Danfoss iSave 50-70 Energy Recovery Device Instruction Manual
- June 16, 2024
- Danfoss
Table of Contents
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.
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© Danfoss | 2023.12
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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
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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
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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
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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
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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
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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
-
Max. allowable working pressure of continous operation. For lower and higher pressure, please contact Danfoss.
-
Typical pressure level at start-up and permeate flush.
-
Intermittent pressure is acceptable for less than 10 minutes within a period of 6 hours.
-
Typical average flow at 60 barg and 3 barg differential pressure
-
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. -
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.
-
Balanced flow: The mixing rate is defined at balanced flow when HP-out is equal to LP-in.
-
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
- 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
- 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))
- 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
- A-weighted sound pressure level at 1 m from the ERD
unit surfaces (reference box) acc. to EN ISO 20361
- 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))
- 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
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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
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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
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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.
- 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
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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
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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″)
- 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.
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Data sheet
Headline Myriad Pro max. 26/26 pt. and min. 18/18 pt.
max. 3 rows
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Data sheet
Product type
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DPaatratsslhisetet
Headline Myriad Pro max. 26/26 pt. and min. 18/18 pt.
mEnaxe.r3gryowrescovery device iSave 50 – 70
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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.
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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
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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.
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Data sheet
3. Exploded view iSave 50-70
Product type
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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
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Data sheet
Product type
5. Assembly unit drawing iSave 50-70 Vertical mounting
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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
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Data sheet
Product type
5. Assembly unit drawing iSave 50-70 Vertical mounting
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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
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Data sheet
Product type
7. Assembly unit drawing iSave 50-70 Horizontal mounting
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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
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Data sheet
Product type
Electric Motors
Motor Manual
hoyermotors.com
Manual
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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
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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
- High-pressure pumps by Danfoss, world leading manufacturer | Danfoss
- Mechanical Pipe Joining & Fire Protection Solutions | Victaulic
- Global AC drive manufacturer - Danfoss Drives | Danfoss
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