Danfoss iSave 50-70 Energy Recovery Device Instruction Manual

June 16, 2024
Danfoss

Danfoss iSave 50-70 Energy Recovery Device

Danfoss-iSave-50-70-Energy-Recovery-Device

Product Information

Specifications

  • Product Type: iSave 50-70
  • Installation, Operation and Maintenance Manual: 180R9357_AQ265943679828en-001003
  • Website: hpp.danfoss.com

Product Usage Instructions

Validity
The product is valid for use in various applications. Please refer to the installation, operation, and maintenance manual for specific details and guidelines.

Service/Maintenance

Safety Regulations
Before performing any service or maintenance on the product, ensure that all safety regulations are followed. This includes wearing appropriate protective gear and following proper procedures to avoid any injuries.

Support
If you require any assistance or support regarding the product, please contact our customer support team. They will be happy to assist you with any queries or issues you may have.

Maintenance Schedule
Regular maintenance is essential to ensure the optimal performance and longevity of the product. Refer to the maintenance schedule provided in the installation, operation, and maintenance manual for recommended intervals for maintenance tasks.

Recommended Service Intervals on Internal Parts
To maintain the efficiency and functionality of the product, it is recommended to service the internal parts at regular intervals. Refer to the installation, operation, and maintenance manual for specific recommendations on service intervals for internal parts.

Lubrication of Bearings in Electric Motor
Proper lubrication of bearings in the electric motor is crucial for smooth operation and to prevent premature wear. Refer to the installation, operation, and maintenance manual for instructions on how to lubricate the bearings.

Troubleshooting

Safety Regulations
When troubleshooting any issues with the product, ensure that all safety regulations are followed. Take necessary precautions to avoid any potential hazards during troubleshooting.

Appendices

Data Sheet iSave 50-70 (521B1378)
Refer to this data sheet for detailed information about the iSave 50-70 product.

Start and Stop Procedures (180R9213)
Follow the start and stop procedures outlined in this document to ensure proper operation of the product.

Membrane Cleaning of the RO System with iSave Unit (180R9214)
This document provides instructions on how to clean the RO system membrane using the iSave unit.

APP Pumps and iSave Overload Protection (180R9372)
Learn about the APP pumps and iSave overload protection in this document.

Hose Assembly and Installation (180R9084)
For guidance on hose assembly and installation, refer to this document.

iSave Part List 50-70 (521B1428)
Check this part list for a comprehensive list of components and parts for the iSave 50-70.

Operating and Maintenance Instruction, Electric Motor (180R9230)
Refer to this document for detailed instructions on operating and maintaining the electric motor of the product.

FAQ

Q: Where can I find the installation, operation, and maintenance manual?
A: The installation, operation, and maintenance manual can be found on our website at hpp.danfoss.com. Please refer to the product type and manual number mentioned in the user manual.

Q: How often should I perform maintenance on the internal parts?
A: The recommended service intervals for internal parts can be found in the installation, operation, and maintenance manual. It is important to follow these intervals to ensure optimal performance of the product.

Q: What should I do if I encounter any issues with the product?
A: If you encounter any issues or have any concerns regarding the product, please contact our customer support team. They will provide you with the necessary assistance and guidance to resolve the issue.

DOaptearsahtienegt guide
Headline Myriad Pro mEnaerxgy. R2e6co/v2er6y Dpetv.icaend min. 18/18 pt.
miSavxe. 350ro-7w0s Installation, Operation and Maintenance Manual

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003
hpp.danfoss.com | 1

Data sheet

Product type

1. Validity

Document information and copyright
Installation, Operation and Maintenance Manual. Danfoss can accept no responsibility for possible errors in the manual and instructions. 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 rights reserved. Contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise translated or published without Danfoss’ express written consent.

This manual is valid for iSave 50 -70

Code No./Description

Serial no.

180F7020 iSave 50 without motor

XXXXXX02-XXX

180F7021 iSave 70 without motor

XXXXXX02-XXX

180F7038 iSave 50 Vertical (IEC motor)

XXXXXX02-XXX

180F7023 iSave 50 horizontal (IEC motor)

XXXXXX02-XXX

180F7040 iSave 70 vertical (IEC motor)

XXXXXX02-XXX

180F7025 iSave 70 horizontal (IEC motor)

XXXXXX02-XXX

The serial number is referring to the Serial no. on the product label. The digits shown (02) indicate the version number of the pump. This document is only valid for ERD version 2 and upwards.

4 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet 2. Introduction

Product type

2.1 General iSave is manufactured by Danfoss A/S, and is sold and marketed by a net of authorised distributors world wide.
This manual contains the necessary instructions for the installation, operation and service of the iSave.
All personnel who are responsible for the operation and maintenance of the iSave unit must read and fully understand these instructions, especially the section “Safety” before:

2.3 Symbols
Indicates something to be noted by the reader. Indicates a situation which will or couldresult in damage to the iSave and its function.
Indicates a situation which will or could result in personal injury and/or damage to the iSave.
Electrical hazard. Indicates a high-voltage warning
Safety glasses required

· Transporting of the iSave unit. · Lifting the unit. · Installing the iSave unit on a frame. · Connecting the iSave unit to the fluid
system. · Connecting the electrical motor and
instrumentation. · Commissioning the unit. · Servicing the iSave unit, mechanics and
electrics. · Decommissioning the iSave unit.
Ensure that these instructions are always readily available to all personnel concerned.

Hearing protection required
Safety shoes required
Safety helmet required
2.4 Manufacturer and customer service Danfoss A/S High Pressure Pumps DK-6430 Nordborg, Dinamarca Tel.: +45 7488 2222 E-mail: highpressurepumps@danfoss.com Homepage: hpp.danfoss.com

2.2 Target group
This manual is intended for use by personnel with qualified training and experience in the operation and maintenance of a Sea Water Reverse Osmosis (SWRO) or Brackish Water Reverse Osmosis (BWRO) system.

2.5 Country specific information
2.5.1 United Kingdom
Danfoss Ltd. 22 Wycombe End HP9 1NB Beaconsfield United Kingdom

If the recommendations in the manual are not followed, Danfoss reserves the right to void the warranty.

© Danfoss | 2023.12

2.6 Additional technical documents Below documents are not present in this Operating guide. Please contact Danfoss.

Document name Service guide: 180R9387 Disassembling and assembling Design guide: 180R9367 Pipe connection Guide line: 180R9371 Pressure safety valve in SWRO systems
Guide line: 180R9370 Review sheet P&ID

Content
Description of how to disassemble and assemble the iSave Design guide on how to make har piping with Victaulic clamps Guide line on how to evaluate if a safty valve is needed in a SWRO system Detailed description about the need for each individual component in the preferred P&ID

180R9357_AQ265943679828en-001003 | 5

Data sheet 3. Safety

Product type

3.1 General

The iSave must not be used for other

·

purposes than those recommended and

specified without first consulting your local

·

iSave distributor.

·

This manual must be read and completely

understood by the responsible specialist

personnel prior to installation and

commissioning.

·

Use of this manual does not relieve operation

and maintenance personnel of the responsibility

of applying normal good judgment in the

operation and care of this product and its

·

components.

This manual must be available to all personnel

concerned at the site at all time.

·

An iSave must always be installed and used

in accordance with existing national and local

sanitary and safety regulations and laws. It is the

responsibility of the safety officer or the chief

operator to assure compliance with all local

·

regulations that are not taken into account in this

manual.

The iSave is a rotating machine that typically operates at high pressure.
·

Always wear suitable safety and lifting

·

equipment when handling the iSave.

Improper installation can cause fatal injuries. The iSave must not operate outside the application range. During the initial start-up, slowly raise the pressure of the system and adjust the over-pressure protection equipment for proper limit settings. Make sure that the pressure is released from the iSave before the iSave is disconnected from any pipe or hose connections. Make sure that the iSave can be drained without injuring anyone and without contaminating nearby equipment or the environment. Before intervening in the iSave/system, the power must be shut off and the starting device must be locked. When intervening in the iSave unit, follow the instructions for Service/Maintenance, chapter 8. A failure not to follow the instructions can result in personal injury and/or damage to the iSave. It will also invalidate the warranty.
The iSave must never run dry. Dry running produces heat and will cause damage to internal parts. If the iSave does not function satisfactorily, contact your local iSave distributor.

· Bolt the iSave properly to the base before start-up to avoid personal injury and/or damage to the iSave.
· The pipe connections to the iSave must be stress-free mounted, securely fastened to the iSave and well supported. Improper installation will or could result in personal injury and/or damage to the iSave.
· Proper installation and care of shutdown devices and over-pressure protection equipment is essential.

Use of this manual does not relieve operation and maintenance personnel of the responsibility of applying normal good judgment in the operation and care of this product.
3.2 Intended use The iSave is designed for use as energy recovery device in Sea Water Reverse Osmosis (SWRO) or Brackish Water Reverse Osmosis (BWRO) system. The iSave must not be used for other purposes than recommended and quoted for without consulting your local iSave distributor.

· All electrical installation work must be carried out by authorised personnel in accordance with EN60204-1 and/or local regulations.
· Install a lockable circuit breaker to avoid inadvertent starting. Protect the motor and other electrical equipment from overloads with suitable
· equipment. · The electric motors must be supplied with
adequate cooling ventilation.

3.3 Application range For application range see data sheet 521B1378 available in appendix 10.1.
Applications not suitable for the iSave can cause damages to the iSave unit, with risk of personal injury.

6 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

3.4 Preferred system design

Danfoss recommends building systems with

a high degree of safety. Our preferred system

design can be found in the data heet in appendix · It is always the system builders’

10.1.

responsibility that the system design does

not cause any form of hazard and are

adapted to local regulations.

· Proper installation and care of shutdown

devices and over-pressure protection

equipment is essential.

4. Arrival inspection, handling and storage

4.1 Arrival inspection The iSave is packed in a wood container. The iSave ports connector are protected by plastic caps that protect the iSave against dust and particles. Do not remove the caps before the system have been flushed and the iSave can be installed.
Remove all packing materials immediately after delivery. Immediately check the shipment for damage on arrival and make sure that the name plate/type designation is in accordance with the packing slip and your order.
In case of damage and/or missing parts, a report should be drawn up and presented o the carrier at once.

4.3 Transport and Handling
·
· Personnel involved in lifting and transportation of the equipment must be trained in proper handling and safety procedures.
· Observe the local regulations regarding lifting.
· Use suitable, permitted lifting equipment. · The iSave (set) could slip the lifting
arrangement. · Be aware of individuals located in the
operation area while lifting the component.

The identification label on the iSave states the specific type, the serial number and the code number of the iSave; see fig. below. The last three digits of the Serial No. indicate the week and year of production.

PUMP

Type

iSave 50 ERD

Code no. 180FXXXX

Serial no. XXXXXX02-XXX

MADE IN DENMARK Danfoss A/S, 6430 Nordborg, Denmark

4.2 Return to the supplier
Flush the iSave with clean water. Drain the iSave and plug the port connections with a cap/cover.

The weight of the iSave including electric motor can be found in the datasheet. All parts weighing more than 20 kg (44 lb) must be lifted using lifting slings and suitable lifting devices, e.g. an overhead crane or fork lift.
Do not use connections/nozzles for lifting. Do not use only one sling! Make sure that the load is balanced before attempting the lift.

Pack the iSave into a suitable container and make sure that it is suitably fastened to the container.

When lifting the ERD without motor use the lifting eyes.

Please coordinate the shipment with your local authorized distributor or contact anfoss direct to obtain a return shipping address.

© Danfoss | 2023.12

When you have finished using the lifting eyes, remove them to prevent corrosion.
180R9357_AQ265943679828en-001003 | 7

Data sheet

Product type

When the iSave is mounted with an electric motor (horizontal), it must not be lifted in the lifting eye. An iSave assembled with motor (horizontal) must be handled by using two slings around the unit. One sling must be attached to the electric motor and one sling around the iSave. Make sure that the unit/load is balanced before lifting. The centre of the mass may vary.

Lifting the iSave with electric motor (vertical):
The two lifting belts around the bell housing before lifting the unit.

Some motors and pumps have specific lifting eyes. Do not use connections/nozzles for lifting!
Always use two slings.

Lift the iSave unit with only one fastening point. Incorrect lifting can result in personal injury and/ or damage of the unit.

4.4 Assembly iSave to electric motor

1. Mount the coupling flush or maximum 1

5. Measure from motor flange to the top of the

mm offset from the iSave shaft end. Ensure

coupling. That measurement “B” shall be 3-5

an air gap between coupling parts of 3-5

mm (0.12-0.2 inch) shorter than the measure

mm (0.12-0.2 inch).

ment “A”.

2. Mount the bell housing on iSave. Secure

nuts with the right torque.

(“A” and “B” can be found on the next page).

3. Measure the longest distance “A” from top

of bell housing to the button of coupling

claw.

4. Mount the coupling on motor shaft. Ensure

the coupling and motor flange are not in

contact with each other.

8 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

1: Bolts: torque 100 Nm 2: Screw: torque 40 Nm 3: Torque see table below

6. Adjust respectively, verify the measure ment, and secure both couplings with the right torques on the locking screws (see coupling operation & mounting instruc tion).
7. Mount the elastic gear ring and mount the bell housing/iSave on the motor. After mounting it must be possible to move the elastic gear ring 3-5 mm (0.12 0.2 inch) axial “C”. The check can be done through the inspection hole of bell housing. Secure flange bolts with the right torque.

If alternative mounting is desired, please contact Danfoss High Pressure Pumps.
Choose proper tolerances to ensure an easy mounting of the elastic coupling without use of tools.
Please take care to observe the recommended length tolerances of the chosen coupling, as an axial force on the pump will damage the pump.
(“C” can be found on the drawing below).

