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Installation, Operation and Maintenance Manual APP S 674 pumps

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1. fm TT TT Never use only one sling and make sure the slings do not slip off the pump 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 180R9270 IOM APP S 674 v01 03 2013 Wrong lifting H 11 Ki S m Ir E Ir E O L T o E I IL Q Q9 IL When lifting the pum
2. 3 INSSIAA MO J PIINPIY Z dois 14e3s 3JOS Cp ainssaid anno 977 ainssaid ysuiebe sups duing ee abewep duund 1938 onb10 jue su0 ee duund wo eJnssaJd anno uBiu ool Le 14eys dund uo 5210 JeIXV S L abewep dung 9 1 duund jo 10138301 ON vi e1nsseJd Mop ON L 4030UI 21112 JO UOHE201 ON Cl BuisisA91 duing SL C Buluun Aig nj 63 180R9270 IOM APP 5674 v01 03 2013 Instruction 1 No flow no pressure 2 2 Trouble shooting guide for APP and APP S 674 pumps 1 1 Dry running no water supply to the pump 1 2 Pump reversing electric motor is running the wrong direction i e counter clockwise 1 3 No rotation of electric motor 1 4 No rotation of pump 1 5 Axial load on pump shaft may cause high internal leakage Only applying to APP 0 6 to APP 3 5 and APP 21 to APP 26 only Also applying to APP S 674 pumps 1 6 Pump damage the internal parts may be damaged If no water comes out of the pump 1 1 1 Check that inlet valve is open 1 1 2 Check that booster pump is running 1 2 1 Change the phase on the electric motor to make it run clockwise WARNING The pump must not run without water for more than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure in pump housing and will eventually break down 1 3 1 Check that main switch is switched on 1
3. 11 15 16 46 Responsibility O 7 9 16 SLUG C 10 15 45 ROsystem 6 8 9 21 32 39 45 Rotation 8 13 25 27 41 43 64 65 67 S Safety aos as 6 7 8 9 12 13 14 16 Safety valve 7 32 39 40 Scrapping criteria 16 Serial number 4 Service 6 7 8 9 13 14 15 16 21 EU S Pa 1035 36 46 47 53 Servicing 6 8 14 STUEGOM o ade oa ee xS 14 15 36 46 Signsofwear 65 67 69 Sound pressure level 30 31 Space requirement 8 Sparepart 14 54 56 58 Startup 7 8 11 12 16 32 39 43 44 67 Storage 9 10 12 15 44 45 uad 3 ey k ON RRO HR 6 System 6 7 8 9 11 12 13 14 15 21 ak ork se ee 30 32 36 39 45 66 67 68 Systems 7 21 66 T Table of Contents 2 18 20 38 53 62 Technical data 8 22 44 Temperature 7 10 11 12 13 14 16 M Won eee d 7 29 32 39 44 45 65 66 Transportation 6 9 12 15 Trouble shooting 14 16 61 63 Trouble shooting guide 14 16 61 V Valve 7 11 12 13 14 16 21 28 32 E doe dues 39 40 43 64 65 67 69 W Warning 6 9 43 64 67 Warranty st mes 6 9 14 15 30 36 46 Danfoss can accept no responsibility for possible errors in catalogues brochu
4. Inlet outlet connection Parallel key DIN 6885 5x5x5 34 inlet flange ASME B16 5 Hn 3 outlet flange ASME B16 5 M6 Hexagon Allen key 5 mm 4 bolt flange For other requirements on flange connections please contact Danfoss High Pressure Pumps 4 bolt flange ISO 3019 1 82 2 180R9270 IOM APP S 674 v01 03 2013 33 Data sheet APP S 674 pumps 9 2 APPS 674 5 1 9 0 335 75 13 22 60 5 2 38 179 7 05 Inlet outlet connection Bleeding screw Parallel key DIN6885 10x8x45 m 0 39 x 0 31 x 1 77 m in Bleeding G 1 4 Hexagon Allen key 6 mm 1 2 inlet flange ASME B16 5 1 2 outlet flange ASME B16 5 For other requirements on flange connections please contact Danfoss High Pressure Pumps Pump mounting flange 150 3019 2 100 B4 34 180R9270 IOM APP S 674 v01 03 2013 Data sheet APP S 674 pumps 9 3 APPS 674 21 38 447 85 17 632 370 3 14 579 42 99 1 693 3 99 157 279 10 984 B B 70 2 756 VAR m SES 39 99 1 574 V7 A 8xM10x1 5 17 depth M12x1 75 13 depth M12x1 75 13 depth M12x1 75 13 depth Description APP S 674 21 38 Accessories Parallel key DIN 6885 12 x 8 x 70 ASME B16 5 E 7777 2 outlet flange ASME B16 5 Bleeding G Y Hexagon Allen key 8 mm 8 bolt flange For other requirements on flange connections please contact Danfoss High Pressure Pumps Pump mou
5. Installation Operation and Maintenance APP S 674 pumps A It is always the system builders 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 3 1 Approved applications and operational limits for the pumps The pump and the pump unit are designed for the use in a Sea Water Reverse Osmosis SWRO system and Brackish Water Reverse Osmosis BWRO system The APP S 674 pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor A 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 180R9270 IOM APP S 674 v01 03 2013 o 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 appendi
6. 60 180R9270 IOM APP S 674 v01 03 2013 MAKING MODERN LIVING POSSIBLE Guideline Trouble shooting guide for APP and APP S 674 pumps ro solutions com Instruction Table of Contents Trouble shooting guide for APP and APP S 674 pumps 62 Trouble shooting guide for APP and APP S 674 pumps Trouble shooting fish bone chart 1 2 6 1 6 2 6 3 No flow no pressure Reduced flow reduced pressure High torque on electric motor Noise from pump Noise from installation Typical signs of wear Valve plate Port plate Swash plate 180R9270 IOM APP S 674 v01 03 2013 Trouble shooting guide for APP and APP S 674 pumps Instruction Trouble shooting fish bone chart GER ER dWnd uonej e3su WO4 SION S duind wodj SION r 1030UJ 211329 9 au Jadwep uoneJqiA S S 10310UJ uo nbio1 YBIH ldu p ds uone101 ubiH Sy uue1J uo 12 4Ip pe1unoui sedid sesoH be ss uJJl s SOH Ce Buisi A i duing r r eJnssoJd J9 UI Jeuruou xeu ul EE eui 19 3n0 39 U1 yo suoisueuuip u16ue Z S dune Jo suonipuo 2 sedid sesou suonoeuuo 3 nno lul Le piny ul aly b C Ndy 2 C eJnssaJd 3e ui MO ez piny YIH LL L Z piny Jo ad L 6 L z 5eye Ieuj lu duind ul sea UZ uoneny urew 8 L T jueuneeJ eJd S
7. When starting up again follow the bleeding procedure described in section 4 Initial start up Instruction 6 Operation 7 Long term shutdown 8 Storage 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 Super Duplex 2 2 APP S 674 pumps 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 For a long term shutdown period the SWRO system including the pump must be flushed with fresh water permeate to remove any salt 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 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 180R9270 IOM APP S 674 v01 03 2013 100 000 160000 It is recommended to make few turns on the pump to flush it prope
8. ec aa Z gt 161 LLL Soen geng asse dxf pp o x Lb Lo oLoLo Lolo Lo Loo Super Duplex j j usse LL j j Screw M8x16 AISI 316 w w w xixixl SuperDupe xi xj pp LL LLL DuplevyEkKii 1 x x 1 fete j j II pe ECH o j j j j al L TTT superDuplexEk T I o al LL x L j TTT Hastelloy Ca FKM xt O j 0 I j p i 1 Coverforshaftseal SuperDuplex J J p p p xt III x L L TTT 1 Super Duplex x j j AISI 316 Checknutmi2 Juss E P P P P P oj jJ jJ oj o o al Ll Lo _ A A PE ES o al L L x valvecone SuperDuplex PX Aleng soc j j x x 25 x ix COE Duplex 6 y y y y Super Duplex Supe NBR NBR NBR AISI 316 AISI AISI 3 FPM mo d j j Retainerbal SuperDuplex J dels super Duplex j j ix EE AO x L L _ swew x x _ ES V ass s
9. MAWP psig Inlet operating pressure barg psig Inlet design pressure barg psig Min speed continuous rom Max speed continuous rom Media temperatur C F Ambient temperatur C F I F Pumpssze APPSG A3035 APPS67454 90 APP S6742138 1 160 2 0 10 7 25 145 29 145 29 145 1 500 36 122 32 122 30 435 15 217 700 40 to 70 40 to 70 40 to 70 40 to 158 40 to 158 40 to 158 m sl vl x For lower pressure please contact Danfoss High Pressure Pumps 2 Ifinlet pressure exceeds inlet operating pressure Danfoss recommends inspection of the pump and shaft seal Dependent on the NaCl concentration 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 180R9270 IOM APP S 674 v01 03 2013 Note VVe recommend that the pump unit includes a pressure gauge atinlet and outlet Dry running VVhen running the pump must alvvays 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
10. as well as fluid and torque requirements Instrumentation pressure switch should be designed to See Data sheet for the used conform to the environment corrosion and humidity equipment Check the factory settings of the safety relief valves or See Data sheets for the used pressure relief valves 8 amp 9 valves Check the settings of the pressure transmitter switch 3 set See Data sheet or Instruction at min inlet pressure appendices 1 and 2 CP10 Check that all pressure indicators PI are selected to be able Scaling should at least be 1 bar to measure the system pressure range or more precise CP11 Check coupling distance air gab movement of the spider 3 5 mm see Instruction appendix 2 CP12 Check correct connections on the pump in amp outlet ee ESB check piping for possible air gaps gt 5 7 Lifting and positioning 5 9 Electrics Lift the pump unit onto base Remember All electrical installation work must be carried vibration dampers if needed Fasten the motor out by authorized personnel in accordance with to the base EN60204 1 and or local regulations see also Safety chapter 2 See also chapter 4 Arrival inspection transporta tion handling lifting and storage Turn off the safety circuit breaker and lock it Mount the power cable on the electric motor 5 8 Mount the different equipment connections pipes tubes check and safety relief Ifa VFD is used adjust the protective motor
