.1-9.0: 40 ± 4 Nm / 30 ± 3 lbf ft

APP S 674 21-38: 40 ± 4 Nm / 30 ± 3 lbf ft

2 = Bolts:

APP S 674 3.0-3.5: 40 ± 4 Nm / 30 ± 3 lbf ft

APP S 674 5.1-9.0: 75 ± 5 Nm / 55 ± 3.5 lbf ft

APP S 674 21-38: 75 ± 5 Nm / 55 ± 3.5 lbf ft

3 = Torque, see table beside:

Thread size

M4

Torque (Nm)

1,5

M5

2

M6

4,8

M8 M10 M12

10 17 40

Torque (lbf)

1.1

1.5

3.5

7.4 12.5 29.5

3.2 Direction of rotation

The direction of rotation is indicated by an arrow at the pump label.

3.3 Orientation

The pump can be mounted/orientated in any horizontal direction; vertically only with the shaft pointing upwards.

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Instruction APP S 674 pumps

3.4 Connections

3.4.1 APP S 674 3.0-3.5

4 x M8 x 1.25

12 depth

Ø49.82 [1.961

]

6

Inlet

Outlet

Mounting of flange connections

Bolt torque: 30 ± 3 Nm

22 ± 2 lbf. ft

3.4.2 APP S 674 5.1-9.0

8 x M8 x 1.25

15 depth

Ø64 [2.52]

Outlet

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Inlet

Mounting of flange connections

Bolt torque: 30 ± 3 Nm

22 ± 2 lbf. ft

Instruction APP S 674 pumps

3.4.3 APP S 674 21-38

8 x M10 x 1.5

17 depth

Ø87 [3.425]

Inlet

Outlet

Mounting of flange connections

Bolt torque: 30 ± 3 Nm

22 ± 2 lbf. ft

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 using an internal flushing valve, to remove possible impurities from pipes, hoses etc.

3. Loosen top bleeding plug (see item 3.4) using an Allen key (only plugs with internal hexagan sockets). Retighten the plug, when water 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.

4.1 APP S 674 3.0-3.5

4.2 APP S 674 5.1-9.0

Internal flushing valve Internal flushing valve

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Instruction APP S 674 pumps

4.3 APP S 674 21-38

5. Technical data

8

1)

2)

Pumps size

Outlet min. pressure, continuous

1)

Outlet max. pressure,

MAWP

Inlet operating pressure

2)

barg psig

Inlet design pressure

barg psig

Min. speed, continuous

Max. speed, continuous

Media temperatur

3)

rpm rpm

°C

°F

Ambient temperatur

barg psig barg psig

Storage temperature

Weight

°C

°F

°C

°F

Kg lb

APP S 674 3.0-3.5

20

290

80

1,160

0.5-10

7.25-145

15

217

700

3,000

2-50

36-122

0-50

32-122

-40 to +70

-40 to +158

15

33

APP S 674 5.1-9.0

30

435

80

1,160

2.0-10

29-145

15

217

700

1,800

2-50

36-122

0-50

32-122

-40 to +70

-40 to +158

40

88

For lower pressure, please contact Danfoss High Pressure Pumps

If inlet pressure exceeds inlet operating pressure, Danfoss recommends inspection of the pump and shaft seal

Dependent on the NaCl concentration

APP S 674 21-38

30

435

80

1,160

2.0-10

29-145

15

217

700

1,500

2-50

36-122

0-50

32-122

-40 to +70

-40 to +158

110

242

Inlet pressure:

If using lower inlet pressure than stated in above table, the pump will cavitate, which will damage the pump.

The inlet line connection must be properly tightened as entrance of air will cause cavitation.

Outlet pressure:

MAWP (Maximum Allowable Working Pressure) must be within specifications.

If pump operates below minimum outlet pressure, it may cause cavitation/erosion in the pump.

Note: We recommend that the pump unit includes a pressure gauge at inlet and outlet.

Dry running:

When running, the pump must always be connected with water supply in order to avoid pump damage.