31 2

Thread size Torque (Nm)

M5

M6

M8

M10

2

4.8

10

17

Details on how to install iSave 50/70 on Danfoss vertical and horizontal frame can be found in the Service guide 180R9387.

4.5 Storage When each iSave is tested before shipment in demineralized water. When tested the iSave is emptied and “plugged”, this will prevent frost damages. The storage temperature is is: -40 °C to +70 °C (-40°F to 158 °F) ­ provided that the iSave is drained of fluid and stored “plugged”.
Frost protection is required if the iSave is not completely drained of fluids at temperatures below 1 °C .
Storage of iSave that have been in operation: For shorter periods of storage flush the iSave with permeate and store. For long term storage (more than 2 months) Danfoss recommends servicing the product and clean any biological growth of the surfaces. Store the pump dry witout water inside.

Danfoss recommends using DOWFROST from DOW Chemical Company or Chillsafe mono propylene glycol from Arco Chemical Company.
For further information on anti-freeze media, please contact Danfoss High Pressure Pumps.
The iSave is NOT delivered frost-protected from the factory. Only remove caps from the openings of the iSave at the time of installation.
4.6 Outdoor Storage
For outdoor storage cover the iSave (set) with waterproof material.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 9

Data sheet

Product type

5. Technical data and design review

5.1 Design details

1: 3″ Victaulic connections 2: Shaft 3: Low pressure shaft seal 4: Port flange 6: Valve plate 7: Cylinder drum 9: Port plate (brine) 10: Port pllate (sea water) 11: Vanes 12: Coupling 13: Intermediate flange 14: Rotor 15: Rotor element 16: Sealing plate 17: Stator 18: Motor end flange

5.2 Sound level of the iSave The A-weighted sound pressure level @ 1m, LPA, 1M is for the iSave including the iSave motor.
Measurement are according to EN ISO 3744:2010. The test is made under following conditions: 1. iSave and electrical motor mounted on
Danfoss base plate. 2. Baseplate is isolated from concrete ground
by rubber vibration dampers. 3. Flexible hoses are used on high pressure
and low pressure sides of the iSave. 4. Rotation speed is max. rpm 5. System pressure max. allowable working
pressure and a booster pressure of 3 barg.
Influences Since the iSave is mounted on a base plate and connected to the electromotor by a bell housing, the noise level can only be determined for the complete unit (system). It is therefore important that the iSave unit is mounted correctly on a frame with dampers to minimise vibrations and noise.
It is also strongly recommended to use highpressure flexible hoses between the hard piping in the RO plant and the iSave.

See “Hose assembly and installation” 180R9084 in chapter10.5 and Guide line Pipe connections 180R9367. Alternative use multiple flexible Victaulic® couplings on the hard piping. Alternativamente, emplee acoplamientos Victaulic® flexibles en la tubería rígida.
The noise level is influenced by: · The speed of the iSave. High speed creates
more noise than low speed. · Rigid mounting of the iSave baseplate
generates more noise than flexible mounting · Pipe mounting directly to the iSave increases the noise level compared to flexible hoses. · Higher pressure provides higher sound level.
5.3 Materials All critical parts of the iSave are made of super-duplex 1.4410/UN S32750/1.4462/ UN S32205/S31803 or the like. Non-critical parts that are not in contact with sea water are made of AISI 316. The shaft to the electrical motor is sealed by a standardised mechanical seal.

10 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

5.4 Temperature and corrosion
The chart below illustrates the corrosive resistance of different types of stainless steel related to NaCl concentration and temperature.

Depending on the NaCl concentration, the fluid temperature must be between:
+2 °C y 50 °C (35,6 °F y 122°F).

80 º C 70 60 50 40 30
20 100 160

316L

Duplex

Super Duplex

1000 1600

10 000 16000

100 000

CI ppm

160000

NaCI ppm

In order to minimise the risk of crevice corrosion, always flush the iSave according to the specified start/stop procedure.
5.5 Dimensions and weights For dimensions and weights please refer to the iSave datasheet. See appendix 10.1
5.6 Electrical motor data See datasheet in appendix 10.1 and “Operating and Maintenance instructions, electric motor” in appendix 10.7

5.7 How does the iSave work? Figure 5.1 shows a section view of the iSave.
The iSave consists of a rotating isobargic pressure exchanger and a positive displacement pump, also called booster pump. The rotation speed of the pressure exchanger and the pump is exactly the same, as they are driven by the same electric motor.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 11

Data sheet

Product type

5.8 Seawater quality
5.81 Pre-filtration It is important that the incoming water is filtered properly to assure optimum service life of the iSave. A true graded density melt-blown depth filter cartridge rated at 3 m is therefore recommended. Poor pre-filtration of the feed water will result in reduced service life of the iSave.
The iSave may request a different pre-filter of the seawater than the HP pump and other omponents in the RO system.
It is important to use a proper filter housing that allows a good seal between housing and filter cartridge. If there is a high risk of water by-pass it is recommended to use a second stage filter solution.
As the various filters on the market differ greatly, Danfoss High Pressure Pumps recommends using cartridges with consistent, reliable performance and high efficiency, in which fibres are blown continuously onto a central support core.
Danfoss High Pressure Pumps does not recommend cartridges requiring any type of binders or resins.
Filters can be purchased from Danfoss High Pressure Pumps.

5.8.3 Chemicals The iSave can be flushed with biocide like the membranes. The biocide must be compatible with the materials used in the iSave. iSave material can be found in the parts list, appendix 10.6.
5.8.4 Initial start up and flushing Prior to the initial start-up, all piping associated with the iSave unit should be thoroughly flushed to assure that no impurities enter the iSave. Inadequate pre-flushing will strongly affect the life of the iSave and may lead to its eventual breakdown. It is essential that the water used for the final pre-flush is pre-filtered to a level described in chapter 5.8 It is recommended to disconnect all connections to the iSave and to thoroughly flush the piping before the iSave is connected to the inlet and outlet connections.It is recommended to install temporary basket strainers at both inlets to the iSave during the initial start-up and commissioning. Strainers do not eliminate the need for thoroughly pipe flushing before commissioning.
Also see “Instruction for start and stop of the SWRO with iSave unit” – 180R9213 in appendix 10.2.
5.9 Initial start up and settings of safety equipment
The system designer is responsible to design the equipment according to the local regulations where the equipment is running. According to PED 2014/68/ EU a risk assessment must be made to identify and evaluate hazards which apply to his equipment on account of pressure.

For more information on the importance of proper filtration, please consult our publication “Filtration”, AI317041322125en-000201 which also will provide you with an explanation of filtration definitions and guidance on how to select the right filter.

Where under reasonable foreseeable conditions, the allowable limits could be exceeded, the pressure equipment must be fitted with, or provision made for fitting of a suitable protective device. Dischage pressure on the pump is generated only by the restriction in the pipelines, valves and membranes.

5.8.2 Air bubbles
Large bubbles in a pressurised RO system can result in damage to piping and equipment. All air must be bleed from both the LP and HP before the RO system is pressurised. Special consideration should also be given to air bubbles in feed flow, continuously fed into the HP pump and iSave.

The pump can build up pressure that will exceed the mechanical strength of the membrane vessels, pipes and other accessories. The pressure rise can be fast and may exceed the response time for electrical safety equipment, like pressure switch and control loop.

12 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet © Danfoss | 2023.12

Product type

To prevent such over-pressurisation, appropriate relief valves should be used and procedures should be implemented to safeguard the HP and LP sides of the iSave and/or the RO system.
5.10 Flushing RO membranes require periodic flushing to limit biological fouling. There are two types of flushing: feed water (Seawater) flush and fresh water (Permeate) flush. Regardless of the flush water used, the water must be pre-filtered to the level described in chapter 5.8. All parts of the iSave must be flushed, i.e. LP- and HP flow channels.
Follow the guide line 180R9213 “Start and stop of the SWRO with iSave in appendix 10.2.
It is required to flush with permeate: · After chemical treatment · For stop more than 1 day the iSave must be
rotated during permeate flush · Before long time shut down It is required to flush with fresh sea water prior to every shut down.

5.12 High pressure remains after shutdown The HP line of the RO system equipped with an iSave can remain pressurised for a long time after shutdown. Pressure decreases as water slowly leaks through the iSave. If more rapid system depressurisation is required, the system should be bled through a suitable valve on the HP concentrate line.trado HP.
Always check the pressure in the high-pressure lines before making service in the HP lines or pressurised equipment.
5.13 Over-pressurisation caused by low pressure isolation
If the low-pressure side of the iSave is blocked and the iSave is exposed to high-pressure, there is a risk that the iSave or the LP piping could be damaged by over-pressurisation.
To prevent such over-pressurisation, appropriate relief valves should be used and procedures should be implemented to assure that the HP of the iSave is depressurised prior to the isolation of the LP side..

Special attention should be given to the pressure in the HP line (7) as the iSave may start to cavitate when it runs at high speed and the pressure in the P line (7) drops below 2 bargs. This can be avoided by reducing the speed of the iSave and keeping the pressurein the HP line at the minimum of 2 barg. At this low pressure the iSave may only run for a maximum of 10 minutes.
Failing to flush the iSave with fresh water before extended shutdowns may result in extensive biological growth and cause corrosion in the iSave and other equipment in the RO system.
5.11 CIP or membrane cleaning The purpose of membrane cleaning is to reduce scaling and fouling in the membranes. For optimal performance specific chemicals are required, depending on the cause of the pollution. After chemical treatment the system must be flushed with permeate.

5.14 Over-pressurisation caused by the high-pressure pump.
Discharge pressure on the pump is generated only by the restriction in the pipelines, valves and membranes. The pump can build up pressure that will exceed the mechanical strength of the membrane vessels, pipes and other accessories. The pressure rise can be fast and may exceed the response time for electrical safety equipment, like pressure switch and control loop.
To prevent such over-pressurisation, appropriate relief valves should be used and procedures should be implemented to assure that the HP of the iSave is protected against excess pressure.
5.15 Explanation of P&ID set-up See data sheet in appendix 10.1.

The flush water coming out of the membranes may consist of a large amount of suspended inorganic particles. It is important to assure that hese particles must not enter the iSave as the waste product of flushing exceed the iSave filtration.

Also see instruction “Membrane cleaning of RO system with iSave unit” in appendix 10.3.

180R9357_AQ265943679828en-001003 | 13

Data sheet

Product type

6. On-site installation

6.1 Design details For safety instruction see chapter 3.
6.2 Installation and alignment The figure below illustrates the major iSave components.

An unlocked bolt can result in personal injury and/or damage to the iSave
Misalignment of the base frame to the iSave may cause stress and/or damage.
6.3 Orientation The iSave can be mounted horizontally and vertically.
When mounted vertically, the electric motor must be placed above the iSave.
6.4 Piping and joints Piping material and schedule is of high importance. The strength of the Victaulic® connections is influenced by the material used for both the Victaulic® clamps and the hard piping.
The hard piping and connections used must be of proper design and must be installed in accordance with the manufacturer’s recommendations.
Hard piping to the iSave must be properly aligned to avoid stress on the iSave port connections. Pipe connection must be aligned as shown in the figures next page. Don’t use the iSave as a strain for hard piping.

The iSave is connected to the electric motor by the bell housing and a flexible coupling. If not using Danfoss base frame both the iSave and the motor must be supported without applying stress/load to the bell housing. Danfoss provides the iSave with a base frame and support brackets. Although the base frame is of a sturdy design, it can flex or bend when it is bolted to the foundation. The base frame thus requires a solid foundation such as concrete or rigid steel frame. The base frame itself must be aligned to avoid bending caused by bolting to an uneven foundation. A rigid foundation for the iSave assembly is important, and must fulfil Eurocode 2: EN1992-1-1, and the iSave assembly must be bolted to the foundation with M12 bolts. The bolts used must be of proper design and must be installed in accordance with bolt manufacturer’s recommendations. To reduce noise it is recommended to use resilient mounts between the baseplate and the foundation. Make sure that the bolts are properly locked and will stay locked over time.

Ccrrect piping alignment
!

Incorrect piping alignment

The hard piping and connections used must be of proper design and must be installed in accordance with the manufacturer’s recommendations.
A failure to comply with this will or may result in personal injury and/or damage the iSave.

14 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet © Danfoss | 2023.12

Product type

Misalignment of the hard pipes may place stress on the iSave port connections and may damage the iSave.
6.5 Mounting of coupling The figure below illustrates how to mount the flexible coupling between the iSave and to connect it to the electric motor..

100 NM ± 10 NM C

Min. 3 -5 mm air space A

When connecting to the power supply, check the direction of rotation. The rotation can only be checked with water connected and iSave bleeded. This can be made by:
1. Looking at the fan in the end of the electric motor.
2. Removing the plug in the bell housing and watch the rotation of coupling.
3. Before assembling the iSave on the electric motor, check the rotation of the shaft on the electric motor.
Special attention has to be on NON PROTECTED – FREE ROTATING shaft on the electric motor. Ignorance will or could result in personal injury.

40 NM ± 4 NM

B A: Flexible coupling B: Bell housing C: Motor shaft

Any axial and radial load on the shaft must be avoided.
6.6 Accessibility With respect to the service and replacement of the complete iSave unit, it is recommended to maintain sufficient space around the unit.
The space must be sufficient enough to allow for safe lifting of the equipment, with no risk for personal injury and/or damage to the iSave.
6.7 Drives 6.7.1 Electric motor The iSave must only be driven by an electric motor.

Running the iSave in the wrong direction for more than a few minutes can cause unintended wear on the iSave. If the electric motor is running at a lower speed, extra care must be taken to ensure that the electric motor is NOT overheated. External cooling may be necessary.
6.7.3 Starting torque for the iSave Because of the inertia and stick-slip friction of the iSave internal parts, the torque may exceed the maximum allowable operation torque for the iSave when the speed is ramped up from zero to maximum.
It is required to use a VFD. See Danfoss guide line 180R9372 “APP pumps and iSave overload protection”.