11. the fluid without being damaged Too high inlet pressure causes too high pressure inside the pump damaging the pistons and eventually the pump Inlet pressure below 1 bar causes cavitation and insufficient internal lubrication resulting in wear on internal pump parts Mount a low pressure switch in front of the pump and check its set point function The low pressure switch will ensure that the pump does not start until the inlet pressure has reached 1 bar If pump rotates in wrong direction it will take in water from the high pressure outlet line Pressure will be built up inside the pump and it will eventually be damaged Higher rpm than specified in the pump data sheet results in wear of the pistons i e pistons may be damaged High rpm will also increase pressure pulsations from the pump and the noise level will increase If rpm is changed noise frequency will also change At too low outlet pressure the pump will create higher pressure pulsations and thus make noise Too low pressure also causes insufficient internal lubrication and wear on internal parts Pump may eventually be damaged Too high outlet pressure may damage the pump Noise frequency changes during soft start up stop 67 Instruction Trouble shooting guide for APP and APP S 674 pumps 5 Noise from installation CTN Gomes 0 5 1 Inlet outlet connections hoses pipes 5 1 1 Use flexible hoses at inlet outlet connec Non flexibl
12. 2 The pumps are supplied with an integrated flushing valve that allows the saltwater to flow from inlet to the outlet when the pump is not running The pumps are made for flange connections All parts included in the pumps are designed to provide long service life i e long service life with a constantly high efficiency and minimum service required Retainer plate Piston shoe Valve plate Swash plate Cylinder barrel Springs Port plate Flushing valve 1 2 3 4 5 6 Z 8 9 Housing Tail stock screws Drain plug Zero risk of lubricant contamination Oil lubricants are replaced with the pumped medium seawater or brackish water so SWRO and BWRO applications are completely free of any contamination risk from the pump o Low maintenance costs Efficient design and all Super Duplex stainless steel construction ensure exceptionally long life When Danfoss specifications are met service intervals up to 8 000 hours can be expected Low energy costs The highly efficient axial piston design provides the lowest power consumption of any comparable pump on the market The pumps are used in RO systems for produc tion of fresh water This water can be used for drinking or as technical water used for NOx reduction in gas turbines or as water used for in
13. 242 242 242 For lower pressure please contact Danfoss High Pressure Pumps 2 If inlet pressure exceeds inlet operating pressure Danfoss recommends inspection of the pump and shaft seal 3 Dependent on the NaCl concentration o LA e I dan UJ olo I s ln UJ e I UJ olo I N ON UJ olo I ab ui JE S Ambient temperatur o o 31m160 b Un O N Se Un n Un Un Un O 24 180R9270 IOM APP S 674 v01 03 2013 2 2 Data sheet APP S 674 pumps 5 Flow Ifthe required flow and rotation speed rpm of the pump are known the below diagram can be used to select the pump that fits the application best 5 1 APPS 674 3 0 3 5 flow curves at max pressure APP S 674 3 5 APP S 674 3 0 APP S 674 3 5 APP S 674 3 0 180R9270 IOM APP S 674 v01 03 2013 25 Data sheet 26 APP S 674 pumps 5 2 APPS 674 5 1 9 0 flow curves at max pressure 180R9270 IOM APP S 674 v01 03 2013 A APPS674 9 0 APP S 674 8 2 APP S 674 7 2 APP S 674 6 5 APP S 674 9 0 APP S 674 8 2 APP S 674 7 2 APP S 674 6 5 Data sheet APP S 674 pumps 5 3 APPS 674 21 38 flow curves at max pressure APP S 674 38 APP S 674 33 APP S 674 30 APP S 674 26 APP S 674 24 APP S 674 21 APP S 674 38 APP S 674 33 APP S 674 30 APP
14. 3 2 Check the electricity at the facility 1 3 3 Ensure that motor relay is switched on 1 3 4 Ensure that fuse is not blown 1 3 5 Ensure that booster pump is started 1 3 6 Check that the monitor switches are working correctly 1 3 7 Disconnect pump from electric motor and check that the motor is capable of running with no load 1 4 1 Ensure that coupling between electric motor and pump is connected 1 4 2 Check if coupling is damaged 1 4 3 Check that electric motor is sized correctly 1 4 4 Check that the electrical installation is correctly sized 1 4 5 Contact Danfoss Sales office for guidelines in how to troubleshoot internal pump parts 1 5 1 Ensure that the air gap between the two coupling parts is min 5 mm It should always be possible to move the plastic part on the coupling at least 3 mm 1 6 1 Contact Danfoss sales office for guidelines in how to troubleshoot internal pump parts 64 180R9270 IOM APP S 674 v01 03 2013 Mount a low pressure switch in front of the pump and check its set point function The low pressure switch ensures that the pump does not start until the inlet pressure has reached minimum inlet pressure see Data sheet Rotation direction for the APP or APP S 674 pump is shown by an arrow on the sticker on the side of the pump If motor type relay or the electrical fuse is blown check that electric motor is sized correctly To ensure easy mounting of the flexible coupling with
15. 3 d edition pipe size F Inlet pressure In order to eliminate the risk of cavitation and other pump damage inlet pressure must be maintained within 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 HPrelief 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 8 4 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 mini mum pressure loss large flow minimum pipe length minimum number of bends connections and fittings with small pressure losses 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 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 Ensure flange loads 4 do not exceed max allowable loads on pr
16. 674 21 38 Parts list 7 UN UNOL UNE WNOE e d A d E a m Diy O Cu NS WNZ WNOL O 1 2 IAE NS NS Y WNE UNOS WNZ WNOL Ww A MED en NES WNE WNOE d MM ISSSSSSSVI 22 AU LE Str PAP PP PPP PP PPP NN 2 7 W g lt IS gt SS 2 22 2 22222722222 NZ www T 7777777 ANA ch 59 180R9270 IOM APP S 674 v01 03 2013 Parts list APP S 674 pumps 8 Toolsets Note The parts listed are not sold separately only in various kits 180B4347 Tool set APP S 674 21 38 Designation Adjustable pin wrench ES Nut M8x6 5x13 ES Guide bolt M8x140mm ES Press Bush 245 ES Eye bolt M8 ES Press bush for valve plate ES Stop for retainer plate ES Screw M8x20 ES Screw M8x70 Screw M8x140 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
17. G General information 7 Guideline 16 36 61 64 H Handling 7 9 12 15 Initial start up 8 43 44 67 Inspection 9 12 13 14 15 22 23 Lo 24 36 41 44 46 47 Installation 6 7 8 11 12 14 15 16 64 68 Instruction 6 7 8 9 10 12 14 15 37 Pe qu pu ee 41 54 56 58 64 67 Instrumentation 6 12 Introduction 24 4444 x9 4 xu wes 6 21 M Maintenance 6 7 10 13 14 21 30 36 46 Mechanical failure 16 Mounting us 8 11 13 15 30 33 34 35 PU LEG EARN RR RESET 40 41 42 43 64 68 Motor requirements 29 N Name plate 9 11 12 13 63 Noise 8 14 30 67 68 L Leaking 3 yeh 3 b wamak a Wa 16 L LL O 6 9 10 12 15 Local regulations 6 7 0 11 12 16 O Open system design 32 39 Operation 6 7 8 9 13 14 15 16 29 EE 36 41 45 46 65 67 Operational conditions 7 16 P Partslist 14 15 51 54 56 58 60 Installation Operation and Maintenance APP 5 674 pumps PIPINO 3 62 0424 54555 9 11 12 16 Positioning 12 Preferred system design 7 11 Premounting 11 Protection 6 7 8 10 32 39 40 R Recommended service intervals 47 Relief valve 12 13 14 32 39 40 Repas
18. Pompe haute pression Type de machine APP S 674 3 0 APP S 674 3 5 APP S 674 5 1 APP S 674 6 5 APP S 674 7 2 APP S 674 8 2 APP S 674 9 0 APP S 674 21 APP S 674 24 APP S 674 26 APP S 674 30 APP S 674 33 APP S 674 38 Num ro de s rie N A Personne de contact pour le dossier technique Manager d partement qualit Normes harmonis es appliqu es DS EN ISO 12100 2011 Signature du fabricant Titre LI Lt TTT EE A i DEET TTT 2012 12 19 Datum Welm Friedrichsen Leiter F amp E 2012 12 19 Date Welm Friedrichsen Director R amp D 48 180R9270 IOM APP S 674 v01 03 2013 2012 12 19 Date VVelm Friedrichsen Directeur R amp D Instruction APP S 674 pumps 180R9270 IOM APP S 674 v01 03 2013 49 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 50 180R9270 IOM APP S 674 v01 03 2013 MAKING MODERN LIVING POSSIBLE Parts list APP
19. and handling d q dorso 9 4 5 Elei 10 4 6 10141 eee 0003709 0000000090 5000007 10 5 Installation and commissioning 11 5 1 H dimensions u icc ab added 11 5 2 LS CS I s A PREIS 11 5 3 PUL Wel e cU ER 11 5 4 do EE 11 5 5 Local ted dt CEET 11 5 6 Pre mounting checklist based on Danfoss preferred system design 11 5 7 Bette Ehe l l r ii olla o oo ero EEG d o Eo O 0000 0500770000 I 12 5 8 Mount the different equipment 12 5 9 EL T R aa Geen yeh pee aa aa 12 5 10 A 000 3 12 5 11 COL iy l 3033030709 12 512 Ensure Oe io yaa cvs 13 5 13 Verify setting of safety relief valveS 13 5 14 EU ie PUM EEN 13 5 15 Bleed and remove air from the pump 13 5 16 Verity direction OF fOtdtlODon EE 13 5 17 Commis A II waqa 13 5 18 Check the filter condition 13 5 19 Instruct operator and maintenance personnel 13 6 Operation ol pup UNIE escarnio ida ea iaa hq bae e arta eu 14 6 1 General safety information 14 6 2 Whattodisten and OOK TOE AUT dede saone 14 180R9270 IOM APP S 674 v01 03 2