Disconnection:

If inlet line is disconnected from the water supply, the pump will be emptied which will cause dry running.

When starting up again, follow the bleeding procedure described in section 4: Initial start-up.

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Instruction

6. Operation

80 º C

70

60

50

40

30

20

100

160

APP S 674 pumps

6.1 Temperature

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 S 674 pump is made of 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 minimise the risk of crevice corrosion.

NaCl vs. temperature

316L

1000

1600

Duplex

Super Duplex

10 000

16000

100 000

160000

7. Long-term shutdown

For a long-term shutdown period, the SWRO system including the pump must be flushed with fresh water (permeate) to remove any salt.

It is recommended to make few turns on the pump to flush it properly.

8. Storage

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 furter information on anti-freeze media, please contact Danfoss High Pressure Pumps.

3. Connect the pump to a tank containing anti-freeze additive. Connect a hose to the inlet port of the pump and through another hose return the flow from the outlet port to the tank with anti-freeze 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.

Recommended procedure:

1. Disconnect water supply to the pump.

2. Through the lower bleeding plug, empty the pump housing for water and close it again.

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Instruction APP S 674 pumps

9. Service and warranty

Danfoss APP S 674 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.

If Danfoss recommendations concerning system-design are not followed, it will strongly

influence the life of the APP S 674 pumps.

Maintenance:

After 8,000 hours of operation, it is strongly recommended to inspect the pump and change any worn parts, e.g. pistons. 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

service intervals.

Standstill:

The APP S 674 pumps are made of Super Duplex materials with excellent corrosion properties.

It is always recommended to flush the pump with freshwater when the system is shut down.

9.1 Repair

In case of irregular function of the APP S 674 pump, please contact Danfoss High Pressure

Pumps.

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Instruction APP S 674 pumps

9.2 Recommended service intervals

The recommended service intervals on the different parts in the APP S 674 pumps appear from the table below:

Position Qty. for all pump sizes

3.0-3.5

5.1-9.0

21-38

1 1 1

Description

1 Housing, main bearing

Material

Super Duplex,

PEEK

121

31

66

1

1

7

1

1

9

1

1

9

Port flange

Swash plate

Pistons Super Duplex,

PEEK

Service interval

No need for service

Super Duplex No wear part

Super Duplex 40,000 hours

Recommended inspection on a yearly basis; evaluate, if replacement is needed

92

91

61

1

1

1

1

1

1

1 Valve plate

1 Port plate

Super Duplex 24,000 hours

Super Duplex,

PEEK

24,000 hours

Super Duplex 40,000 hours

65 1 1

1 Cylinder barrel

1 Retainer plate

Super Duplex 24,000 hours

64

71

1 1

1

62

63

142

124

125

93

5, 123,

126, 127,

128,

133,147,

153

1

1

1

1

7

1

1

1

1

9

1 Retainer ball Super Duplex 40,000 hours

1 Retainer guide

Super Duplex,

PEEK

40,000 hours

4 Spring Hastelloy, C4 40,000 hours

Spring guide PEEK 40,000 hours

Super Duplex No wear part 1 Stop for shaft seal

1 Shaft seal

1 Flange for shaft seal

Hastelloy and

NBR/FFKM

It is good practice to change the seal after each disassembly of the pump

Super Duplex No wear part

9 Back-up ring

O-ring

(overall)

Screw

(overall)

Teflon

NBR

AISI 316

24,000 hours

24,000 hours

No wear part

152 1 1

Pin (overall)

Pin (overall)

AISI 316, PEEK

AISI 316,

Super Duplex

Super Duplex,

PEEK

No wear part

40,000 hours

134

3

67

2

1

2

1

1 Valve cone

(flushing valve)

Bleeding screw

4 Bleeding screw

1 Parallel key

Super Duplex No wear part

Super Duplex No wear part

AISI 316 40,000 hours

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10. EC Declaration of

Conformity

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Instruction APP S 674 pumps

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Instruction APP S 674 pumps

Danfoss A/S

High Pressure Pumps

DK-6430 Nordborg

Denmark

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice.

This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.

All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

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