Using anything other than an electric motor can lead to an irreparable fracture of the iSave’s internal parts.
6.7.2 Speed control The rotation speed on the electric motor can be controlled by a VFD. The VFD must be able to operate at constant torque over the whole range of speed. The direction of rotation can be seen on the identification label.

180R9357_AQ265943679828en-001003 | 15

Data sheet

Product type

6.7.4 Torque overload protection on the iSave
The electric motor and iSave must always be protected against overload.
As continuously operation the maximum torque on the iSave must be monitored.
The electric motor must be shut off if the maximum torque of the iSave exceeds the defined limit.
If more electric motors are powered by the same VFD, each electric motor must be equipped with “torque limit equipment” to protect the iSave against overload.
Below are examples of equipment which can measure the load on the electric motor or limit the torque on the iSave.

1. VFD with integrated current monitoring relays.
2. External current monitoring relays suitablefor VFD control.
The electric motor and iSave must always be protected against overload. See Danfoss guide line 180R9372 “APP pumps and iSave overload protection” in the appendix 10.4.
If torque exceeds the maximum operation torque, it may lead to an irreparable fracture of the iSave’s internal parts.

7. Commissioning,

7.1 Safety regulations

start-up and shutdown

7.3 Commissioning
Before starting up the iSave and the highpressure pump, make sure the following requirements are met:

The operator ensures that all inspection and installation work is performed by authorised, qualified specialized personnel who are thoroughly familiar with the manual..
· Before starting up the iSave and the high-pressure pump, make sure that the following requirements are met:
· The iSave has been properly connected to the electric power supply and is quipped with all protection devices in accordance with EN 60204-1
· Check that all motor protections are properly set.
· All safety equipment, auxiliary equipment and connection required are properly connected and operational.
· Check all bolts in all connections and in the foundation of the iSave and the pumps.
7.2 Support Danfoss A/S offers commissioning and service at system manufacturer’s location. Rated quotes are offered upon request.

· All pipes are flushed, free from debris and full of water.
· The iSave has been bled and is full of water.
· At pressure lower that 10 barg, check the system for leakage.
Slowly raise the pressure in the system and set all pressure switches to the correct limit and continually check all connections.
· If pressure relief valve is present, set pressure relief valve on both low and high-pressure at the maximum system pressure.
· Check high-pressure hoses for proper assembly and inspect for external leakage for all connections.
· At low pressure, start the iSave and check direction of rotation.
· “Start and stop procedure” Guide line 180R9213. – appendix 10.2.

16 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

8. Service/Maintenance

8.1 Safety regulations

Three months after commissioning:

The operator ensures that all maintenance, inspection and installation work is performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual.
Before intervening in the iSave/system: · The power must be shut off and the main
switch must be locked. · The pressure in the high-pressure lines
must be drained to the low-pressure side. · The water in all connected pipes must be
drained.
Always use suitable safety and lifting equipment when handling the iSave, and follow the instructions in chapter 4.3.
· Assure correct settings of safety equipment before start-up.
· When the system is re-started after service and maintenance follow the instruction in chapter 8 and in “Start and stop procedures” in guide line 180R9213 in appendix 10.2.

1. Re-check bolts in the foundation and the base plate of the iSave and tighten the bolts to specified torque if necessary.
2. Re-check alignment of the iSave base plate and iSave.
3. Visually inspect all pipe connections/ couplings for external leakage.
4. Re-check bolts in all pipe connections/ couplings and tighten the bolts to specified torque if necessary.
1. Replace filters if necessary. 2. Clean the filter housing and install the new
filter. Make sure no debris enters the system. 3. Audibly inspect the iSave assembly. If there is irregular sounds or vibration inspect the internal parts of the iSave and replace if necessary.
Half year:
1. For vertical mounted electric motor lubricate motor bearings.

8.2 Support Danfoss A/S offers commissioning and service at the system manufacturer’s location. Tates/quotes are offered upon request.
8.3 Maintenance schedule The schedule of preventive maintenance below will help ensure that the iSave provides years of trouble-free performance.
One day after commissioning:

Annually:
1. Re-check bolts in the foundation and the baseplate of the iSave and tighten the bolts to specified torque if necessary.
2. Re-check alignment of iSave base plate and iSave.
3. Visually inspect all pipe connections/ couplings for external leakage.
4. Re-check bolts in all pipe connections/ couplings and tighten the bolts to specified torque if necessary.

1. Re-check bolts in the foundation and the base plate of the iSave and tighten the bolts to specified torque if necessary.
2. Visually inspect all pipe connections/ couplings for external leakage.
3. Re-check bolts in all pipe connections/ couplings and tighten the bolts to specified torque if necessary.
1. Replace filters if necessary. 2. Clean the filter housing and reinstall
filters. Make sure no debris enters the system.

1. Replace filters if necessary. 2. Clean the filter housing and nstall the new
filter. Make sure no debris enters the system. 3. Visually inspect iSave coupling and replace if necessary. 4. Audibly inspect the iSave assembly. If there is irregular sounds or vibrations inspect the internals parts of the iSave and replace if necessary. 5. Check power consumption. If there are irregular parts of the iSave and replace if necessary. 6. Lubricate motor bearings.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 17

Data sheet

Product type

8.4 Recommended service intervals on internal parts
Se below table. For detailed information on parts see Service guide 180R9392 Parts list.

Description Tool kit Screw and seal kit Shaft seal kit Coupling kit Port plate kit (PE), iSave 50 Port plate kit (PE), iSave 70 Vane kit (8 pcs) Valve kit, Pressure exchanger Rotor element and sealing plates kt

Service interval
32.000 hours 32.000 hours 56.000 hours 32.000 hours 32.000 hours 56,000 hours 32.000 hours 32.000 hours

8.5 Lubrication of bearings in electric motor

Service interval (2nd, 3rd)
26.000 hours 26.000 hours 56.000 hours 26.000 hours 26.000 hours 56,000 hours 26.000 hours 26.000 hours

Motors with a re-greasing system must be lubricated with high quality lithium complex grease, NLGI grade 2 or 3 with a temperature range between -40 °C to 150 °C.
For electric motors in vertical mount; grease every 6 months.
For electric motor in horizontal mount; grease every 12 months.
If the motor has increased vibrations or sound check the bearings.
Follow manufacturer’s recommendations for electric motor service and maintenance, see appendix 10.7.

18 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

9. Trouble-shooting

9.1 Safety regulations

The operator ensures that all inspection and installation work is performed by authorised, qualified specialist personnel who are thoroughly familiar with the manual.

Before intervening in the iSave/system: · The power must be shut off and the
starting device be locked. · The pressure in the high-pressure lines
must be drained to lowpressure side. · The water in all connected pipes must be
drained.

The numbers in () correspond to the preferred system design and P&ID (see data sheet)

Problem

Possible cause

Action

VFD cannot start the iSave at initial start-up VFD is not designed for constant torque

Torque on iSave is too high during operation Permeate production is too low (17)

VFD cannot deliver sufficient start torque
Ramp-up settings in the VFD are not correct. VFD is tilting Valve (9) is closed
Pressure in the HP line (5) is too high
Pressure difference from HP-out (5) to HPin (10) is too high Debris in the booster pump or iSave Wear in the booster pump or iSave Design of the basic plant does not fit the performance of the iSave Valves (6), (7), (8) or (16) are leaking Internal leakage in iSave HP pump flow (2) is too small

Pressure on the membranes (5) is too high

Fouling on the membranes Mixing in the iSave is too high Flow out of the iSave is too low and causes a recovery rate that is too high

Pressure on the membranes (5) is too low

Valves (6), (7), (8) or (16) are leaking Internal leakage in iSave Pressure on the membranes (5) is too low

Choose a VFD that is designed for constant torque Choose a VFD that is designed for sufficient start torque. See guide line 180R9372 Set ramp-up parameters correct. See guide line 180R9372 Open valve (9) Start the iSave only when the pressure in the HP line is low
Clean or change membranes
Clean the system Repair or change the parts
Change design to fit the iSave performance
Repair or change valve(s) Repair iSave Correct speed on the HP pump Check the HP pump and repair if necessary Clean the membranes Check flow on LP-in (12) and adjust flow Check speed on iSave and change if necessary Booster pump in the iSave is worn out. Perform service on the VP Repair or change valve (s) Repair iSave Incorrect speed on the HP pump Check the HP pump and repair, if necessary

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 19

Data sheet

Product type

20 | 180R9357_AQ265943679828en-001003

© Danfoss | DCS-SGDPT/SI | 2023.12

Data sheet

Product type

Appendices
Energy Recovery Device iSave 50-70 Appendices – Installation, Operation and Maintenance Manual

© Danfoss | 2023.12

180R9357_AQ265h94p3p6.7d9a8n28foens-s0.0c1o0m03 | 21

Data sheet Appendices

Product type

10.1

Data sheet iSave 50-70 – (AI264763692435en-000902) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

10.2

Start and stop procedures (180R9213). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

10.3

Membrane cleaning of the RO system with iSave unit (180R9214) . . . . . . . . . . . . . . . . . . . . . . .51

10.4

APP pumps and iSave overload protection(180R9372) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

10.5

Hose assembly and installation (180R9084) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

10.6

iSave part list 50-70 (521B1428) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

10.7

Operating- and maintenance instruction, electric motor (180R9230) . . . . . . . . . . . . . . . . . . . . .87

22 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet Data sheet
Headline Myriad Pro mmiiSSaaaaxvv.ex3e5.®r0o2Ew/n6sieS/ra2gv6ey 7Rp0etc.oavnedrmy iDn.e1v8i/c1e8 pt.

© Danfoss | 2023.12

180R9357_AhQp26p5.9d4a3n67f9o8s2s8.ecno-0m01003
| 1

Data sheet Table of Contents

Product type

Contents

General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Benefits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

4.1

iSave without motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

4.2

iSave with IEC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.3

iSave with NEMA motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Performance curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5.1

Flow at different rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5.2

iSave 50 flow curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5.3

iSave 70 flow curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

5.4

Torque curve for iSave 50 and iSave 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

5.5

Mixing curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Temperature and corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

6.1

Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

7.1

Operation and mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

7.2

Horizontal mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

7.3

Connection to inlet or discharge ports: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

7.4

Filtration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

7.5

Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

7.5

RO systems with an iSave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Dimensions and connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

8.1

iSave 50-70 without electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

8.2

iSave 50-70 with with IE3 motor 18.5 kW on base frame vertical_front mounted . . . . . . . . .37

8.3

iSave 50-70 with with IE3 motor 18.5 kW on base frame vertical_back mounted. . . . . . . . . .38

8.4

iSave 50-70 with with IE3 motor 18.5 kW on base frame horizontal. . . . . . . . . . . . . . . . . . . . . . .39

8.4

iSave 50-70 with NEMA motor 30 HP on base frame vertical – front mounted. . . . . . . . . . . . .40

8.5

iSave 50-70 with NEMA motor 30 HP on base frame vertical – back mounted . . . . . . . . . . . . .41

8.5

iSave 50-70 with NEMA motor 30 HP on base frame horizontal . . . . . . . . . . . . . . . . . . . . . . . . . .42

Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

9.1

Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

9.2

Operational conditions of concern. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

9.3

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

9.4

Repair assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Useful documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

24 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet 1. General information

Product type

Energy Recovery Devices (ERD) are used in reverse osmosis (RO) systems to recycle the energy held in discharged brine from the membranes. Thus, iSave 50 and iSave 70 are designed for use with low viscosity and corrosive fluid such as sea water.
The Danfoss iSave Energy Recovery Devices all consist of an isobaric pressure exchanger and a positive displacement pump combined into one compact unit. The high-pressure booster pump is based on the vane pump principle enabling a very light and compact design. The vane pumps are fixed displacement pumps in which the flow

is proportional to the number of revolutions (rpm) of the driving shaft ­ enabling flow control. Speed control is made by a VFD. The iSave design ensures lubrication of the moving parts by the fluid itself. All parts included in the iSave 50 & 70 are designed to provide long service life with a constant high efficiency and minimum service required. Unlike a centrifugal pump, it produces a similar flow at a given speed no matter what discharge pressure.