20. at the inlet 5 is always to be maintained at min inlet pressure and max inlet pressure Recom 180R9270 IOM APP S 674 v01 03 2013 mend 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 mem brane vessel works as an accumulator and will send flow backwards in case the pump stops momentarily 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 39 Instruction 3 40 Building up the pump unit APP S 674 pumps Media filter 8 E 4 7 AS AM Permeate D gt 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 press
21. 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 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 180R9270 IOM APP S 674 v01 03 2013 3 9 Airbubbles 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 A 3 10 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 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 User manual Installation Operation and Maintenance APP S 674 pumps Pumps which have a weight above 20 kilos see Data sheet appendix 1 must be handled by using lifting eyes and slings
22. 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 A 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 appen dix 1 Data sheet and in appe
23. item 5 6 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 housing 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 180R9270 IOM APP S 674 v01 03 2013 5 17 Commissioning Close all the bleeding and draining plugs o 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
24. stop in order to minimize the risk of crevice corrosion All wetted parts of the APP S 674 pumps are made of Super Duplex 100 000 160000 7 Motor requirements The power requirements can be determined using one of the following guiding equations l min x bar 16 7 x m h x bar 0 26 x gpm x psi Required power kW or kw or 1 34 hp Calc factor Calc factor Calc factor 0 75 kW 1 kW 1 34 hp APP S 674 3 0 3 5 Calc factor 485 3 79 min 11 min 0 26 gpm APP S 674 5 1 9 0 Calc factor 485 4 40 gpm 1 gpm 0 23 m h APP S 674 21 38 Calc factor 504 Both power and torque requirement must be verified in order to determine the correct motor size when the motor does not operate at nominal speed 180R9270 IOM APP S 674 v01 03 2013 29 Data sheet 8 30 Installation APP S 674 pumps The figure below illustrates how to mount and connect all pump sizes to an electric motor or combustion engine If alternative mounting is required please contact Danfoss High Pressure Pumps for further information Pump Bell housing Flexible coupling Motor Inlet Outlet flange C a o o I e ESOS ANN 8 1 Filtration Proper filtration is crucial for the performance maintenance and vvarranty of your pump Protect your pump the application in vvhich it is installed by alvva
25. up time of minimum 10 seconds is required to avoid damage of the pump Monitor the inlet and outlet pressure 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 specifled 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 A 5 18 Check the filter condition Evaluate contamination found in filter replace filter elements if necessary A 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 Quotes are offered upon request 13 User manual 6 7 Operation of pump unit Maintenance and servicing the pump unit Installation Operation and Maintenance APP 5 674 pumps A 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
26. 013 User manual Installation Operation and Maintenance APP S 674 pumps 7 Maintenance and servicing the pump unit 14 7 1 General safety information 14 7 2 Service and inspection interval for the pump 14 7 3 SUP OOW MOL THe WR bd es dan aa ray rias 14 74 Disassembling and assembling the pump unit 15 15 Assembling the pump unit 15 7 6 Procedure for mounting the pump onto the electric motor 15 ra Getting the pump unit back into operation 15 7 8 Storage OF ING Romo A 15 8 Troubleshooting and scrapping criteria 16 8 1 General safety information 16 8 2 Operational conditions which can cause pump failures 16 8 3 Mechanical ITE arar da 16 8 4 ages Panne EE 16 8 5 RESPONSE EE 16 8 6 GESEIS 16 Appendices APP S 674 pumps 17 Data sheet APP 56 4 pumps 52181187 unir rada daa 19 Pump instruction APP S 674 180R9276 37 Parte list APP S674
27. 2 Installation Operation and Maintenance APP S 674 pumps 1 1 General The APP S 674 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 Sea Water Reverse Osmosis SWRO system and Brackish Water Reverse Osmosis BWRO system In case the pump delivered is ATEX certified the additional ATEX instruction must also be read The APP S 674 pumps must not be used for other purposes than those recommended and specified without first consulting your local pump distributor A 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 A All personnel being responsible for operation and maintenance of the pump unit must read and fully understand these instructions especially the section Safety before e Transportation of the pump unit e Lifting the unit e Installing the pump unit e Connecting the pump unit to the water system e Connecting the electric motor and instru mentation Commissioning the unit Servicing the pump unit mechanical and electrical parts e Decommissioning the pump unit The pump must always be installed and used in accordance with existing national local sanitary safety regulations and laws Itis the responsibil
28. 4 Jana eunsseud punos o o o o N c o 8 2 3APP 5674 21 38 pump mounted on motor 75 kW 4 pole v aP ul Wd 7 849 eunsse1d punos E o o Q N c o 31 180R9270 IOM APP 5674 v01 03 2013 Data sheet 32 APP S 674 pumps 8 3 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 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 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 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 switch stops the pump if inlet temperature is higher than the set value 2 2 E Connections Ensure flange loads 5 do not exceed max allowable loads on connections according to API 674
29. 4 pumps 6 Typical signs of wear 6 1 Valve plate Picture 1 A normally worn valve plate has no marks scratches but only a slightly polished surface No scratches or marks should be felt The surface must be flat and level Picture 2 A worn valve plate has scratches and or a polished surface Even small scratches will give a loss of flow Scratches Picture 3 A good way to identify a worn valve plate is to hold a straight knife edge over the valve plate When holding it up to the light it will be possible to see any space between the knife edge and the valve plate See picture 3 If any light can be seen between the two arrows on the picture the valve plate is worn If any scratches or marks can be felt by running a fingernail over the surface the valve plate is worn The valve plate on picture 3 is highly damaged 180R9270 IOM APP S 674 v01 03 2013 69 Instruction Trouble shooting guide for APP and APP S 674 pumps 6 2 Portplate Picture 1 B IV C If the port plate has scratches level differences or both between the arrows i the port plate must be replaced Even small scratches or wear will cause loss of flow To check See item 6 1 picture 3 6 3 Swash plate Picture 1 If the swash plate is polished 360 it is an indication of insufficient filtration The surface of the swash plate must be plane and even at same level all over To check this please see item 6 1 picture 3 If the surface ha
30. D Switch off the motor 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 User manual Installation Operation and Maintenance APP S 674 pumps A 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 Unscrew the bolts that fasten the pump and bell housing to the motor and afterwards unscrew the bolts nuts from the pump and bell housing l 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 ro solution
31. M APP S 674 v01 03 2013 LI APP S 674 pumps Parts list Exploded view APP S 674 3 0 3 5 3 UN ev m UN CL N g NG o UNE UNS US SS SSS SS SN 1 NS WN sawan SS NS N INN LA Y SS AX 6 CH j ANI SS Q ZX INT Zl Z E ZW H SS lt A le d 2 7 NC Les 32 2 22 UNE UNOS UN UNOp L 31V0S 3 vlad 55 180R9270 IOM APP 5674 v01 03 2013 Parts list APP S 674 pumps 4 Spare parts list APP S 674 5 1 9 0 Including PMI report Including material certificate no traceability Including material certificate traceability CC CS T tos O 3 3 gm T 3 seems yi Lame m LEE ST ssis LE TEES lm s s s L L L L L T f o sense epes T T Lx r menma s s s T T DE ES TT L L L TO T IE EIN E w t re remet aom eiis Em Teen EE el rene E op oem m Ta ar 7 Pontes E rows lm Dm Ra can IEEE uuu 0 pe fons e Ts el eet superou sa femmes fase 17 lm T EI E EI E Deus Ip x 1 56 180R9270 IOM APP S 674 v01 03 2013 3 180B4250 Fl