1. 3″ Victaulic connections 2. Shaft 3. Low pressure shaft seal 4. Port flange 6. Valve plate 7. Cylinder barrel 9. Port plate (brine) 10. Port plate (sea water) 11. Vanes 12. Coupling 13. Intermediate flange 14. Rotor 15. Rotor element 16. Sealing plate 17. Stator 18. Motor end flange

2. Benefits

· Significant power savings and low specific

energy consumption (SEC)

· Corrossion resistance (all wetted parts are

· Simple and space-saving installation with

made of high corrosion-resistant materials

both pump and pressure exchanger in one

e.g. Super Duplex or Duplex)

unit

· Fewer components

· Simple system design and monitoring

without requirement for high-pressure flow

meters

· Simple operation with design that prevents

overspin/overflushing

· Easy modular service

3. Applications

Danfoss iSave ERDs are built into a broad range of RO desalination plant around the world. Typical applications for iSave 50 – 70 will be:
· Containerized solutions for hotels and resorts on islands as well as coastal regions
· Onboard systems for ships · Offshore platforms for the oil and gas
industry · Municipal and private waterworks

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 25

Data sheet 4. Technical data

Product type

4.1 iSave without motor

iSave size Code number Pressure Max. differential pressure (HP out – HP in) Min. pressure HP out (min. allowable working pressure) Max. pressure HP out (Max. allowable working pressure, MAWP) 1) Min. pressure on HP in, intermittent 2) 3) Max. pressure LP in (MAWP) 1)
Max. pressure LP in, peak
Min. allowable working pressure LP in
Max. differential pressure (LP in – LP out)
Max. static test pressure (HP in and HP out)
Max. static test pressure (LP in and LP out) Speed Min. speed Max. speed Typical flow 4) Flow at min. speed, HP out
Flow at max. speed. HP out
Max. lubrication flow at 60 barg (871 psig)
Peak flow, LP in 10)
Max. allowable working flow, LP in 7)

barg psig barg psig barg psig barg psig barg psig barg psig barg psig barg psig barg psig barg psig
rpm rpm
m³/h gpm m³/h gpm l/min gpm m³/h gpm m³/h gpm

iSave 50 180F7020
5 72 40 580 83 1200
2 29
5 72 10 145
2 29 0.53 7.69 108 1566 13 189
525 650
42 184
52 228
25 6.6 120 528 57.2 252

iSave 70 180F7021
5 72 40 580 83 1200
2 29
5 72 10 145
2 29 0.79 11.46 108 1566 13 189
625 875
50 220
70 308
25 6.6 120 528 70 308

26 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

Technical specifications

oC Media temperature 5)
oF

oC Ambient temperature
oF

Filtration requirements (nominal) 6)

m

Salinity increase at membrane at 40% recovery rate at balanced flow 9)

kg Weight (dry)
lb

kg Weight (operation with water)
lb

Noise

Sound pressure level LPA 1 m 8) Torque data

dB(A)

Max. allowable working torque

Nm lbf-ft

Max. starting torque (stick/slip)

Nm lbf-ft

2-35 36-95
0-50 32-122 5 micron melt-blown
2-3%
164 362 172 379
83
170 125 180 132

2-35 36-95
0-50 32-122
164 362 172 379
86
190 140 180 132

  1. Max. allowable working pressure of continous operation. For lower and higher pressure, please contact Danfoss.

  2. Typical pressure level at start-up and permeate flush.

  3. Intermittent pressure is acceptable for less than 10 minutes within a period of 6 hours.

  4. Typical average flow at 60 barg and 3 barg differential pressure

  5. Dependent on NaCI concentation. 6) Please see section 7.4 filtration. 7) Continuous operation: iSave can operate
    continuously with up to 10% over flush with the limitation that the flow rate at LP inlet shall not exceed 70 m3/h.

  6. A-weighted sound pressure level at 1 m from the pump unit surfaces (reference box) acc. to EN ISO 20361 section 6.2. The noise measurements are performed acc. to EN ISO 3744:2010 on a motorpump-unit at max. pressure and rpm.

  7. Balanced flow: The mixing rate is defined at balanced flow when HP-out is equal to LP-in.

  8. At system start-up: iSave can run for up to 10 min. with 150% of max. rated flow at LP inlet. The time where max. rated flow is exceeded should be kept as short as possible to minimize wear.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 27

Data sheet

Product type

4.2 iSave with IEC motor

i iSave size

Code number (vertical)

Code number (horizontal)

Pressure, Speed, Flow, Temperature and Torwue are identical with

Efficiency

Efficiency at max. speed at 60 barg (871 psig) %

Technical specifications

°C Media temperature 5)
°F

Filtration requirements (nominal) 6)

kg Weight (dry) vertical/horizontal
lb

Weight (operation with water) vertical/

kg

horizontal

lb

Noise

Sound pressure level LPA 1 m 2) Footprint

dB(A)

Footprint (vertical position) 3)

m² foot²

Footprint (horizontal position) 3)

m² foot²

Torque data

Max. allowable working torque

Nm lbf-ft

Max. starting torque (stick/slip)

Nm lbf-ft

Motor data

Nominal speed

rpm

Rated current at 400V

A

kW Motor size
HP

Frame size

IEC Poles

Rated motor torque at nominal speed

Nm lbf-ft

°C Rated motor ambient temperature 4)
°F

Motor insulation

Class

Motor degrees of protection

IP

iSave 50 180F7038 180F7023 180F7020 and

iSave 70 180F7040 180F7025 180F7021

93.7

92.4

2-35

2-35

36-95

36-95

5 micron melt-blown

441/463

441/463

972/1021

972/1021

470/471

470/471

1036/1038

1036/1038

83

86

0.44

0.44

4.71

4.71

0.76

0.76

8.14

8.14

170

177

125

130.5

180

180

132

132

985 37
18.5 30.0 200 L
6 177 130.5 40 104
B 55

985 37
18.5 30.0 200 L
6 177 130.5 40 104
B 55

  1. A-weighted sound pressure level at 1 m from the ERD 6) Please see section 7.4 Filtration

unit surfaces (reference box) acc. to EN ISO 20361

  1. Typical efficiency for pressure exchanger,

..

section 6.2. The noise measurement are performed

booster pump, electrical motor and VFD at 3

acc. to EN ISO 3744:2010 on an ERD with motor

barg differential pressure after a system has . . .

(motor pump unit) from min. to max. pressure and

been commissioned and run in.

speed.

3 Area covered with recommended IE3 motor

configurations (excl. of space to service the ERD))

  1. For higher temperature, contact Danfoss. 5) Dependent on NaCI concentation.

28 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

4.3 iSave with NEMA motor

iSave size

Code number (vertical)

Code number (horizontal)

Pressure, Speed, Flow, Temperatue and Torque are identical with

Efficiency

Efficiency at max. speed at 60 barg (871 psig) 7) %

Technical specifications

°C Media temperature 5)
°F

Filtration requirements (nominal) 6)

kg Weight (dry) vertical/horizontal
lb

Weight (operation with water) vertical/

kg

horizontal

lb

Noise

Sound pressure level LPA 1 m 2) Footprint

dB(A)

Footprint (vertical position) 3)

m² foot²

Footprint (horizontal position) 3)

m² foot²

Torque data

Max. allowable working torque

Nm lbf-ft

Max. starting torque (stick/slip)

Nm lbf-ft

Motor data

Nominal speed

rpm

Rated current at 400V

A

kW Motor size
HP

Frame size

NEMA Poles

Rated motor torque at nominal speed

Nm lbf-ft

°C Rated motor ambient temperature 4)
°F

Motor insulation

Class

Motor degrees of protection

IP

iSave 50 180U0062 180U0003 180F7020

iSave 70 180U0064 180U0005 180F7021

93.7

92.4

2-35

2-35

36-95

36-95

5 micron melt-blown

484/506

484/506

1067/1116

1067/1116

513/535

513/535

1131/1179

1131/1179

83

86

0.44

0.44

4.71

4.71

0.76

0.76

8.14

8.14

170

177

125

130.5

180

180

132

132

1180 36.2 22.5 30.0 324/6T
6 179 132 40 104
B 55

1180 36.2 22.5 30.0 324/6T
6 179 132 40 104
B 55

  1. A-weighted sound pressure level at 1 m from the ERD

unit surfaces (reference box) acc. to EN ISO 20361

  1. Please see section 7.4 Filtration

section 6.2. The noise measurement are performed 7) Typical efficiency for pressure exchanger,

..

acc. to EN ISO 3744:2010 on an ERD with motor

booster pump, electrical motor and VFD at 3

(motor pump unit) from min. to max. pressure and

barg differential pressure after a system has . . .

speed.

been commissioned and run in.

3 Area covered with recommended IE3 motor

configurations (excl. of space to service the ERD))

  1. For higher temperature, contact Danfoss. 5) Dependent on NaCI concentation.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 29

Flow [GPM]

Data sheet

Product type

5. Performance curves

5.1 Flow at different rpm
The diagram shows that the HP flow can be changed by changing the rotation speed of the iSave. The flow/rpm ratio is constant, the required flow is obtainable by changing the rotation speed to a required value.

For accurate data and advise, please contact Danfoss High Pressure Pumps.
The iSave is delivered with a 3.1 performance certificate according to EN10204.

5.2 iSave 50 flow curves

Flow curve iSave50® 60

2 bar

50

5 bar

220

40

176

Flow [m3/h]

30

20

10

0

525

650

Motor speed [rpm]

Flow [GPM]

5.3 iSave 70 flow curves

Flow [m3/h]

Flow curve iSave70®

80,0

2 bar

70,0

5 bar

308

60,0

50,0

220

40,0

30,0

20,0

10,0

0,0

625

875

Motor speed [rpm]

30 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type 5.4 Torque curve for iSave 50 and iSave 70 Below curve illustrates typical values.

Torque [Nm]

200 180

Starting torque

160

140

120

100

80

60

40

20

0 525

Torque on iSave50 and iSave70

645

765

Motor speed [rpm]

delta-P: 5 bar delta-P: 4 bar delta-P: 3 bar delta-P: 2 bar delta-P: 1 bar
875

© Danfoss | 2023.12

5.5 Mixing curve

Volumetric mixing [%]

Volumetric mixing versus flushing 14,0

12,0

10,0

8,0

6,0

4,0

2,0

0,0

-10

-5

0

5

10

Flush ratio (larger than 0 means overflush) [%]

180R9357_AQ265943679828en-001003 | 31

Data sheet
6. Temperature and corrosion

Product type

6.1 Operation The chart below illustrates the corrosive resistance of different types of stainless steel related to NaCl concentration and temperature. All critical parts of the iSave is made of Super Duplex 1.4410/UNS 32 750 or Duplex 1.4462/UNS 32803.
Always flush the iSave with fresh water at operation stop in order to minimize the risk of crevice corrosion.

80 º C 70 60 50 40 30
20 100 160

316L

Duplex

Super Duplex

1000 1600

10 000 16000

100 000

CI ppm

160000

NaCI ppm

7. Installation

7.1 Operation and mounting

7.2 Horizontal mount

The iSave 50 and iSave 70 can be mounted horizontally and vertically. When mounted vertically, the electric motor must be placed at the top of the iSave

The iSave is delivered with a standard port orientation. The port orientation can be changed by the customer by rotating the combined iSave and bell housing around the center of the motor shaft.

32 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet © Danfoss | 2023.12

Product type

See example below on how to mount the pump and connect it to an electrical motor.

Note: Any axial and radial load on the shaft must be avoided.
min. 3 – 5 mm air space

A: Flexible coupling B: Bell housing C: Motor shaft

7.3 Connection to inlet or discharge ports:
· When using hard piping, it is important to follow the Guideline 180R9367 – Pipe connection.
· When using flexible hoses, it is recommened to use Hose Whip Restraint. Also follow the guideline 180R9084 – Right and Wrong Hose assembly.

A B C

7.4 Filtration
High quality water extends the service life of the whole system. Water to the iSave must be filtered to 5 m nominal, using melt-blown depth filter with good end sealings. Consult Danfoss for correct choice of filter.
It is important with selection of a proper filter and filter housing to ensure good cartridge end sealing. If there is a high risk of water by-pass it is recommended to use a second stage filter solution.
7.5 Noise

As the various filters on the market differ greatly, Danfoss High Pressure Pumps recommends using cartridges with consistent, reliable performance and high efficiency and where fibres are blown continuously onto a central support core. High Pressure Pumps does not recommend cartridges requiring any type of binders or resins.
Filters can be purchased from Danfoss High Pressure Pumps. For more information on the importance of proper filtration, please consult our publication “Filtration” (code number 521B1009), which also will provide you with an explanation of filtration definitions and a guidance on how to select the right filter.

Since the iSave is mounted on a bell housing and electric motor, the noise level should be determined for a complete system. To minimize vibrations and noise throughout the system, it is improtant that a horizontal iSave unit is mounted correctly on a frame with dampeners.
Rigid designs with metal pipes cause vibration and noise. It is therefore recommended to use high-pressure flexible hoses between the hard piping in the RO-plant and the iSave or to used multiple connections with Victaulic clamps where possible.
The noise level is influenced by: Speed:
· High rpm makes more fluid/structure-borne pulsations/vibrations than low rpm due to higher frequency.

Pressure: · High pressure makes more noise than low
pressure. Mounting: · Rigid mounting makes more noise than flexible mounting due to structure-borne vibrations.
Connections to iSave: · Pipes connected directly to the iSave 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.

180R9357_AQ265943679828en-001003 | 33

Data sheet

Product type

7.5 RO systems with an iSave

VFD

22

F F
F F

4

Media filter

B

2

C

3

26

Filter

Filter

PI

A

3 micron

10 micron

PI nominel

PI absolut

PS

4

Fresh water permeate flush

  • 12

1

26

LP in

PI

PS

HP out

21

24

11

iSave

HP in

M

M

VFD

22

25

18 25

5

PI

6

PS

18 HP out

Full flow cleaning/CIP
7

11 HP in

10

PI

9

M

M

VFD
23

VFD
23

14 13

PI

PS 20

15

19

17 Permeate
Flowmeter 8
16 28 CIP
27 Drain

  • Second stage filter: If recommended housing design and cartridges are not used, a second stage filter is required

Explanation of P&ID setup
A. Inlet filter: Place inlet filters on LP string in front of the iSave (11). Please see Guide line 521B1009 on Filtration. If recommended housing design and cartridges are not used, a second stage filter is required, see above (*). Thoroughly clean pipes and flush system prior to start-up.
B. Inlet pressure: Must assure that iSave is running according to specifications. Refer to iSave data sheet. Required: Must assure min. pressure to avoid cavitation. Recommended: Must assure max. pressure to avoid hydraulic and mechanical overload. (13) used for iSave 21 and iSave 40. (24) used for iSave 50 and iSave 70.
C. Piping and hoses: Dimension the piping to obtain minimum pressure loss (large flow, minimum pipe length, minimum number of bends/ connections and fittings to prevent pressure loss and flow turbulence). Use flexible hoses to minimize vibrations and noise. Please consult the Danfoss Hoses and Hose Fittings data sheet (521B0909 ) and Right and wrong Hose assembly (180R9084) for guidance.

D. Inlet flow control and mixing: To balance LP flow up against HP flow on the iSave and control mixing, place a flowmeter on low-pressure inlet (12) or low pressure outlet (20) of the iSave.
E. Outlet pressure control: In order to control the inlet pressure needed a back pressure valve (15) must be installed in the common outlet pipe from the iSaves. The valve should be designed to control flow. It is recommended to use a manual valve with lock function or an automatic controlled valve.
F. Variable speed and overload protection: Install a VFD to control the speed of the iSave and protect it against mechanical overload. See instruction 180R9372 for guidance of VFD settings.
G. LP discharge flow control: See “E”.
H. Air venting: Install an air bleed valve (8) on the highest point of the high-pressure piping to ensure the air is purged from the system before startup.

34 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

I. Pressure relief (high pressure): The pressure relief valve (6) protects the whole system against pressure overload and relieves the water if the pressure exceeds the maximum set pressure. If the high-pressure pump is a positive displacement pump, the pump can built up a very high pressure that will exceed mechanical strength of the membrane housing, pipes and other accessories. When using Danfoss APP pumps with Danfoss VCM check valves, it is recommended to place a pressure relief valve or pressure safety valve as illustrated. In case the Danfoss check valves are not used, the valve must be placed between pump and check valve (See 180R9371, Design Guide Pressure saftey valve in seawater RO sytem for more details).

J. Pressure relief (low pressure): The pressure relief valve or pressure safety valve (19) protects the low-pressure pipes against pressure overload and relieves the water if the pressure exceeds the maximum allowable pressure.
For a more eleborate description of the P&ID setup, please consult the Danfoss Design Guide Piping & Instrumentation Diagram (P&ID) (180R9370) or contact Danfoss.
The iSave 50 and iSave 70 can be mounted in parallel. For more information, please see “Design Guide Parallel-coupled APP and iSave” -180R9354 or contact Danfoss.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 35

Data sheet

Product type

8. Dimensions and connections

8.1 iSave 50-70 without electric motor

36 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

8.2 iSave 50-70 with with IE3 motor 18.5 kW on base frame vertical_front mounted

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 37

Data sheet

Product type

8.3 iSave 50-70 with with IE3 motor 18.5 kW on base frame vertical_back mounted

38 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

8.4 iSave 50-70 with with IE3 motor 18.5 kW on base frame horizontal

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 39

Data sheet

Product type

8.4 iSave 50-70 with NEMA motor 30 HP on base frame vertical – front mounted

40 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

8.5 iSave 50-70 with NEMA motor 30 HP on base frame vertical – back mounted

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 41

Data sheet

Product type

8.5 iSave 50-70 with NEMA motor 30 HP on base frame horizontal

42 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet 9. Service

Product type

9.1 Warranty

9.3 Maintenance

The Danfoss iSave is designed for long operation, low maintenance and reduced lifecycle costs.
Provided that the iSave has been running according to the Danfoss specifications, Danfoss guarantees one year service-free operation, however, max. 18 months from date of production.

Periodic inspections are required to ensure worn parts (if any), are replaced in due time. Operational conditions such as water quality should be taken into consideration when determining the frequency of the inspections. Danfoss recommends yearly inspections.
It is recommended to order the purposedesigned tool kit.

9.2 Operational conditions of concern Particular attention should be paid to the following factors to avoid increased wear and spare parts costs:
– Insufficient filtration – Insufficient bleeding and venting – Running at speeds outside specificat
tions – Wrong direction of rotation – Insufficient flushing or periods of standstill with sea water inside the iSave.

9.4 Repair assistance
In case of irregular function of the Danfoss RO components, please contact Danfoss High Pressure Pumps.

10. Accessories

Description 3″ Inlet hose kit – 2 m (79″) 6 barg (87 psig) 3″ Outlet hose – 1 m (39.4″) 80 barg (1160 psig) 3″ Outlet hose – 1.79 m (70.0″) 80 barg (1160 psig) Coupling iSave 50 – iSave 70 Base plate horizontal Base plate vertical

Type 3″ Victaulic, style 77 3″ Victaulic, style 77 3″ Victaulic, style 77 Softex 55H7-32H7 IEC200/NEMA324TC IEC200/NEMA324TC

Code no. 180Z0144 180Z0611 180Z0612 180Z4003 180Z4007 180Z4025

11. Useful documents

Literature number Description

180R9213

Start and stop of the SWRO with iSave

180R9214

Membrane cleaning of the RO system with the iSave

180R9354

Parallel coupled APP and iSave

180R9367

Pipe connections

180R9371

Pressure safety valve in the SWRO system

180R9372

APP and iSave overload protection

180R9370

Review sheet P&ID

521B1009

Filtration

iSave selection tool (hpp.danfoss.com)

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 43

Data sheet

Product type

44 | 180R9357_AQ265943679828en-001003

© Danfoss | DCS-SGDPT/SI | 2023.12

DDaetsaigsnhegeutide
Headline Myriad Pro miSaavxe.E2n6er/g2y6Rpecto.vaenrdymDine.v1i8c/e18 pt.
mStaaxr.t3arnodwstop of the SWRO with iSave

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003
hpp.danfoss.com | 1

Data sheet Table of Contents

Product type
Prior to start-up…………………………………………………………………………………………………………………………………………….47 Starting up the system…………………………………………………………………………………………………………………………………48 Daily system shutdown……………………………………………………………………………………………………………………………….48 More than one day system shut down……………………………………………………………………………………………………….49

46 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

© Danfoss | 2023.12

Below procedures are general guidelines for the start-up and shut-down functions of SWRO-systems with the Danfoss iSave Energy Recovery Device. Procedure details may differ depending on the system design. The numbers marked in () refer to the diagram on page 5.
iSave can be both a single iSave and multiple iSaves in parallel.
General SWRO system understanding with ISave
· Basically the permeate flow is the same as the flow from the high-pressure pump.
· The HP concentrate flow into iSave HP-in and HP seawater-out is determined by the rpm of the iSave.
· The iSave (s) HP flow determines the recovery rate (higher rpm on the iSave gives lower recovery rate and vice versa).
· Flow on the low-pressure side of the iSave is determined by feed pump and the pressure control valve LP-out (15) (not by the rpm of the iSave).
· The flow on the low-pressure side must be at least the same as on the high- pressure side of the iSave (LP in flow = HP in flow; this is called balanced flow).
· Continuously operation: · To minimize mixing, the flow on the
low-pressure side can be adjusted up to 10% higher than the high-pressure flow with the limitation that the flow rate at LP inlet may not exceed 70 m³/h.

Prior to start-up
High quality water extends the service life of the whole system. Both the APP pump and iSave are sensitive to hard particles. Before connecting any APP pump or iSave to a piping system ALL pipes must be thorough flushed with high quality pre-filtered water or mechanical cleaned.
1. Install all filter cartridges in the system.
2. With the iSave(s) and APP pump(s) disconnected from the piping, the system must be flushed in order to remove possible impurities from the system (pipes, hoses, membranes etc.). Flushing must run until the system can be ensured clean.
3. Connect the iSave(s) and APP pump(s) to the pipework. The iSave(s) and APP pump(s) are now ready for start-up.
Starting up the system
1. Make sure that all valves are set in normal operating positions.
2. Start the seawater supply pump (A).
3. Make sure all pipework is flushed with water. Vent all air from the system through air valve (8) and iSave unit (11). After venting, close valve (8). At initial start-up also bleed the iSave(s) and APP pump(s).

180R9357_AQ265943679828en-001003 | 47

Data sheet

Product type

4. Start the iSave(s).

“LP-out” pressure (14) is below 1 barg/

In general: Only start the iSaves when the

14.5 psig, adjust the flow by raising the

pressure “HP in” (10) is below 20 barg/290

flow from the seawater supply pump (A).

psig. Always start the iSave unit before the

3. If the “LP-in” flow (12) is too high, reduce

high-pressure pump is started.

flow by closing the pressure control

valve (15) or the flow from the seawater

There are in principle two ways to start multi

supply pump (A).

ple iSaves:

– Slowly ramp up all the iSaves at the same 10. For iSave 50 and iSave 70:

time.

Check the low pressure flow rates (12), and if

– Slowly ramp up one by one.

required, adjust flow with valve (15) to

achieve balanced flow to the iSave(s).

Starting sequence – one by one:

a) Start iSave #1.

1. If the “LP-in” flow (12) is too low and the

b) After 5 sec. start iSave #2.

“LP-in” pressure (21) is higher

c) In a sequence of 5 sec. start the

than 2 barg/29 psig, increase flow and

remaining iSaves.

decrease pressure by opening the

Comments:

pressure control valve (15).

– Ramp up time on iSaves is set between

2. If the “LP-in” flow (12) is too low and the

10 ­15 sec.

“LP-in” pressure (21) is below 2 barg/

29 psig, adjust the flow by raising the

Starting sequence – Start all iSaves at the

flow from the seawater supply pump

same time.

(A).

Comments:

3. If the “LP-in” flow (12) is too high, reduce

– Ramp up time on iSaves is set between

flow by closing the pressure control

10 ­15 sec.

valve (15) or the flow from the seawater

supply pump (A).

If the pressure (10) at “HP in” drops below

3 barg/43.5 psig, the sound will change of

the iSave. This is due to cavitation. “HP in” Daily system shutdown

pressure at 3 barg/43.5 psig is acceptable

for less than 10 min. within a period of 6 1. The system is running in normal operation

hours. Run the iSave at its min

and producing permeate flow.

allowable speed during this period to

reduce cavitation.

2. Stop the high-pressure pump (4).

5. With a pressure control valve (15), adjust the back pressure of the “LP- out” to fulfill the minimum presure requested in the Data sheet. (May only be necessary at initial start up).
6. An “over flush” of the iSave can be done to bleed any remaining air from the system. Flush over a period of minimum 2 minutes.
7. Adjust the speed of the iSave unit to desired flow (rpm). The speed is controlled by a VFD.

3. Keep the iSave(s) (11) running until the TDS in the high-pressure line is equal to the TDS in the low-pressure line. NB! If the pressure (10) at “HP in” drops below 3 barg/43.5 psig, the sound will change of the iSave. This is due to cavitation. “HP in” pressure at 3 barg/43.5 psig is acceptable for less than 10 minutes within a period of 6 hours. Run the iSave at its min allowable speed during this period to reduce cavitation.

8. Start the high-pressure pump(s) (4), and the system pressure (5) will rise until the permeate flow (17) almost equals the flow (2) from the high-pressure pump.

4. Stop the iSave(s)(11). 5. Stop the seawater supply pump (A).

9. For iSave 21 and iSave 40: Check the low pressure flow rates (12), and if required, adjust flow with valve (15) to achieve balanced flow to the iSave(s).

1. If the “LP-in” flow (12) is too low and the “LP-out” pressure (14) is higher than 1 barg/14.5 psig, increase flow and decrease pressure by opening the pressure control valve (15).
2. If the “LP-in” flow (12) is too low and the

48 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

More than one day system shutdown
1. Run the “daily system shutdown” procedure.
2. Supply permeate water to the SWRO system by using fresh water/permeate flush connection..
3. When the pressure “HP in” (10) is below 20 barg/ 290 psig start the iSave(s).
NB! If the pressure (10) in “HP in” drops below 3 barg/43.5 psig, the sound will change of the iSave. This is due to cavitation. “HP in” pressure at 3 barg/43.5 psig is acceptable for less than 10 minutes within a period of 6 hours. Run the iSave at its minimum allowable speed during this period to reduce cavitation.
4. Start the APP pump(s) in a period of 5 sec. by using normal ramp-up settings.
5. Stop the APP pump(s) after 5 sec.

6. Run the iSave(s) until the TDS in the highpressure line is equal to the TDS in the lowpressure line.
7. Stop iSave(s) and permeate water supply.

VFD

22

F F
F F

4

Media filter

B

2

C

3

26

Filter

Filter

PI

A

3 micron

10 micron

PI nominel

PI absolut

PS

4

Fresh water permeate flush

  • 12

1

26

LP in

PI

PS

HP out

21

24

11

iSave

HP in

M

M

VFD

22

25

18 25

5

PI

6

PS

18 HP out

Full flow cleaning/CIP
7

11 HP in

10

PI

9

M

M

VFD
23

VFD
23

14 13

PI

PS 20

15

19

17 Permeate
Flowmeter 8
16 28 CIP
27 Drain

  • Second stage filter: If recommended housing design and cartridges are not used, a second stage filter is required

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 49

Data sheet

Product type

50 | 180R9357_AQ265943679828en-001003

© Danfoss | DCS-SGDPT/SI | 2023.12

DDaetsaigsnhegeutide
Headline Myriad Pro mmEiMSnaaeaxevm.erx3gb.ryor2awR6nsee/c2oc6vleeaprnytiD.ngaenvodifcmeRiOn.-1s8y/s1t8epmt.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003
hpp.danfoss.com | 1

Data sheet Table of Contents

Product type
Membrane cleaning……………………………………………………………………………………………………………………………………………53 P&ID No.1………………………………………………………………………………………………………………………………………………………………54 P&ID No. 2 …………………………………………………………………………………………………………………………………………………………….55

52 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

Below procedures are general guidelines for the membrane cleaning of SWRO- systems with the Danfoss iSave. Procedure details may differ depending on the system design. The numbers marked in () refer to the diagram’s below.
The purpose of membrane cleaning is to reduce scaling and fouling in the membranes. For optimal performance specific chemicals are required, depending on the cause of the contamination. After chemical treatment the system must be flushed with fresh water. The flushing water, coming out of the membranes, may consist of a large amount of suspended inorganic particles. It is important to assure that these particles are not fed into the iSave(s) or pump(s).
NB! It is recommended to disconnect the piping from the “HP in” of the iSave and flush the contaminated water from the membranes directly to drain. By disconnecting the pipes there will be no accumulation of contaminations in the HP-piping and HP-valves. See P&ID no 2.