32. MAKING MODERN LIVING POSSIBLE User manual Installation Operation and Maintenance Manual APP S 674 pumps ro solutions com User manual Table of Contents Installation Operation and Maintenance APP S 674 pumps Ee MEET 4 EU Declaration or CONTO E aa wes 5 1 Idee CIC EE 6 1 1 GENET EEN 6 1 2 s npo Ao nn ee ee ee ee 5700007 6 1 3 Manufacturer and customer service address 7 2 ec eee eee ee 7 2 1 ace o de den d qi PARERE dore 7 2 2 Preferred system design 7 2 3 Commissioning and servicing the unit 8 2 4 Adhere to the following important points 8 2 5 000 uuu u care oe O UI ee eee 8 4 Cai A EE 8 3 1 Approved applications and operational limits for the pumps 8 3 2 Applicaton TANG 8 3 3 k H C Moto dates 8 3 4 ir og 0000079 8 3 5 Dimension i AA EE 8 3 6 Space requirement nadar eu ee aaa 8 3 7 BI ET 9 3 8 Properties EE 9 3 9 QMOUDDU ux TEE 9 3 10 Ba un EE 9 4 Arrival inspection transportation handling lifting and storage 9 4 1 Arrival inspections EE dra khas 9 4 2 A PEC 0 0009000005 0000000 9 4 3 General safety information 9 4 4 Transport
33. S 674 26 APP S 674 24 APP S 674 21 The curves above also show that the flow can be rotation speed to a corresponding value Thus changed by changing the rotation speed of the the required rpm can be determined as pump The flow rpm ratio is constant and the required flow can be obtained by changing the Required flow x Typical rpm Required rpm Typical flovv 180R9270 IOM APP S 674 v01 03 2013 27 Data sheet 28 APP S 674 pumps 5 4 Flushing valve characteristics The diagrams show the flow characteristics of the integrated flushing valve that allows the water to flow from inlet to outlet when the pump is not running 5 4 1 APPS 674 3 0 3 5 integrated flushing valve curve Pressure drop bar 5 4 2 APP S Flow m h 674 5 1 9 0 integrated flushing valve curve Pressure drop bar 3 5 3 4 A U UuoGcuan nu A TZ Flow m h S N 2 b 5 4 3APPS 674 21 38 integrated flushing valve curve Pressure drop bar 3 0 2 3 2 0 1 5 1 0 Flow m h 180R9270 IOM APP S 674 v01 03 2013 2 2 Data sheet APP S 674 pumps 6 Corrosion The chart below illustrates the corrosive If the water pump is operated at high salinity resistance of different types of stainless steel always flush the water pump with fresh water at related to NaCl concentration and temperature operation
34. 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 Parts list 52 APP S 674 pumps 180R9270 IOM APP S 674 v01 03 2013 Parts list Table of Contents Parts list APP S 674 pumps APP S 674 3 0 3 5 APP S 674 5 1 9 0 APP S 674 21 38 521B1248 Ts General APP S 674 pumps 1 2 3 General Spare parts list APP S 674 3 0 3 5 Exploded view APP S 674 3 0 3 5 Spare parts list APP S 674 5 1 9 0 Exploded view APP S 674 5 1 9 0 Spare parts list APP S 674 21 38 Exploded view APP S 674 21 38 This parts list provides an overview of the content of the various service sets for the APP S 674 3 0 3 5 APP S 674 5 1 9 0 APP S 674 21 38 as well as exploded views of the pumps 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 180R9270 IOM APP S 674 v01 03 2013 53 Parts list APP S 674 pumps N Spare parts list APP S 674 3 0 3 5 N Including PMI report Including material certificate no traceability Including material certificate traceability COCO peon m T s s _ ee l m CI O IS IS IS O IS E s EL x IS dT ES O i A Super Duplex L j p j Lolo Super Duplex 180B4231 Cylinder barrel 180B4232 Va
35. ating pressure Inlet design pressure o o o o Speed Min speed continuous Max speed continuous 5 rem Typical Flow m3 h m3 h 1500 rpm at max pressure 3000 rpm at max pressure N NO UJ NO LA LA UT 1800 rpm at max pressure gpm 3000 rpm at max pressure gpm Typical motor size 1500 rpm at max pressure kW Nils Uu N U1 1800 rpm at max pressure hp Z C Ca Torque at max outlet pressure m lbf ft 2 50 36 122 36 122 F Ambient temperatur C For lower pressure please contact Danfoss High Pressure Pumps 2 If inlet pressure exceeds inlet operating pressure Danfoss recommends inspection of the pump and shaft seal For higher speed please contact Danfoss High Pressure Pumps Dependent on the NaCl concentration Media temperatur o 180R9270 IOM APP S 674 v01 03 2013 Data sheet APP S 674 pumps 4 2 APPS 674 5 1 9 0 Pumps size APPS6745 1 APPS6746 5 APPS6747 2 APPS6748 2 APPS6749 0 senm Omer orearen Owen orenen os wm msl si ar s s k pe ms mul m l e nu me CTN SOS 27 3 4V e nl nl am xml w sol al als Lal al s als 7 For lower pressure please contact Danfoss High Pressure Pumps 2 If inlet pressure exceeds inlet operating pressure Danfoss recommends inspection of the pump an
36. burns If there is any leakage at start up or during operation a high pressure jet can cause eye or skin damage 180R9270 IOM APP S 674 v01 03 2013 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 In order to avoid water leaking into the electric motor see Installation and commission ing chapter 5 and Operation chapter 6 re 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 4 Trouble shooting guide as guideline or send the pump to Danfos
37. cy of only 50 which will cause internal wear and must always be followed by a main filter Insufficient filtration means that too many or too large hard particles can pass the main filter because it is damaged bypassed or simply too poor Filtration efficiency must be 99 98 Beta 5000 at 10 um to prevent abnormal wear of the pump Temperature gt 50 C will cause wear on internal pump parts Mount a temperature switch and check its set point function The temperature switch will ensure that the pump stops at fluid temperatures gt 50 C If the pressure drop across the filters is too high the booster pump does not deliver sufficient flow pressure No pressure or low pressure results in cavitation and insufficient internal lubrication causing wear on internal pump parts Mount a low pressure switch in front of the pump and check its set point function The low pressure switch ensures that the pump does not start until the inlet pressure has reached 1 bar Speeds below 700 rpm result in insufficient internal lubrication causing wear on the internal pump parts 65 Instruction Trouble shooting guide for APP and APP S 674 pumps 3 High torque on electric motor 3 1 Too high outlet pressure from pump 3 1 1 Check fluid salinity Pump conditions may change more salt lower 3 1 2 Check temperature water temperature or scaling of RO membrane 3 1 3 Check pressure drop across RO membrane causing higher pressure resu
38. d beyond repair A 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 Figure 1 Recommended system design Media filter 180R9270 IOM APP S 674 v01 03 2013 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 A 5 5 Local regulations Commissioning must always be done in accordance with valid regulations and local standards 5 6 Pre mounting checklist based on Danfoss preferred system design Permeate M 1 7 User manual 2 2 Installation Operation and Maintenance APP S 674 pumps Table 1 Check points when assembling and commissioning system Ensure that the environmental conditions are safe See Arrival inspection transportation handling lifting and storage chapter 4 Minimum and maximum start up temperature for fluid and See Instruction appendix 2 7 pump Filtration condition 10 um absolute 8 x 50001 See Danfoss requirements in Data sheet and Instruction appendices 1 and 2 Povver supply for electric motor and VFD See Data sheetfor the used motor and VFD Safety circuit breaker must be sized for the motor and See Data sheet for the used environment corrosion and humidity safety circuit Bolts and screvvs must conform to environmental conditions
39. d shaft seal Dependent on the NaCl concentration 180R9270 IOM APP S 674 v01 03 2013 23 Data sheet APP S 674 pumps 4 3 APPS 674 21 38 APP S 674 21 APP S 674 33 On request On request S psig 435 435 435 435 psig 1160 1160 1160 1160 1160 psig APP S 674 38 On request 4 27 1 cm rpm Geometric displacement in rpm Outlet min pressure continuous barg I M UJ UJ o W 435 Outlet max pressure MAWP 1160 Inlet operating pressure 2 0 10 Inlet design pressure 1000 rpm at max pesar kw 1000 ram at max pres hp o o o DI DI DI ue ue 0 N o N a gt Uu N o N el Sei Uu N o N 1 mis Uu N o N 1 Uu N OIN 1 Uu N m UT 217 psig 700 1500 UT UT Iii e UT e I ul z o II w EA olo NA ee UJ 00 I 17 5 N N I E I Go Un N a o o N O N OV NO NA gt NA N o UJ UJ vv 106 5 117 6 138 146 6 169 N 0 LA N gt UJ N Un x Nm 56 639 Ibf ft 273 6 304 6 332 6 391 410 471 3 Torque at max outlet pressure Media temperatur 36 122 0 50 32 122 32 122 32 122 32 122 32 122 32 122 Weight 110 110 110 110 110 110 mp o 242 242 242
40. dling lifting and storage Installation Operation and Maintenance APP S 674 pumps A A 3 7 Filtration 10um absolute 3 50001 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 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 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 A 4 2 Warning Before any lifting operation is performed environmental conditions must be taken into consideration Ex rated areas wind speed wet dry