Membrane cleaning
The procedures below are based on Dow’s Cleaning and Sanitization: Cleaning steps described in Dow’s Form No. 609-02090-1005. Other procedure may be used depending on the membranes used.
Below procedure is according P&ID no 1.
1. Stop the high-pressure pump(s) (4), and stop the iSave(s) (11).
2. Stop the seawater supply pump (A).
3. Close valve (9 and 27) and open valve (16 and 28), and feed cleaning solution through valve (7).
4. Pump mixed cleaning solutions to the vessel at conditions of low flow rate and low pressure to displace the process water. Use only enough pressure to compensate for the pressure drop from feed to concentrate. The pressure should be low enough that essentially no or little permeate is produced. A low pressure minimizes re-deposition of dirt on the membrane. Dump the brine/ concentrate to prevent dilution of the cleaning solution.
5. Recycle: After the process water is displaced, cleaning solution will be present in the concentrate/ brine stream. Recycle the cleaning solution from the piping to the cleaning solution tank.
6. Turn of the pump and allow the elements to soak.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 53

Data sheet

Product type

7. Feed the cleaning solution at high flow into the “full flow cleaning” adapter (7). The high flow rate flushes out the foulants removed from the membrane surface by the cleaning.
8. Flush RO permeate or deionised water into the “full flow cleaning” adapter (7). Flush out the cleaning solution. It is essential that the water used for the final pre-flush is pre-filtered to a level described in the datasheet.

9. Open valve (9) and continue flushing. The iSave(s) may start to rotate backward ­ this is OK.
10. When flushing is finalised ­ assure that no foulants remain in the piping or valve (9).
11. Close the high pressure “full flow cleaning” valve (7) and close valve (16 and 28).
12. Open valve (27)

P&ID no. 1

VFD

22

F F
F F

4

Media filter

B

2

C

3

26

Filter

Filter

PI

A

3 micron

10 micron

PI nominel

PI absolut

PS

4

Fresh water permeate flush

  • 12

1

26

LP in

PI

PS

HP out

21

24

11

iSave

HP in

M

M

VFD

22

25

18 25

5

PI

6

PS

18 HP out

Full flow cleaning/CIP
7

11 HP in

10

PI

9

M

M

VFD
23

VFD
23

14 13

PI

PS 20

15

19

17 Permeate
Flowmeter 8
16 28 CIP
27 Drain

  • Second stage filter: If recommended housing design and cartridges are not used, a second stage filter is required

Below procedure is according P&ID no 2.
1. Stop the high-pressure pump(s) (4), and stop the iSave (11).
2. Stop the seawater supply pump (A).
3. Disconnect pipe in joint (9) and connect the pipe to low pressure “Full flow cleaning” joint (16).
4. Plug pipe in joint (9).
5. Close valve (27) and open valve (28)
6. Pump mixed cleaning solutions through valve (7) to the vessel at conditions of low flow rate and low pressure to displace the process water. Use only enough pressure to compensate for the pressure drop from feed to concentrate.

The pressure should be low enough that essentially no or little permeate is produced. A low pressure minimizes re-deposition of dirt on the membrane. Dump the brine/ concentrate to prevent dilution of the cleaning solution.
7. Recycle: After the process water is displaced, cleaning solution will be present in the concentrate stream. Recycle the cleaning solution from the piping to the cleaning solution tank.
8. Turn of the pump and allow the elements to soak.
9. Feed the cleaning solution at high flow into the “full flow cleaning” adapter (7) on the feed side of the membrane. The high flow rate flushes out the foulants removed from the membrane surface by the cleaning.

54 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet P&ID no. 2

Product type

10. Flush RO permeate or deionised water into the “full flow cleaning” adapter (7) on the feed side of the membrane. Flush out the cleaning solution. It is essential that the water used for the final pre-flush is pre-filtered to a level described in the datasheet.

11. When flushing is finalised ­ Close the high pressure “full flow cleaning” valve (7) and close valve (28).
12. Connect the high pressure pipe to joint (9) again.

VFD

22

F F
F F
v

4

Media filter

B

2

C

3

26

Filter

Filter

PI

A

3 micron

10 micron

PI nominel

PI absolut

PS

4

Fresh water permeate flush

  • 12

1

26

LP in

PI

PS

HP out

21

24

11

iSave

HP in

M

M

M

M

VFD

22

25

18 25

5

PI

6

PS

18 HP out

Full flow cleaning/CIP
7

11 HP in

10
PI
9

VFD
23

VFD
23

14 13

PI

PS 20

15

19

17 Permeate
Flowmeter 8
16
28 CIP
27 Drain

  • Second stage filter: If recommended housing design and cartridges are not used, a second stage filter is required

© Danfoss | 2023.12

VFD

22

F F
F F

4

Media filter

B

2

C

3

26

Filter

Filter

PI

A

3 micron

10 micron

PI nominel

PI absolut

PS

4

Fresh water permeate flush

  • 12

1

26

LP in

PI

PS

HP out

21

24

11

iSave

HP in

M

M

M

M

VFD

22

25

18 25

5

PI

6

PS

18 HP out

Full flow cleaning/CIP
7

11 HP in

10
PI
9

VFD
23

VFD
23

14 13

PI

PS 20

15

19

17 Permeate
Flowmeter 8
16 28 CIP
27 Drain

  • Second stage filter: If recommended housing design and cartridges are not used, a second stage filter is required

180R9357_AQ265943679828en-001003 | 55

Data sheet

Product type

56 | 180R9357_AQ265943679828en-001003

© Danfoss | DCS-SGDPT/SI | 2023.12

DDaetsaigsnheGeutide
Headline Myriad Pro mmAPaaPx.xp3u.rmo2wp6ss/a2n6d iSpatv.e®and min. 18/18 pt.
overload protection

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003
hpp.danfoss.com | 1

Data sheet Table of Contents
1. Introduction

Product type

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

APP pump and iSave overload protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

2.1

Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Standard preferred settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

3.1

VLT FC 202 and VLT FC 302. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Examples of VLT overload limit settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

APP and iSave maximum load and speed limit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

5.1

APP pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

5.2

iSave energy recovery device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

5.3

Time delay before start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

This document shows what to consider when programming a VFD that can protect the APP pump and the iSave against overloads. It also shows how to program the Danfoss VLT FC 202 and FC 302 in connection with the APP pump and iSave. Similar functions need to be available on other VFD brands.
There are principal two choiches that can be made when selecting the torque limits for the pump and iSave.

1. Protecting the pump or iSave against maximum allowable load, means maximum torque at maximum pressure. This choice may not give the possibility to detect additional critical torque caused by wear of internal parts. See graph in example #1 in chapter 2.1.
2. Protecting the pump or iSave against significant change in actual load. This choice gives you the possibility to detect additional critical torque caused by wear of internal parts. This means the torque limit typical will b set lower than maximum Allowable Operating Torque. See graph in example #2 in chapter 2.1. Danfoss strongly recommend to use the possibility to detect significant change in actual load.

58 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

2. APP pump and iSave overload protection

When protecting the pump and iSave against overload both the maximum torque and maximum pressure must be taken into account.
– Maximum allowable operation torque is the maximum torque the product can handle in normal operation.
– Maximum allowable operation torque is the maximum torque the product need in a specificl operation.
Example #1

2.1 Maximum torque
Start up: · Ramp up speed from 0 to set-point · The starting torque must not exceed maxi-
mum Starting Torque according to chapter 5.
Ongoing operating: · Continuously the torque must not exceed
120% of maximum Allowable Operating Torque for more than 30 sec. · Periodically the torque can for a very short time go up to maximum Starting torque.

Percent of max load

Load Protection VFD setting: According to maximum allowable operating torque
160
Max starting torque 140

120
30 sec 100

20% overload Max allowable operating torque

30 sec

20% overload

80

60

40

20

Torque

0

0

10

20

30

40

50

60

70

80

90

100

100

100

100

100

Percent of design speed

Example #2

Percent of max load

Load Protection VFD setting: According to actual load
160
Max starting torque 140

120

100

80

30 sec

60

20% overload

Maximum allowable operating torque Maximum Operating torque

30 sec

20% overload

40

20

Torque

0

0

10

20

30

40

50

60

70

80

90

100

100

100

100

100

Percent of design speed

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 59

Data sheet

Product type

3. Standard preferred settings

3.1 VLT FC 202 and VLT FC 302
For detailed information on how to program a VLT FC 202 or FC 302 we refer to the “Programming Guide VLT Aqua Drive FC 202 and FC 302”. vlt- drives.danfoss.com

To calculate setting for parameter 4-16 and 4-18 please contact Danfoss.

Programming VLT: Parameter 0-01 Parameter 0-02 Parameter 0-20

“Language” “Motor speed unit” “LCD Display”

Set language Set to rpm Choose rom, Amp, kW, Hz, Torque

Parameter 1-03 Parameter 1-06 Parameter 1-20 Parameter 1-22 Parameter 1-23 Parameter 1-24 Parameter 1-25 Parameter 1-29
Parameter 1-71 Parameter 1-72

“Torque characteristic” “Clockwise direction” “Motor power kW” “Motor voltage” “Motor frequency” “Motor current” “Motor nominel speed” “Automatic motor adaption AMA”
“Start delay” “Start function”

Set to 0 (Constant torque) Set to inverse (Clockwise) According to motor name plate According to motor name plate According to motor name plate According to motor name plate Rpm according to name plate Run full AMA. (Remember to fuse terminals 12 and 27. Push hand on. Remove fuse after AMA) Set in sec. (See chapter 5.3) Set to 0. (DC hold/delay/time)

Parameter 2-00

“DC hold current”

Set in % (please contact Danfoss or see chapter 5.2 for iSave)

Parameter 3-02 Parameter 3-03 Parameter 3-41
Parameter 3-42

“Minimum reference” “Maximum reference” “Ramp 1. Ramp up time”
“Ramp 1. Ramp down time”

Set to 0
Set needed rpm. For application
Motor ramp up time. Pump: 10-60 sec. = 1 barg/sec. iSave: 10.15 sec.
Motor ramp down time. Pump: 10-60 sec. = 1 barg/sec. iSave: 10-15 sec.

Parameter 4-11
Parameter 4-13
Parameter 4-19 Torque limit Parameter 4-16
Parameter 14-25 Current limit Parameter 4-18

“Motor speed low limit” “Motor speed high limit” “Max. output frequency” “Torque limit motor mode” “Trip delay at torque limit” “Current limit”

Set low limit [rpm] for product according to chapter 5 Set max. limit [rpm] for product according to chapter 5 [Hz] Set max. output for product
Set in [%] (please contact Danfoss or see chapter 5.2 for iSave) Set to 30 sec.
Set in [%] (Par. 4-18 must always be larger or equal to Par. 4-16), (please contact Danfoss or see chapter 5.2 for iSave)

60 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

Below is two examples of how to calculate the

4. Examples of VLT

torque limit settings for an APP pump.

overload limit settings All calculations are made in the Danfoss HPP

calculation tool (please contact Danfoss HPP for

help).

Example 1: Settings are made according to actual operating pressure (see graph

2 in chapeter 2.1).

Example 2: Settings are made according to maximum allowable operating pressure (see graph #1 in chapter 2.1)

· 77 m³/h and 60 barg max. operating pressure · Design pressure 60 barg Calculated operating torque: 934 Nm at 1,490
rpm and 60 barg. Selected motor:
· 160 kW, 4 pole · Efficiency: 95.8% · Power factor (cos): 0.87 · Power supply: 400 [V] · Rated speed: 1,490 rpm · Max. current: 275 [A] · Max. operating torque: 1,026 Nm Calculate torque at 20% higher than 934 Nm = > 1,121 Nm Parameter 4-16 setting = 107% Calculate starting torque at 40% higher than 934 Nm = > 1,308 Nm Parameter 4-18 setting = 121% Calculated DC-hold: Parameter 2-00 is 49% Selected delay before start Parameter 1-71 is 4 (see chapter 5.3) Trip delay torque limit: Parameter 14-25 is 30 sec. Calculated starting current: 334 [A] Calculated operating current at 60 barg: 257 [A]

· 77 m³/h and 60 barg max. operating pressure · Design pressure 80 barg Calculated maximum operating torque:
1,246 Nm at 1,490 rpm and 80 barg. Calculated operatin torque: 934 Nm at 1,490
rpm and 60 barg. Selected motor:
· 200 kW, 4 pole · Efficiency: 96% · Power factor (cos): 0.88 · Power supply: 400 [V] · Rated speed: 1,490 rpm · Max. current: 340 [A] · Max. operating torque: 1,282 Nm Calculate torque at 20% higher than 934 Nm = > 1,121 Nm Parameter 4-16 setting = 90% Calculate starting torque at 40% higher than 934 Nm = > 1,308 Nm Parameter 4-18 setting = 102% Calculated DC-hold: Parameter 2-00 is 47% Selected delay before start Parameter 1-71 is 4.5 Trip delay torque limit: Parameter 14-25 is 30 sec. Calculated starting current: 345 [A] Calculated operating current at 60 barg: 271 [A]

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 61

Data sheet

Product type

5. APP and iSave maximum load and speed limit

APP pump

Code number

APP 86/1700 APP 78/1500 APP 65/1500 APP 53/1500 APP 43/1700 APP 38/1500 APP 30/1200 APP 30/1500 APP 26/1200 APP 26/1500 APP 24/1200 APP 24/1500 APP 21/1200 APP 21/1500 APP 22/1200 APP 22/1500 APP 19/1200 APP 19/1500 APP 17/1200 APP 17/1500 APP 16/1200 APP 16/1500 APP 13/1200 APP 13/1500 APP 11/1200 APP 11/1500