41. e connections mounted directly on tions Danfoss can provide flexible hoses the frame will cause even small pressure Please contact Danfoss sales office for pulsations from pump and create vibrations in further information the system plant 5 1 2 Mount the connections to the frame by a vibration damper mounting plate 5 2 Length dimension of inlet outlet line 5 2 1 Increase pipe diameter and or reduce the 1 Too small pipes or too many bends may create number of bends too fast flow turbulence through the pipes and thus increase the noise level 5 3 Hose stiffness 5 3 1 Use a more flexible hose Danfoss can Too stiff hoses cannot damp the small pressure provide flexible hoses Please contact pulsations from the pump and subsequently Danfoss sales office for further informa vibrations occur in the system plant tion 5 4 Hoses pipes mounted directly on frame 5 4 1 Mount the connections to the frame by a If the hoses are mounted directly on the frame vibration damper mounting plate the small pressure pulsations from the pump can be transferred to the frame and the rest of the system plant 5 5 Vibration damper under the electric motor 5 5 1 Mounta vibration damper below the When no damper is installed below the electric motor pump motor vibrations from the motor and pump may be transferred to the frame and the rest of the system plant 68 180R9270 IOM APP S 674 v01 03 2013 Instruction Trouble shooting guide for APP and APP S 67
42. ens pump specifications G LPrelief valve 2 Can be installed in order to avoid system or pump damage in case the pump stops momentarily or spinning backwards H HPrelief 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 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 mini mum 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 edition pipe size E In order to eliminate the risk of damage and cavitation a positive pressure
43. er Unterschrift Titel 2012 12 19 Datum Welm Friedrichsen Leiter F amp E EC Declaration of Conformity according to Directive 2006 42 EC We hereby declare that the machine is designedaccording to the directive 2006 42 EC Machine description High pressure pump Machine designation APP S 674 3 0 APP S 674 3 5 APP S 674 5 1 APP S 674 6 5 APP S 674 7 2 APP S 674 8 2 APP S 674 9 0 APP S 674 21 APP S 674 24 APP S 674 26 APP S 674 30 APP S 674 33 APP S 674 38 Serial number N A Technical dossier Contact person Manager Quality Department Used harmonised standards DS EN ISO 12100 2011 2012 12 19 Date VVelm Friedrichsen Director R amp D 180R9270 IOM APP S 674 v01 03 2013 D claration de conformite CE conformement a la Directive 2006 42 CE Par la presente nous declarons que la machine est concue conformement a la Directive 2006 42 CE Description de la machine Pompe haute pression Type de machine APP S 674 3 0 APP S 674 3 5 APP S 674 5 1 APP S 674 6 5 APP S 674 7 2 APP S 674 8 2 APP S 674 9 0 APP S 674 21 APP S 674 24 APP S 674 26 APP S 674 30 APP S 674 33 APP S 674 38 Numero de serie N A Personne de contact pour le dossier technique Manager departement qualite Normes harmonisees appliqu es DS EN ISO 12100 2011 Signature du fabricant Titre 2012 12 19 Date VVelm Friedrichsen Directeur R amp D User manual 1 Introduction 2
44. fx x x _ Am S 7 T J T jom m SuperDupex yi Spring Hastelloyczs LL deje J j j superduplePEER j afen asse x j J j j o x N q 2 oi SU o 5 ou Uv 9 bd m Y g y 2 5 S l i v Oo ES o M uy D C lt S S 4 e Dl sie O Dl gt o Eo un c E Js lo v9vikyi ic c EY Z lt cic ol D c c a V 5 V ca 8 un ac a gt AE edn l a I I 4 4 seewmens asse x J j w SuewMed asis x j sees pe x jJ J j j j c n gt Lu D gt m O O O n n ON UC loost lin ol i MN m ilimi amis IL NP UG INIT MIE TIN OAIR joala O INI mMInI N m Les e e N OY O OY CN N N N N N N N N m mM e mM r r r r r LO Ln Ln les les les Le le les le le im le le le Le lee le le Le LR Housing Including material certificate no traceability Including material certificate traceability ICC Including PMI report N m 180R9270 IOM APP S 674 v01 03 2013 00 LO APP S 674 pumps Exploded view APP S
45. gvej 81 D25 DK 6430 Nordborg Denmark Telephone 45 7488 4024 Fax 45 7445 3831 Email ro solutions danfoss com Homepage www ro solutions com A 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 e 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 from the electric motor Protect the motor and other electrical equip ment from overloads with suitable equipment In case the pump delivered is ATEX certified 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 180R9270 IOM APP S 674 v01 03 2013 Your local Danfoss pump distributor can be found on our homepage Data sheets and instructions on all accessories are available
46. 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 15 User manual 8 Troubleshooting and scrapping criteria 2 2 Installation Operation and Maintenance APP S 674 pumps A 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 o 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 vvrong direction The filtration is insufficient The pump is not being serviced according to Danfoss specifications end of life o 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
47. ion of the APP S 674 pump please contact Danfoss High Pressure Pumps 2 2 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 Description mali Service interval 1 Housing Super Duplex No need for service main bearing PEEK 1 Swash plate uper Duplex 40 000 hours Pistons Super Duplex Recommended inspection on a PEEK yearly basis evaluate if replace ment is needed 1 Valve plate Super Duplex 24 000 hours 1 Port plate Super Duplex 24 000 hours PEEK 1 Cylinder Super Duplex 40 000 hours barrel Retainer Super Duplex 24 000 hours plate 1 1 Retainer ball Super Duplex 40 000 hours 1 Retainer Super Duplex 40 000 hours guide PEEK 4 Hastelloy C4 40 000 hours Spring guide PEEK 40 000 hours seal Hastelloy and It is good practice to change the NBR FFKM seal after each disassembly of the pump Back up ring 24 000 hours O ring NBR 24 000 hours overall 5 123 Screw AISI 316 No wear part 126 127 overall 128 133 147 Pin overall AISI 316 PEEK Pin overall AISI 316 No wear part Super Duplex Valve cone Super Duplex 40 000 hours flushing PEEK valve Bleeding Super Duplex No wear part screw Bleeding Super Duplex No wear part screw Parallel key AISI 316 40 000 hours 180R9270 IOM APP S 674 v01 03 2013 47 EC Decla
48. ity of the safety officer or the chief operator to assure compliance with all local regulations that are not taken into account in this manual A Changing the pumps or pump units opera tional limits and hardware e Changes to the delivered pump or pump unit may only be done with a written approval from Danfoss High Pressure Pumps 180R9270 IOM APP S 674 v01 03 2013 e Operation outside the Danfoss specifications requires a written approval from Danfoss High Pressure Pumps e fany 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 A Indicates a situation which will or could result in personal injury and or damage to the pump A Electrical hazard Indicates a high voltage warning Safety glasses required Safety shoes required Hearing protection required to Safety helmet required o Protective garments must be worn Danger HOT AN K Do not touch N ener Electrical hazard Protective garments must be worn User manual 2 Safety 2 2 Installation Operation and Maintenance APP S 674 pumps 1 3 Manufacturer and customer service address Danfoss A S High Pressure Pumps Nordbor
49. jection into wells APP S 674 pumps are not only applicable for offshore applications but can also be used on 180R9270 IOM APP 5674 v01 03 2013 Easy configuration The lightest and most compact design available Pump can be installed vertically and horizontally No pulsation dampeners necessary due to extremely low pressure pulsation Powered direct by electric motor or combustion engine Pump can be delivered with all types of flange connections Certified quality Pump is designed according to API 674 3 edition Super Duplex stainless steel M 630 from NORSOK M 650 certified foundries Full traceability and material certifi cates on pressure containing parts Pump available as ATEX certified category 2 zone 1 or category 3 zone 2 refineries or in processes where API 674 is required As the APP S 674 pumps are made in Super Duplex stainless steel it makes them suitable for rough offshore applications Apart from that the small and compact pumps are a perfect choice for applications where component size really matters 21 Data sheet 4 22 Technical data APP S 674 pumps APPS 674 3 0 3 5 1 APS 6743 0 sens Fcodenumber onreguest Onrequest Geometric displacement pressure 0 Outlet min pressure 0 15 217 Outlet max pressure ki psig 1160 psig 7 25 145 SCH rpm Inlet oper
50. lting in higher motor torque 3 2 Pump starts against pressure 3 2 1 Check that electric motor is correctly sized Pumps run in parallel with cascade start may 3 2 2 Check internal parts see item 2 1 switch off the motor relay due to too high 3 2 3 Systems with more than one electric torque caused by high outlet pressure motor installed Start motors simultaneously 3 3 Constant torque 3 3 1 Please contact Danfoss sales office If the electric motor is too small for the APP or APP S 674 pump it cannot provide sufficient torque 66 180R9270 IOM APP S 674 v01 03 2013 Instruction 4 Noise from pump 2 2 Trouble shooting guide for APP and APP S 674 pumps 3 4 Water pump damage 4 1 Air in fluid 4 2 Bleeding conditions of pump 4 3 Min max nominalinlet pressure 4 4 Pump reversing 4 5 High rotation speed rpm 4 6 Outlet pressure 4 7 Soft start stop 3 4 1 Dismantle pump and check for wear 4 1 1 Ensure that the entire inlet line is bled before starting up the system 4 1 2 Ensure that air cannot enter into the inlet line 4 2 1 Follow the instructions Initial start up supplied with the new pump 4 2 2 Ensure that the pump is completely bled before start up 4 3 1 Ensure that inlet pressure is between 1 and 5 bar 4 3 2 Check the pump for internal damage 4 4 1 Dismantle pump and check if anything is broken or worn See 1 No flow item 1 2 Pump reversing WARNING The
51. lve plate set 180B4235 Swash plate 180B4237 Flushing valve set APP S 674 3 0 180B4236 Swash plate 180B4234 Piston set APP S 674 3 5 180B4197 Shaft seal 180B4233 Retainer set a LE 2 1 Mm lt y E N lt 24 o a co a o a z ES gt 1 End flange LA 1 Swash plate 1 Tight fitting bolt Super Duplex PEEK CH 5 1 Cylinder barrel Super Duplex PEEK OY N mi OV UJ Ww UT LA BR N N 1 Spring Hastelloy C4 1 Spring guide PEEK 1 Retainer ball O Super Duplex 1 Retainer plate Super Duplex 7 Piston Super Duplex PEEK AISI 316 O N A o lt 1 Port plate Super Duplex PEEK N 1 Valve plate Super Duplex PTFE UJ 7 Back up ring NO 7 O ring NBR 1 Port flange Super Duplex PEEK 122 1 O ring NBR 123 1 O ring NBR 124 1 Shaft seal B 125 1 Cover for shaft seal Super Duplex 126 PEEK 5 2 gt gt Screw moas TEL TI 128 Screw M8x55 AISI 316 a 130 O ring NBR MH 131 2 Connection cover 132 2 O ring NBR Screw M8x25 AISI 316 i LA LA 134 3 Bleed screw M6 Super Duplex AISI 316 2 Tailstock screw M12 2 Check nut M12 AISI 316 B 45 Valve cone PEEK N 5 LA 1 Spring Hastelloy C276 N 1 B 15 Valve guide Super Duplex 155 1 O ring NBR 1 Press bush tools 1 nstruction 4 180R9270 IO
52. ndix 2 Instruction For spare parts and service tools please see appendix 3 Parts list 180R9270 IOM APP S 674 v01 03 2013 G Drop in flow and or pressure may indicate wear of 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 the Trouble shooting guide appendix 4 The appendix gives good advises regarding design installation wiring and trouble shooting 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 breakdown See also service and warranty section in appendix 1 Data sheet or appendix 2 Instruction 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 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
53. nting flange ISO 3019 2 180 B4 TW 180R9270 IOM APP S 674 v01 03 2013 35 Data sheet 10 Service Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark APP S 674 pumps 10 1 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 produc tion If Danfoss recommendations concerning system design are not followed it will strongly influence the life of the APP S 674 pumps 10 2 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 2 2 Ifthe parts are not replaced more frequent inspection isrecommended according to our guidelines Standstill The APP S 674 pumps are made of Super Duplex materials with excellent corrosion properties It is however always recommended to flush the pump with freshwater when the system is shut down 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 necessar
54. ocess connections according to API 674 3 edition pipe size 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 Recom 180R9270 IOM APP S 674 v01 03 2013 mend 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 mem brane 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 Data sheet APP S 674 pumps Media filter Permeate 9 Dimensions and 9 1 APPS 674 3 0 3 5 connections 218 9 8 648 17 9 705 ON 27 e 124 4 882 82 55 3 25 110 4 331 20 787
55. on www ro solutions danfoss com CE Declaration of Conformity can be found on page 5 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 A 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 A 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 amp ID are found in appendix 1 Data sheet and appendix 2 Instruction User manual 3 Technical data
56. or piston is worn 2 1 5 Analyse fluid for content of particles 2 1 6 Check that filters are OK and working correctly 2 1 7 Install correct pre filter 1um nom string wound filter 2 1 8 Check that the correct filter type is used particles in fluidmust not exceed 10 um Danfoss High Pressure Pumps supplies filters please contact the sales office 2 1 9 The APP and APP S 674 pumps are designed for seawater operation for any other fluid please contact Danfoss High Pressure Pumps sales office for further help 2 1 10 If fluid temperature is above 50 C stop the pump immediately 2 1 11 Check internal parts see above 2 2 1 Check that booster pump supplies the right pressure flow 2 2 2 Check if filters require replacement 2 3 1 If VFD operated check frequency 2 3 2 Check that rotation speed of the electric motor is as stated on name plate on electric motor Check that the motor rotor winding is not damaged 180R9270 IOM APP S 674 v01 03 2013 Typical signs of wear Polished surface all over the swash plate Normally only half of the swash plate the pressure side is polished See index 6 3 If the ring is missing the piston is very worn The filters can be bypassed even if they are correctly mounted Some filters can create channelling where particles can pass trough the filter in tunnels String wound filters are typically channelling filters A string wound filter may have a filtration efficien
57. out using tools the tolerances must be dimensioned accordingly WARNING Any axial and or radial loads on the shaft must be avoided Any axial or radial load will cause breakdown A Bell housing B Flexible coupling C Motor shaft Instructions on internal elements 180R9092 180R9085 for APP 0 6 1 0 180R9091 180R9147 180R9089 for APP 1 5 3 5 180R9093 180R9090 for APP 5 1 10 2 180R9228 180R9227 for APP 11 13 and APP 16 22 180R9121 180R9139 for APP 21 38 180R9281 for APP S 674 3 0 3 5 180R9280 for APP S 674 5 1 9 0 180R9278 for APP S 674 21 38 are available on www ro solutions com Instruction 2 Reduced flow reduced pressure 2 2 Trouble shooting guide for APP and APP S 674 pumps 2 1 Wear on pump Large internal leakage due to Pre treatment Main filtration Fluid type High fluid temperature 2 2 Low inlet pressure 2 3 Rotation speed rpm 2 1 1 Dismantle the pump 2 1 2 Check valve plate Valve plate has marks scratches on the surface facing the port plate Minor wear on valve plate can cause large internal leakage See Index 6 1 Check port plate Port plate has marks scratches on the surface facing the valve plate Minor wear on port plate can cause large internal leakage See Index 6 2 Check cylinder barrel Liners in cylinder barrel may be scratched or worn Insert a piston in the liner and check the fit If there is any space clearance between liner and piston liner
58. p 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 unit size to pump unit size How to mount the pump and the electric motor correctly see appendix 2 Instruction A Incorrect lifting can result in personal injury and or damage to the pump unit see appendix 2 Instruction 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 User manual 5 Installation and commissioning Installation Operation and Maintenance APP S 674 pumps A 5 1 Important dimensions Physical dimensions and connections of the pump unit are described in appendix 1 Data sheet A 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 damage
59. pump must not run without water for more than a few seconds If the pump takes in water from the high pressure outlet line it builds up pressure and will eventually be damaged 4 5 1 If electric motor rpm is too high dismantle pump and check for damage 4 5 2 If the rpm is within the specified range of the pump data sheet and abnormal noise remains dismantle pump and check for damage 4 6 1 If outlet pressure is too low check set point of outlet pressure valve 4 6 2 If outlet pressure is lower than mentioned in the pump data sheet please contact Danfoss High Pressure Pumps technical support 4 6 3 If outlet pressure has exceeded its maximum check set point of outlet pressure valve 4 6 4 Check internal parts for wear damage 4 71 Checkif noise is normal when the pump is running at operation speed 4 7 2 f noise is abnormal at operation speed check internal parts see above 180R9270 IOM APP 5674 v01 03 2013 Too heavy damage in the pump will increase friction causing a high torque see item 6 Typical signs of wear Small air bubbles will accumulate and create large bubbles causing internal cavitation and thus making the pump very noisy WARNING The pump can only run few minutes with air in the fluid without being damaged The pump and the inlet line must be com pletely bled before start up otherwise the pump will cavitate and make high noise WARNING The pump can only run few minutes with air in