180B7802 180B7800 180B7803 180B7801 180B3072 180B3071 180B3060 180B3062 180B3056 180B3057 180B3054 180B3055 180B3051 180B3052 180B3257 180B3253 180B3256 180B3252 180B3255 180B3251 180B3254 180B3250 180B3214 180B3213 180B3212 180B3211

5.1 APP pumps

Max. starting torque
Use without VFD control 1700 [Nm] 1700 [Nm 1700 [Nm 1700 [Nm
851 [Nm] 851 [Nm] 851 [Nm] 851 [Nm] 851 [Nm] 851 [Nm] 851 [Nm] 851 [Nm] 851 [Nm] 851 [Nm] 596 [Nm] 596 [Nm] 596 [Nm] 596 [Nm] 596 [Nm] 596 [Nm] 596 [Nm] 596 [Nm] 384 [Nm] 384 [Nm] 384 [Nm] 384 [Nm]

Max. starting torque
Use in Parameter 4-18
1155 [Nm] 1700 [Nm] 1541 [Nm] 1205 [Nm] 764 [Nm] 851 [Nm] 851 [Nm] 699 [Nm] 738 [Nm] 596 [Nm] 685 [Nm] 543 [Nm] 585 [Nm] 497 [Nm] 596 [Nm] 427 [Nm] 521 [Nm] 368 [Nm] 480 [Nm] 328 [Nm] 442 [Nm] 312 [Nm] 384 [Nm] 286 [Nm] 321 [Nm] 232 [Nm]

Max. allowable operating torque Use in Parameter
4-16 1111 [Nm] 1246 [Nm] 1101 [Nm] 861 [Nm] 546 [Nm] 608 [Nm] 608 [Nm] 499 [Nm] 527 [Nm] 426 [Nm] 489 [Nm] 388 [Nm] 418 [Nm] 355 [Nm] 426 [Nm] 305 [Nm] 372 [Nm] 263 [Nm] 343 [Nm] 234 [Nm] 316 [Nm] 223 [Nm] 274 [Nm] 204 [Nm] 229 [Nm] 166 [Nm]

Max. allowable operating pressure
70 barg 80 barg 80 barg 80 barg 70 barg 80 barg 80 barg 80 barg 80 barg 80 barg 80 barg 80 barg 80 barg 80 barg 80 barg 70 barg 80 barg 70 barg 80 barg 70 barg 80 barg 70 barg 80 barg 70 barg 80 barg 70 barg

Operational speed (min.) Parameter
4-11 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm 700 rpm

Operational speed (max.) Parameter
4-13 1700 rpm 1500 rpm 1500 rpm 1500 rpm 1700 rpm 1500 rpm 1200 rpm 1500 rpm 1200 rpm 1500 rpm 1200 rpm 1500 rpm 1200 rpm 1500 rpm 1200 rpm 1500 rpm 1200 rpm 1500 rpm 1200 rpm 1500 rpm 1200 rpm 1500 rpm 1200 rpm 1500 rpm 1200 rpm 1500 rpm

62 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

iSave
Code number
Motor
Max. allowable operating differential pressure
Max. allowable operating torque
Max. starting torque
Delay before start Parameter 1-71
DC hold Parameter 2-00
Max. starting torque Parameter 4-18
Max. allowable operating torque Parameter 4-16
Operational speed (Min.) Parameter 4-11
Operational speed (Max.) Parameter 4-13
Delay torque limit Parameter 14-25

5.2 iSave energy recovery device

iSave 21 Plus 180F7016 180F70002) 5.5 kW IEC 3 barg
36 Nm 50 Nm 0.4 sec.
54%
129%
114%
500
1500
30 sec.

iSave 21 Plus 180F7017 7.5 kW IEC 5 barg 49 Nm 50 Nm 0.7 sec. 54% 114% 102% 500 1500 30 sec.

iSave 40 180F7001 180F7003 11 kW IEC
5 barg
102 Nm 150 Nm 0.8 sec.
61%
125%
108%
600
1200
30 sec.

iSave
Code number
Motor
Max. allowable operating differential pressure
Max. allowable operating torque
Max. starting torque
Delay before start Parameter 1-71
DC hold Parameter 2-00
Max. starting torque Parameter 4-18
Max. allowable operating torque Parameter 4-16
Operational speed (Min.) Parameter 4-11
Operational speed (Max.) Parameter 4-13
Delay torque limit Parameter 14-25

iSave 50 180F7022 18.5 kW IEC
5 barg 170 Nm 180 Nm 1.3 sec.
59% 109 % 109% 525 650 30 sec.

iSave 50 NA
30 HP NEMA 5 barg 170 Nm 180 Nm 1.5 sec. 56% 110% 110% 525 650 30 sec.

  1. Maximum torque the electric motor is able to operate with 2) iSave 21 old version

iSave 70 180F7024 18.5 kW IEC
5 barg 180 Nm1) 180 Nm 1.3 sec.
59% 113% 113% 625 875 30 sec.

iSave 40 180F7004 180F7005 15 kW IEC
5 barg
102 Nm 150 Nm 1.1 sec.
59%
89%
101%
600
1200
30 sec.

iSave 40 180F011N206H 180F011N206V 20 HP NEMA
5 barg
102 Nm 150 Nm 1.1 sec.
53%
117%
100%
600
1200
30 sec.

iSave 70 NA
30HP NEMA 5 barg 179 Nm1) 180 Nm 1.5 sec. 56% 114% 114% 625 875 30 sec.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 63

Data sheet

Product type

5.3 Time delay before start

64 | 180R9357_AQ265943679828en-001003

© Danfoss | DCS-SGDPT/SI | 2023.12

DInasttarushcteioetn
Headline Myriad Pro mmRHioagaxsh.ex3ta.raso2snwe6dms/wb2rl6yornopgutt.inagndtipmsin. 18/18 pt.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003
hpp.danfoss.com | 1

Data sheet 1. Hoses up to 2″

Product type

Correct hose installation is essential for safe and satisfactory performance. The size of the hoses impacts the installation recommendations. This manual has therefore been split in recommendation for hoses up to 2″ and recommendation larger than 2″.

Hose routing tips: Danfoss recommends installing hose whip restraints whenever your pressurized hose assemblies are in proximity to personnel or crucial equipment. Check with these examples when installing your hoses.

When installing hoses, avoid twisting the hose as the hose will try to straighten under pressure.

This can cause hose failure via hose blowout from the fitting and/or hose burst at the point of strain.

MIN. 10°
Always provide some angle on straight hose installations, this reduces forces and ensures that hose is only bending i one direction. The Hose must have some slack to compensate for hose length variations.

WRONG
RIGHT
When radius is below the required minimum, use an angle adaptor to avoid sharp bends.
At radius below required minimum, angle adapters should be used to prevent sharp hose bends.

NO PRNEOSSURE
PRESSURE

HIGH PPRREHESISGSSUHURERE

WRONG
RIGHT
User proper angle adaptors to avoid sharp twist or bend in hose.

To allow the hose to expand when pressurized, clamps should not be used at bends. If possible, do not clamp high and low pressure lines together.

Use proper angle adapters to avoid sharp twist or bend of hose.

66 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

WROWNROGNG

RIGHRIGTHT

To prevent hose collapse and flow restriction, hose bend radii should be kept as large as possible. Tight bends can also compromise the hose reinforcement and cause premature hose failure. Refer to hose specification table on page 6 for minimum bend radii.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 67

Data sheet

Product type

2. Hoses larger than 2″

Whenever possible, high pressure hoses should always be connected directly to Danfoss provided adapters and check valves. Elbows and distance pipes should be avoided to prevent excessive side loads.

Danfoss 3″ HP hoses are nylon reinforced; when using hoses that are not steel reinforced the connected items must be grounded to avoid electrical stray currents.

EXPANSION EXPANSION

EXPANSION

MIN. 10°
Always provide some slack on straight hose installations. This compensates for hose length variations with differences in internal fluid pressures. A small angle will reduce the forces from the hose and allow the hose to bend when pressurized.

Flexing a metal hose in two separate planes of movement will torque the hose assembly. Always install the metal hose assembly so that flexing occurs in one plan only and this is the same plane in which bending occurs. If multiple planes of motion are required use a dog leg assembly.

WRONG

The installation should allow a straight distance S before bending the hose. Not doing so may compromise the hose reinforcement and cause hose failure. Max. bending angle and distance S can be found in table 1 on page 6.

RIGHT
Hoses should not be twisted and should only have one bend.

68 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

MAX. BENDING ANGLE

The use of pipe or fittings between pump and iSave connectors and hoses should be avoided. Such configurations can apply excessive loads on the connectors and can cause connector and/or connector bolt failure. If this cannot be avoided, the piping system must be protected by either hose whip restraints mounted directly to the frame or the hard piping must be fixed relative to any pump/iSave movements.

If hose is bent, ensure max. bending angle and distance S from each connector (see table 1 on page 5).

WROWRNONGG

RIGRHIGHTT

WRONG

To prevent hose collapse and flow restriction, hose bend radii should be kept as large as possible. Tight bends can also compromise the hose reinforcement and cause premature hose failure. Refer to hose specification table on page 6 for minimum bend radii.

RIGHT
The hose must have a distance S before bending starts.

NO PPRREENSSSOSUURERE

HIGHHIGH PRPERSESSSUURREE

To allow the hose to expand when pressurized, clamps should not be used at bends. If possible, do not clamp high and low pressure lines together.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 69

Data sheet

Product type

3. Hose specification table
High pressure hoses

Code Pipe connection1

number

[A]

180Z0228 1.5″ Vic. OGS

Pipe connection
material
Super duplex EN 1.4410

Hose size Inner
diameter
25.4 mm (1.0″)

Hose length ISO 1436 [B]

Bending radius

0.66 m (26″) 152 mm (6.08″), max. 90°

180Z0229 1.5″ Vic. OGS

Super duplex EN 1.4410

25.4 mm (1.0″)

1.16 m (45.7″)

152 mm (6.08″), max. 180°

180Z0167 180Z0140

1.5″ Vic. OGS 2.0″ Vic. OGS

180Z0263 2.5″ Vic. OGS) 180Z0280 2.5″ Vic. OGS 180Z0619 2.5″ Vic. OGS 180Z0618 2.5″ Vic. OGS 180Z0612 3.0″ Vic. OGS 180Z0611 3.0″ Vic. OGS 180Z1000 3.0″ Vic. OGS 180Z1001 3.0″ Vic. OGS Low pressure hoses 180Z0298 2.0″ Vic. OGS

180Z0144 3.0″ Vic. OGS

Super duplex EN 1.4410
Super duplex EN 1.4410
Super duplex EN 1.4410
Super duplex EN 1.4410
Super duplex EN 1.4410
Super duplex EN 1.4410
Super duplex EN 1.4410
Super duplex EN 1.4410
Super duplex EN 1.4410
Super duplex EN 1.4410

38.0 mm (1.5″) 50 mm (2.0″) 50 mm (2.0″) 50 mm (2.0″) 65 mm (2.5″) 65 mm (2.5″) 76 mm (3.0″) 76 mm (3.0″) 76 mm (3.0″) 76 mm (3.0″)

1.16 m (45.7″) 1.25 m (49″) 1.78 m (70″) 1.00 m (39.4″) 1.78 m (70″) 1.00 m (9.4″) 1.79 m (70.5″) 1.00 m (39.4″) 1,25 m (49″) 1,6 m (63″)

250 mm (9.84″), max. 180° 630 mm (24.8″), max. 90° 630 mm (24.8″), max. 180° 630 mm (24.8″), max. 90° 200 mm (7.87″), max. 270° 200 mm (7.87″), max. 90° 250 mm (9.84″), max. 270° 250 mm (9.84″), max. 90° 250 mm (9.84″), max. 180° 250 mm (9.84″), max. 180°

Super duplex EN 1.4410
Super duplex EN 1.4410

2.0 m (79″)
2.0 m (79″)

S 79 mm (3.11″) 79 mm (3.11″) 85 mm (3.35″) 115 mm (4.53″) 115 mm (4.53″) 115 mm (4.53″) 150 mm (5.90″) 150 mm (5.90″) 150 mm (5.90″) 150 mm (5.90″) 150 mm (5.90″) 150 mm (5.90″)

  1. The installation instuction for Style 77DX is located in the Victaulic document I-100 Field Installation Handbook (htpp://static.victaulic.com)

S
O.D.
r

S
When using flexible hoses, it is recommened to use Hose Whip Restraint.

70 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet
Headline Myriad Pro max. 26/26 pt. and min. 18/18 pt.
max. 3 rows

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 1

Data sheet

Product type

72 | 180R9357_AQ265943679828en-001003

© Danfoss | DCS-SGDPT/SI | 2023.12

DPaatratsslhisetet
Headline Myriad Pro max. 26/26 pt. and min. 18/18 pt.
mEnaxe.r3gryowrescovery device iSave 50 – 70

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003
hpp.danfoss. com | 1

Data sheet Table of Contents

Product type

Contents

………………………………………………………………………………

General…………………………………………………………………………………………………………………………………… . . . . . . . . . . . . . . .

76

………………………………………………………………………………

Parts list iSave 50-70……………………………………………………………………………………………………………. . . . . . . . . . . . . . .

77

………………………………………………………………………………

Exploded view iSave 50-70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

………………………………………………………………………….. …………………..79

………………………………………………………………………………

Assembly unit iSave 50-70 Vertical mounting……………………………………………………………………. . . . . . . . . . . . . . . .

80

………………………………………………………………………………

Assembly unit drawing iSave 50-70 Vertitical mounting…………………………………………………… . . . . . . . . . . . . . . .