60. pumps 2151246 aaa u l E dayal y idees 51 Trouble shooting guide for APP pumps 61 SGD 6 41818 en E ee eee eee o PA 72 180R9270 IOM APP S 674 v01 03 2013 3 2 2 User manual Installation Operation and Maintenance APP S 674 pumps Validity This manual is valid for APP S 674 pumps with the following code numbers serial numbers 5674 3 5 18087058 APP S 674 5 1 18087050 APP S 674 6 5 18087051 APP S 674 7 2 180B7052 APP S 674 8 2 18087055 APP S 674 9 0 18087056 5674 21 18083094 5674 24 18083088 APP S 674 26 180B3096 5 674 30 18083097 5674 33 18083089 APP S 674 38 180B3091 4 180R9270 IOM APP S 674 v01 03 2013 EC Declaration of Conformity Danfoss A S Danfoss High Pressure Pumps Nordborgvej 81 6430 Nordborg Denmark EG Konformitatserklarung gem EG Richtlinie 2006 42 EG Hiermit erkl ren wir dass die Maschine gem 2006 42 EG entwickelt ist Beschreibung der Maschine Hochdruck Pumpe Maschinentyp APP S 674 3 0 APP S 674 3 5 APP S 674 5 1 APP S 674 6 5 APP S 674 7 2 APP S 674 8 2 APP S 674 9 0 APP S 674 21 APP S 674 24 APP S 674 26 APP S 674 30 APP S 674 33 APP S 674 38 Seriennummer N A Technisches Dossier Kontaktperson Leiter Qualit tsabteilung Angewandte harmonisierte Normen DS EN ISO 12100 2011 Herstell
61. que 30 3 Nm 22 2 Ibf ft 180R9270 IOM APP S 674 v01 03 2013 Instruction 4 Initial start up APP S 674 pumps 3 4 3 APP S 674 21 38 8 x M10 x 1 5 17 depth Bleeding plug Mounting of flange connections Bolt torque 30 3 Nm 22 2 Ibf ft 4 1 Flush inlet line before connecting the pump to remove possible impurities from pipes hoses etc Connect pump inlet to inlet line and flush the pump for 5 min by using an internal flushing valve to remove possible impuri ties from pipes hoses etc 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 APP S 674 3 0 3 5 Internal flushing valve s 180R9270 IOM APP S 674 v01 03 2013 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 2 APPS 674 5 1 9 0 43 Instruction 5 44 Technical data APP S 674 pumps 4 3 APPS 674 21 38 Outlet min pressure barg continuous psig
62. ration of Conformity Danfoss A S Danfoss High Pressure Pumps Nordborgvej 81 6430 Nordborg Denmark EG Konformitatserklarung gem EG Richtlinie 2006 42 EG Hiermit erkl ren wir dass die Maschine gem 2006 42 EG entwickelt ist Beschreibung der Maschine Hochdruck Pumpe Maschinentyp APP S 674 3 0 APP S 674 3 5 APP S 674 5 1 APP S 674 6 5 APP S 674 7 2 APP S 674 8 2 APP S 674 9 0 APP S 674 21 APP S 674 24 APP S 674 26 APP S 674 30 APP S 674 33 APP S 674 38 Seriennummer N A Technisches Dossier Kontaktperson Leiter Qualit tsabteilung Angewandte harmonisierte Normen DS EN ISO 12100 2011 Hersteller Unterschrift Titel EC Declaration of Conformity according to Directive 2006 42 EC We hereby declare that the machine is designedaccording to the directive 2006 42 EC Machine description High pressure pump Machine designation APP S 674 3 0 APP S 674 3 5 APP S 674 5 1 APP S 674 6 5 APP S 674 7 2 APP S 674 8 2 APP S 674 9 0 APP S 674 21 APP S 674 24 APP S 674 26 APP S 674 30 APP S 674 33 APP S 674 38 Serial number N A Technical dossier Contact person Manager Quality Department Used harmonised standards DS EN ISO 12100 2011 Manufactur ature Title D claration de conformit CE conform ment la Directive 2006 42 CE Par la pr sente nous d clarons que la machine est concue conform ment la Directive 2006 42 CE Description de la machine
63. res 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 72 180R9270 IOM APP S 674 v01 03 2013
64. rly 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 45 Instruction 9 46 Service and warranty APP S 674 pumps 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 produc tion 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 180R9270 IOM APP S 674 v01 03 2013 2 2 Ifthe parts are not replaced more frequent inspection isrecommended 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 funct
65. s 9 Cleanliness 11 14 Commissioning 6 8 11 12 13 15 16 Connections 7 9 10 11 12 15 21 po 30 32 33 34 35 39 42 68 Corrosion 12 16 29 36 45 46 Coupling 8 12 13 15 16 30 40 44 64 D Danger 6 7 13 16 Datasheet 7 8 9 10 11 12 14 SS Lour ka 18 19 39 64 67 Declaration of Conformity 5 7 43 Design 7 8 9 11 12 13 14 21 22 23 24 30 32 36 39 44 46 65 Distributor 6 7 8 9 Dimensions 8 11 33 Direction of rotation 13 41 43 Disassembling 15 E EC Declaration of Conformity 5 43 Electric motor 6 7 8 9 10 11 12 13 15 as 16 21 30 43 64 65 66 67 68 Electrical failure 16 Electrical hazard 6 7 16 Electrics 12 F FAUVE uu 3 47 ne EE 9 16 Filter CON GION us cea 13 Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Filtration 9 12 14 16 30 32 39 65 70 Fish bone T L uyw s paqu aa 63 Flow 7 9 13 14 21 22 23 24 25 26 gt gt 27 28 32 39 45 64 65 67 68 69 70 FIOW CHINOS lt a esse 25 26 27 Fluid sa au 11 12 15 16 21 30 65 66 67 Flush 8 11 13 21 28 29 32 36 39 JR 43 45 46 Flushing valve 21 28 43
66. s headquarter in Denmark for evaluation In case the pump needs to be scrapped please follow your local environmental rules User manual Appendices for Installation Operation and Maintenance Manual APP S 674 pumps ro solutions com User manual Appendices APP S 674 pumps Table of Contents Data sheet APP S 674 pumps 521B1187 21 Pump instruction APP S 674 180R9276 39 Parts list APP 5 674 pumps 521B1248 51 61 Troubleshooting quide for APP pumps 18 180R9270 IOM APP S 674 v01 03 2013 MAKING MODERN LIVING POSSIBLE Data sheet 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 Data sheet Table of Contents Data sheet APP S 674 pumps APP S 674 3 0 3 5 APP S 674 5 1 9 0 APP S 674 21 38 521B1187 20 APP S 674 pumps 4 1 4 2 4 3 5 1 5 2 5 3 5 4 5 4 1 5 4 2 5 4 3 8 1 8 2 8 2 1 8 2 2 8 2 3 8 4 9 1 9 2 9 3 10 10 1 10 2 Introduction Benefits Application areas Technical data APP S 674 3 0 3 5 APP S 674 5 1 9 0 APP S 674 21 38 Flow APP S 674 3 0 3 5 flow curves at max pressure APP S 674 5 1 9 0 flow curves at max pressure APP S 674 21 38 flow curves at max pressure Flushing valve characteristics APP S 674 3 0 3 5 integra
67. s any marks scratches it is worn damaged and a new one is required Please contact Danfoss High Pressure Pumps sales office for further infor mation 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 70 180R9270 IOM APP S 674 v01 03 2013 User manual Appendices APP S 674 pumps 180R9270 IOM APP S 674 v01 03 2013 71 User manual Subject index A Accessories 7 33 34 35 Address 7 8 15 Airbubbles 9 67 Appendix 7 8 9 10 11 12 14 15 16 Application areas 21 Applicationrange 8 Approval 6 Arrival 9 12 15 Assembling 12 15 05 06 eee e AXE 6 7 21 B Benefits 21 Bleed 8 9 13 14 15 21 32 33 00 7 34 35 39 43 44 45 C Checklist 11 Checkpoints 12 Chemical
68. s danfoss com Clean all the 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 and if necessary replace them see appendix 3 Parts list D Ifthe 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 should be attached to the shipment 180R9270 IOM APP S 674 v01 03 2013 Productinformation see label on product Only 1 product on each report Cor je number 5 E ria number Operational conditions Application Inlet pressure Rpm pump motor only Hours of operation Qutlet pressure Number of duty cycles valves only Pumps in parallel yes no 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 ro solutions danfoss com 7 6 Procedure for mounting the pump onto the electric motor A 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
69. ted flushing valve curve APP S 674 5 1 9 0 integrated flushing valve curve APP S 674 21 38 integrated flushing valve curve Corrosion Motor requirements Installation Filtration Noise APP S 674 3 0 3 5 pump mounted on motor 5 5 kW 4 pole 11 kW 2 pole APP S 674 5 1 9 0 pump mounted on motor 22 kW 4 pole APP S 674 21 38 pump mounted on motor 75 kW 4 pole Open system design RO system with APP S 674 pump Dimensions and connections APP S 674 3 0 3 5 APP S 674 5 1 9 0 APP S 674 21 38 Service Warranty Maintenance 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 aname change 180R9270 IOM APP S 674 v01 03 2013 Data sheet 1 Introduction 2 Benefits 3 Application areas APP S 674 pumps APP S 674 pumps are made according to API 674 3 edition The pump is designed to supply low viscosity and corrosive fluids under high pressure e g in seawater reverse osmosis applications Danfoss APP S 674 pumps are positive displace ment pumps with axial pistons that move a fixed amount of water in each cycle Flow is proportional to the number of pump shaft revolutions rpm Unlike centrifugal pumps they produce the same flow at a given speed no matter what the discharge pressure Shaft sealing Port flange Bleeding plug 2
70. tup x exi26beT3C O O 38 180R9270 IOM APP S 674 v01 03 2013 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 2 2 switch stops the pump if inlet temperature is higher than the set value E Connections Ensure flange loads 5 do not exceed max allowable loads on process connections according to API 674 3 edition pipe size F Inlet pressure In order to eliminate the risk of cavitation and other pump damage inlet pressure must be maintained in betwe