81

………………………………………………………………………………

Assembly unit iSave 50-70 Horizontal mounting………………………………………………. ………………82

………………………………………………………………………………

Assembly unit drawing iSave 50-70 Horizontal mounting………………………………………………… . . . . . . . . . . . . . . .

83

………………………………………………………………………………

Tool set iSave 50-70……………………………………………………………………………………………………………….. . . . . . . . . . . . . . . .

84

………………………………………………………………………………

1. General

The parts list provides an overview of th content of the various service kits for the iSave 50-70 as well as exploded view of the iSave.
74 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

180F4133 Shaft Seal Kit iSave 50-70 180F4132 Screw and Seal Kit iSave 50-70 180F4134 Coupling Kit iSave 50-70 180F4135 Port Plate Kit PE iSave 50 180F4136 Port Plate Kit PE iSave 70 180F4137 Vane Kit iSave 50-70 180F4138 Valve Plate Kit PE iSave 50-70 180F4139 Rotor/side plade Kit iSave 50-70

Data sheet
2. Parts list iSave 50-70

Product type

Pos. Qty. Description

Material

1

4

2

1

3

1

4

1

5

15

6

2

7

2

8

1

10 2

11 2

12 2

13 2

14 2

15 2

16 2

17 1

18 8

19 8

20 1

21 1

22 4

23 1

24 1

25 8

26 1

27 15

28 1

29 1

30 1

31 4

101 2

102 4

103 4

104 1

105 2

106 16

107 16

Screw M8 Cover O-ring Shaft seal Ø35 Screw M12 Bleeding plug G1/4″ O-ring Ass. Motor flange O-ring Rotor stop mashined O-ring Side plate O-ring Rotor element O-ring Rotor Vane Pin Key Stator Pin O-ring 3″ Vic. Connector, HP Out Screw M8 Intermediate flange Screw M12 O-ring 3″ Vic. Connector, LP In Lifting eye M12 Screw M8 O-ring Clips for retainer plate Pin Port plate (Feed) Valve plate Back-up ring O-ring

AISI 316 Super Duplex NBR NBR/hasteloy AISI 316 Super Duplex NBR Super Duplex/PEEK NBR PEEK NBR Ceramic NBR Ceramic NBR Super Duplex PEEK/Super Duplex PEEK AISI 316 Super Duplex AISI 316 NBR Super Duplex AISI 316 Super Duplex/PEEK AISI 316 NBR Super Duplex AISI 316 AISI 316 NBR PEEK Duplex PEEK/Super Duplex Super Duplex PTFE NBR

X

X

X

X

X

X

X

X

X

X

X

X
X X
X
X X
X X X X
X X

X X X
X X

X

X

X

Note: Danfoss reccommends always to use seals and screw kit for inspection and repair.

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 75

180F4133 Shaft Seal Kit iSave 50-70 180F4132 Screw and Seal Kit iSave 50-70 180F4134 Coupling Kit iSave 50-70 180F4135 Port Plate Kit PE iSave 50 180F4136 Port Plate Kit PE iSave 70 180F4137 Vane Kit iSave 50-70 180F4138 Valve Plate Kit PE iSave 50-70 180F4139 Rotor/side plade Kit iSave 50-70

Data sheet

Product type

2. Parts list cont. iSave 50-70

Pos. Qty. Description

108 1 109 12 110 1 111 1 112 1 113 2 114 1 115 6 116 6 117 6 118 1 119 2 120 4 121 1 122 6 123 1 124 1 125 3 126 3 203 2 204 1 205 4 206 8
1

Spring stop Compression spring O-ring Cylinder barrel Port plate (Brine) Pin Housing Stud bolt M12 Washer M12 Nut Portflange O-ring Screw M8 3″ Vic. connector LP Out Screw M8 3″ Vic. connector HP IN Lifting eye M12 O-ring Bleeding plug G1/4″ Coupling Softex 38/45 Pin Screw M8 Service instruction

Material
Super Duplex Hastelloy C276 NBR Super Duplex PEEK/Super Duplex AISI 316 Duplex Duplex AISI 316 AISI 316 Super Duplex NBR AISI 316 Super Duplex AISI 316 Super Duplex AISI 316 NBR Super Duplex Super Duplex Hytrel Duplex Super Duplex

X X

X

X

X

X X
X X
X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Note: Danfoss reccommends always to use seals and screw kit for inspection and repair.

76 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet
3. Exploded view iSave 50-70

Product type

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 77

Data sheet
4. Assembly unit iSave 50-70 Vertical mounting

Product type

iSave 50-70 Assembly Unit – Vertical mounting

Pos. Qty. Description

iSave 50, Vertical, IEC200L, 18.5 kW

iSave 50, Vertical, NEMA324/6T, 30HP

iSave 70, Vertical, IEC200L, 18.5 kW

iSave 70, Vertical, NEMA324/6T, 30HP

iSave 50-70 without motor

1

1 iSave 50

1

1 iSave 70

Motor

2

1 Motor 18.5 kW IEC200 6-pole 3×400 V IE3

2

1 Motor 324TC 30 HP 3PH 1200 230/460/380

5

4 Screw (not inluded in kit)

6

4 Washer (not included in kit)

iSave 50 – 70 coupling kit

3

1 Bell housing

4

1 Coupling

22

4 Screw M12

23

4 Washer M12

24

1 Grommet sealing

Base frame vertical

12

1 Base frame

13

2 Bracket, long

14

2 Bracket, short

15

4 Screw M12

16

8 Washer M12

17

4 Nut M12

18

4 Screw M10

19

16 Washer Ø10.5

20

4 Nut M10

21

8 Screw M10

IEC Code No. 180F7022
180F7024

NEMA Code No.
180U0004
180U0006

180F7020 180F7021

180Z0530

180U2370

180Z4003

180U2309

X

X

X

X

X

X

X

X

X

X

180Z4025

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

78 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

5. Assembly unit drawing iSave 50-70 Vertical mounting

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 79

Data sheet
4. Assembly unit iSave 50-70 Vertical mounting

Product type

iSave 50-70 Assembly Unit – Vertical mounting

Pos. Qty. Description

iSave 50, Vertical, IEC200L, 18.5 kW

iSave 50, Vertical, NEMA324/6T, 30HP

iSave 70, Vertical, IEC200L, 18.5 kW

iSave 70, Vertical, NEMA324/6T, 30HP

iSave 50-70 without motor

1

1 iSave 50

1

1 iSave 70

Motor

2

1 Motor 18.5 kW IEC200 6-pole 3×400 V IE3

2

1 Motor 324TC 30 HP 3PH 1200 230/460/380

5

4 Screw (not inluded in kit)

6

4 Washer (not included in kit)

iSave 50 – 70 coupling kit

3

1 Bell housing

4

1 Coupling

22

4 Screw M12

23

4 Washer M12

24

1 Grommet sealing

Base frame vertical

12

1 Base frame

13

2 Bracket, long

14

2 Bracket, short

15

4 Screw M12

16

8 Washer M12

17

4 Nut M12

18

4 Screw M10

19

16 Washer Ø10.5

20

4 Nut M10

21

8 Screw M10

IEC Code No. 180F7022
180F7024

NEMA Code No.
180U0004
180U0006

180F7020 180F7021

180Z0530

180U2370

180Z4003

180U2309

X

X

X

X

X

X

X

X

X

X

180Z4025

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

80 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

5. Assembly unit drawing iSave 50-70 Vertical mounting

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 81

Data sheet

Product type

6. Assembly unit iSave 50-70 Horizontal mounting

iSave 50-70 Assembly Unit – Horizontal mounting

Pos. Qty. Description

iSave 50, Horizontak, IEC200L, 18.5 kW

iSave 50, Horizontal, NEMA324/6T, 30HP

iSave 70, Horizontal, IEC200L, 18.5 kW

iSave 70, Horizontal, NEMA324/6T, 30HP

iSave 50-70 without motor

1

1 iSave 50

1

1 iSave 70

Motor

2

1 Motor 18.5 kW IEC200 6-pole 3×400 V IE3

2

1 Motor 324TC 30 HP 3PH 1200 230/460/380

5

4 Screw (not inluded in kit)

6

4 Washer (not included in kit)

iSave 50 – 70 coupling kit

3

1 Bell housing

4

1 Coupling

22

4 Screw M12

23

4 Washer M12

24

1 Grommet sealing

Base frame horizontal

12

1 Base frame

13

1 Bracket, support

14

1 Bracket, service

15

10 Screw M10

16

16 Washer Ø10

17

4 Nut M10

18

8 Washer Ø17

19

4 Screw M16

20

4 Nut M16

21

2 Screw M10

IEC Code No. 180F7023
180F7025

NEMA Code No.
180U0003
180U0005

180F7020 180F7021

180Z0530

180U2370

180Z4003

180U2309

X

X

X

X

X

X

X

X

X

X

180Z4007

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

82 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

7. Assembly unit drawing iSave 50-70 Horizontal mounting

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 83

180F4140 iSave 50-70 Tool kit

Data sheet
8. Tool set iSave 50-70

Product type

Qty. Designation

1 Back-up ring tool

x

2 Bushing for valve plate x

2 M6 screw

x

2 Washer M6

x

2 Nut M6

x

2 M16 washer

x

2 M8 screw

x

1 M8 lifting eye

x

1 Shaft seal tool

x

1 24 mm crow foot socket x

1 19 mm socket

x

1 3/8″ extension

x

1 Torque wrench 3/8″

x

1 4 mm Allen key

x

2 Screw driver

x

1 10 mm HEX socket

x

1 6 mm HEX socket

x

1 Nylon hammer

x

1 10 mm fork wrench

x

1 Screw driver

x

1 16 mm socket

x

1 Service instruction

x

84 | 180R9357_AQ265943679828en-001003

© Danfoss | DCS-SGDPT/SI | 2023.12

Data sheet

Product type

Electric Motors
Motor Manual

hoyermotors.com

Manual

© Danfoss | 2023.12

180R9357_AQ265943679828en-001003 | 85

Data sheet

Product type

Motor Manual

General
This manual concerns the following types of standard induction motors from Hoyer: HMA3, HMC3, HMA2, HMC2, HMD, HMT, MS, Y2E1, Y2E2, YDT These motors are manufactured in accordance with IEC/EN 60034-4 and IEC/EN 60072. Motors are rated for the ambient temperature range -20°C to +40°C and site altitudes 1000 m above sea level. Low-voltage motors are components for installation in machinery. They are CE marked according to the Low Voltage Directive 2014/35/EU. Motors not fulfilling the IE3 efficiency level must be equipped with a variable speed drive when used in EU.
Transport and storage
Check the motor for external damage immediately upon receipt and, if found, inform the forwarding agent right away. Check all rating plate data, and compare it with the requirement of the motor. Turn the shaft by hand to check free rotation, remove transport locking if used. Transport locking must be used again for internal transport also. It is also important that transport locking is used when motors are transported mounted on equipment. All motors should be stored indoors, in dry, vibration- and dust-free conditions.
Lifting eyebolts must be tightened before use. Damaged eyebolts must not be used, check before use. Lifting eyes at motor must not be used to lift the motor when it is attached to other equipment.
Before commissioning, measure the insulation impedance. If values are 10M at 25°C, the winding must be oven dried. The insulation resistance reference is halved for each 20°C rise in motor temperature. It is recommended that shafts are rotated periodically by hand to prevent grease migration.

etc.) using suitable tools, never hit the drive components with a hammer as this will cause damage to the bearing. The motor are balancing with half key, ensure that the drive components are also the same. Correct alignment is essential to avoid bearing, vibration and shaft failure. Use appropriate methods for alignment. Re-check the alignment after the final tightening of the bolts or studs. Check that drain holes and plugs face downwards. We recommend opening the drain hole for motors placed outdoors and not running 24 hours / day, so that the motor can breathe, thus ensuring a dry motor.

Electrical connection
Work is only permitted to be carried out by qualified specialists and must to be carried out in accordance with local regulations. Before work commences, ensure that all power is switched off and cannot be switched on again. This also applies to the auxiliary power circuits, e.g. anti-condense heaters. Check that supply voltage and frequency are the same as rated data. Motors can be used with a supply deviation of ± 5% voltage and ± 2% frequency, according to IEC60034-1.

Connection diagrams for main supply and accessory as PTC or heater are located inside the terminal box.

Connections must be made in such a way as to ensure that a permanently safe electrical connection is maintained, both for the main supply and the earth connection. We recommend that crimped connections are made in accordance with IEC 60352-2.

Tightening torques for terminal board screws:

Thread M5 M6 M8 M10 M12 M16 M20 M24

T.(Nm) 2.5 3.5

7

12

18

35

55

80

Installation
The motor must be fixed on a stable, clear and flat foundation. It must be sufficiently rigid to withstand possible short circuit forces. It is important to ensure that the mounting conditions do not cause resonance with the rotational frequency and the doubled supply frequency. Only mount or remove drive components (pulley, coupling,

Ensure that the terminal box is clean and dry. Unused glands must be closed with blind caps. Check the terminal box gasket before it is remounted.
Maintenance
Inspect the motor at regular intervals, keep it clean and ensure free ventilation air flow, check the condition of shaft seals and replace if necessary. Both electrical and mechanical

86 | 180R9357_AQ265943679828en-001003

© Danfoss | 2023.12

Data sheet

Product type

Motor Manual

connections must be checked and tightened if necessary. Bearing size and type are specified on the rating plate. Motor types HMA3 and HMC3 is as standard with lifetime greased bearings in motors size 180 for cast iron and size 132 for aluminium. Motor types HMA2 and HMC2 is as standard with lifetime greased bearing in motors size 225. Motor types MS and Y2E is as standard with lifetime greased bearing in motors size 160.

Typical duty hours for lifetime lubricated bearings.

Frame size 56 – 160 180 200 225

References

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>

Related Manuals