71. ures 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 1 Mounting max 0 25 mm max 0 01 inch Flexible coupling Bell housing Motor shaft Pump flange 1 Mount the coupling on the pump shaft 3 Measure the longest distance A from top of Ensure an air gap between coupling and bell housing to the button of coupling claw pump flange of min 4 mm 0 16 in 4 Mount the coupling on the motor shaft 2 Mount the bell housing on the pump Secure Ensure the coupling and motor flange are not nuts with the right torque in contact with each other 180R9270 IOM APP S 674 v01 03 2013 2 2 Instruction APP S 674 pumps 5 Measure from motor flange to the top of the If alternative mounting is desired please contact coupling The measurement B shall be Danfoss High Pressure Pumps 3 5 mm 0 12 0 2 in shorter than the measurement A Choose proper tolerances to ensure an easy mounting of the flexible coupling without use of 6 Adjust respectively verify the measurement tools and secure both couplings with the right torques on the locking screws see coupling Please take care to observe the recommended operation amp mounting instruction length tolerances of the chosen coupling as an axial force on the pump will damage the pump E 1 N
72. ushing valve set 180B4244 Cylinder barrel 180B4245 Valve plate set 180B4263 Swash plate APP S 674 6 5 180B4264 Swash plate APP S 674 7 2 180B4248 Swash plate APP S 674 8 2 180B4249 Swash plate APP S 674 9 0 180B4262 Swash plate 180B4247 Piston set APP S 674 5 1 180B4243 Shaft Seal 180B4246 Retainer set 2 o Hi Hi RET C Tu ca a co A lt x X b x gt LA APP S 674 pumps Parts list Exploded view APP S 674 5 1 9 0 5 UNc UNOL UNE WNOE UNc UNOL SY Cas UNE WNOS i 97 D A CU UNE UNOS q CH Le d AE N 722 22 N g A EN Z 57 180R9270 IOM APP S 674 v01 03 2013 APP S 674 pumps Parts list 195 oAJeA Duiusn 4 80278081 Spare parts list APP S 674 21 38 6 8 v 9 S ddV eye d ysems 1609081 EE L9S ddV eld ysems 06078081 0 vZ9 S daV eld ysems 76079081 9C V9 S daV oje d ysems 66098081 Vc v49 S daV oje d ysems s60v8081 LC 719 S ddV eld ysems r60r808L 395 uojsid 680v 8081 8 VL9S ddV jas 612 8081 LC 129 S ddV 195 s ulel H ZOCV808L 8 9 S ddV Jos eld A PA S9EVAOSL IZ V49 S ddV 195 eld A PA y9 908L 9448q Japul AD 01278081 Jees 3jeus 11278081 195 e S 880v 8081 X NO pa
73. uts APP S 674 3 0 3 5 40 x 4 Nm 30 z 3 Ibf ft APP S 674 5 1 9 0 40 x 4 Nm 30 x 3 Ibf ft APP S 674 21 38 40 4 Nm 30 z 3 Ibf ft 7 Mountthe 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 NSS I Pw EDEN ZZ 21 A 2 Bolts APP S 674 3 0 3 5 40 4Nm 30 z 3 bf ft APP S 674 5 1 9 0 75 5Nm 55 3 5 Ibf ft APP S 674 21 38 75 X5 Nm 55 x 3 5 Ibf ft 3 Torque see table beside 3 2 Direction of rotation 3 3 Orientation The direction of rotation is indicated by an arrow The pump can be mounted orientated in any at the pump label horizontal direction vertically only with the shaft pointing upwards 180R9270 IOM APP 5674 v01 03 2013 41 42 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 49 82 1 967 Mounting of flange connections Bolt torque 30 3 Nm 22 2 bf ft 3 4 2 APP S 674 5 1 9 0 q iu plug TL D 2 8 x M8 x 1 25 E H 15 depth O O m OR e E N Bleeding plug Outlet Mounting of flange connections Bolt tor
74. valves etc switch VFD to the current limits found on the name plate of the electric motor e The hard piping and flexible hoses used must be of proper design and must be installed in accordance with the manufactur 5 10 Instrumentation er s recommendations The pressure switch sensor should be mounted Misalignment of the hard pipes may give as close to the pump as possible It is recom unintended stress on the pump port mended to test the pressure sensor switch via an connections and may damage the pump instrumentation manifold e Prevent excessive external pipe load e Do not connect piping by applying external Mount the pressure switch sensors according to force use of wrenches crane etc Piping the manufacturer s instructions must be aligned without residual stress Do not mount expansion joints so that their force applies internal pressure on the pump 5 11 Connections connections Mount and tighten connections and check valve s as specified 180R9270 IOM APP S 674 v01 03 2013 User manual 2 2 Installation Operation and Maintenance APP S 674 pumps 5 12 Ensure free flow Ensure free flow from the safety relief valves 8 and 9 figure 1 item 5 6 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 figure 1
75. x 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 nottry 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 Incase of doubt Please contact Danfoss High Pressure Pumps in case of doubt Contact information are listed in section 1 3 Manufacturer and customer service address 3 2 Application range See Data sheet in appendix 1 3 3 Electric motor data See recommended motor in appendix 1 Data sheet 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 Spacerequirement 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 User manual 4 Arrivalinspection transportation han
76. y 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 36 180R9270 IOM APP S 674 v01 03 2013 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 APP S 674 pumps Table of Contents 1 Identification Instruction APP S 674 2 System design APP S 6743 0 3 5 2 1 Open system design APP S 6745 1 9 0 2 2 RO system with APP S 674 pump APP S 674 21 38 2 3 Protection from too high pressures 180R9276 ES Building up the pump unit 3 1 Mounting 3 2 Direction of rotation 3 3 Orientation 3 4 Connections 3 4 1 APP S 674 3 0 3 5 3 4 2 APP S 674 5 1 9 0 3 4 3 APP S 674 21 38 4 Initial start up 4 1 APP S 674 3 0 3 5 4 2 APP S 674 5 1 9 0 4 3 APP S 674 21 38 2 Technical data 6 Operation 6 1 Temperature 7 Long term shutdown 8 Storage 9 Service and warranty 9 1 Repair 9 2 Recommended service intervals 10 EC Declaration of Conformity Our CLP RO pumps have changed names 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 1 Identification Warning Use only This is ONLY a name change 10um filter with a B value gt 5000 Bleed the pump befor initial star
77. ys ensuring that all filtration specifications are met and by always changing filter cartridges according to schedule Since water has very low viscosity Danfoss APP S 674 pumps have been designed with very narrow clearances in order to control internal leakage rates and improve pump performance To minimize wear on the pump it is therefore essential to filter inlet water properly The main filter must have a filtration efficiency of 99 98 at 10 um We strongly recommend that you always use precision depth filter cartridges rated 10um abs 5000 Please note that we do not recommend bag filters or string wound filter cartridges which typically have only 5096 filtration efficiency This means that out of 100 000 particles that enter such filters 50 000 particles pass right through them compare this to precision depth filters that are 99 98 efficient and only allow 20 of the same 100 000 particles to pass through For more information on the importance of proper filtration including explanation of filtration principles definitions and guidance on how to select the right filter for your pump please consult our Filtration information and specifications Danfoss document number 521B1009 180R9270 IOM APP S 674 v01 03 2013 O O e N a L jJ LI 8 2 Noise Since the pump unit is mounted on a frame the overall noise level can only be determined for a complete s
78. ystem To minimize vibrations and noise throughout the system it is therefore recommended to mount the pump unit correctly on a frame with dampeners and to use flexible hoses rather than metal pipes where possible The noise level is influenced by Pump speed High rpm makes more fluid structure borne pulsations vibrations than low rpm due to higher frequency Discharge pressure High pressure makes more noise than low pressure Pump mounting Rigid mounting makes more noise than flexible mounting due to structure borne vibrations Connections to pump Pipes connected directly to the pump make more noise than flexible hoses due to structure borne vibrations Variable frequency drives VFD Motors regulated by VFDs can increase noise level if the VFD does not have the right settings The curves on the following page indicate the sound pressure level in dB A measured in a reverberation room at a distance of 1 metre from the motor pump unit surface The measurements is according to EN ISO 3744 2010 and the dB A L 1m values is calculated APP S 674 pumps Data sheet 8 2 1 APP S 674 3 0 3 5 pump mounted on motor 5 5 kW 4 pole 11 kW 2 pole 80 bar 5 5 kW V 8P bar 5 5 kW ul L Vd bar 11 kW 7 55 punos E Q o o o n c o D pole 8 2 2 APP S 674 5 1 9 0 pump mounted on motor 22 kW 4 LET EE LET 11 LAAT ET I LUA TE ITT Wap TI

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