Danfoss iSave 40 User Manual Download

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isave.danfoss.com

User manual

Installation, Operation and

Maintenance Manual

iSave 40

Frontpage

Operation guide

Energy recovery device

iSave 40 series 04 and newer

Installation, Operation and

Maintenance Manual

hpp.danfoss.com

Summary of Contents for iSave 40

Page 1: ...s com User manual Installation Operation and Maintenance Manual iSave 40 Frontpage Operation guide Energy recovery device iSave 40 series 04 and newer Installation Operation and Maintenance Manual hpp...

Page 2: ...eserved 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 D...

Page 3: ...3 5 6 Electric motor data 13 5 7 How does the iSave work 13 5 7 1 Pressure exchanger function 14 5 7 2 Booster pump 14 5 7 3 Lubrication flow 14 5 7 4 Volumetric mixing 14 5 7 5 How does the iSave wor...

Page 4: ...iSave parts list 35 10 5 1 Pressure exchanger 35 10 5 2 Booster pump vane pump partslist 36 10 5 3 iSave 180F7011 37 10 5 4 iSave on base plate horizontal 180F7001 and 180F7004 37 10 5 5 iSave on foot...

Page 5: ...result in personal injury and or damage to the iSave Electrical hazard Indicates a high voltage warning Safety glasses required Hearing protection required Safety shoes required Safety helmet require...

Page 6: ...horised 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...

Page 7: ...e barg 20 psig 290 HP max inlet pressure barg 83 psig 1200 HP inlet min pressure intermittent 2 3 barg 3 psig 43 5 LP inlet max pressure barg 5 psig 72 5 LP inlet max pressure intermittent 3 barg 10 p...

Page 8: ...ges to the iSave unit with risk of personal injury 3 4 Preferred system design Danfoss recommends building systems with a high degree of safety The P ID in chapter 5 16 shows the Danfoss preferred sys...

Page 9: ...ontact your local authorised distributor or Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark Telephone 45 7488 2222 Fax 45 7445 3831 Email highpressurepumps danfoss com Homepage www hpp danfos...

Page 10: ...using 3 Position the electric motor on the bell housing Make sure that the two coupling parts are connected properly 4 Tighten the 4 bolts Lift the electric motor ONLY in the lifting eyes provided The...

Page 11: ...using DOWFROST from DOW Chemical Company or Chillsafe mono propylene glycol from Arco Chemical Company 4 3 3Centre of mass The iSave is NOT delivered frostpro tected from the factory Only remove caps...

Page 12: ...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 dampeners to minimise vibrations and nois...

Page 13: ...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 5 4 Temperature and c...

Page 14: ...HP out AND from HP in to LP out However if the feed flow into LP in is higher than the flow into HP in some of the LP feed flow will flow directly to LP out When the iSave is not rotating the seawate...

Page 15: ...booster pump integrated in the iSave must only overcome the pressure drop from HP in 7 to HP out 5 During the RO process operation water is pumped into the HP membrane feed 6 by the HP pump 4 and the...

Page 16: ...t could be damaged by over pressurisation For more information on the importance of proper filtration please consult our publication Filtration 521B1009 which also will provide you with an explanation...

Page 17: ...uld be implemented to assure that the HP of the iSave is protected against excess pressure Special attention should be given to the pressure in the HP line 7 as the iSave may start to cavitate when it...

Page 18: ...ow pressure pipes against pressure overload and relieves the water if the pressure exceeds the maximum allowable pressure Inlet filters assure proper water quality High quality water extends the servi...

Page 19: ...undation The base plate thus requires a solid foundation such as concrete or rigid steel frame The base plate itself must be aligned to avoid bending caused by bolting to an uneven foundation A rigid...

Page 20: ...t piping alignment Incorrect piping alignment Incorrect piping alignment The hard piping and connections used must be of proper design and must be installed in accordance with the manufac turer s reco...

Page 21: ...be monitored The electric motor must be shut of if the maximum torque of the iSave exceeds the defined limit If more electric motors are powered by the same soft starter or VFD each electric motor mus...

Page 22: ...all connections and in the foundation of the iSave and the pumps All pipes are flushed free from debris and full of water The iSave has been bled and is full of water At pressure lower than 10 bars ch...

Page 23: ...xternal leakage 4 Re check bolts in all pipe connections couplings and tighten the bolts to specified torque if necessary 5 Replace filters if necessary 6 Clean the filter housing and install the new...

Page 24: ...ystem Wear in the booster pump or iSave Repair or change the parts Design of the basic plant does not fit the performance of the iSave Change design to fit the iSave perfor mance Permeate production i...

Page 25: ...both the HP and LP side 4 Start the iSave unit when the pipework is full of water and the system and iSave unit has been bled Always start the iSave unit before the high pressure pump is started The...

Page 26: ...0 Underflushing Overflushing P ID Mixing curve Flow curve iSave 40 Media filter M Permeate iSave F F 1 F Flowmeter VFD M HP in HP out VFD Fresh water permeate flush Full flow cleaning 6 17 8 9 16 15 1...

Page 27: ...RO system including the iSave unit must be thoroughly flushed with fresh water to remove any salt Run the daily and 2 14 days system shutdown procedure Further any biological growth should be prevente...

Page 28: ...ntially 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 pro...

Page 29: ...14 Connect the high pressure pipe to joint 9 again Normal operation mode 10 3 3 P ID no 2 Media filter M Permeate iSave F F F Flowmeter v VFD M HP in HP out VFD M HP in HP out VFD Fresh water permeate...

Page 30: ...Operation guide iSave 40 30 180R9239 AQ299555093252en 001601 iSave 40 09 2022 10 4 Dimensional drawings iSave 40 vertical Code no 180F7003 11 kW 6 pole IEC motor...

Page 31: ...Operation guide iSave 40 31 180R9239 AQ299555093252en 001601 iSave 40 09 2022 iSave 40 vertical Code no 180F7005 15 kW 6 pole IEC motor...

Page 32: ...Operation guide iSave 40 32 180R9239 AQ299555093252en 001601 iSave 40 09 2022 iSave 40 horizontal Code no 180F7001 11 kW 6 pole IEC motor...

Page 33: ...Operation guide iSave 40 33 180R9239 AQ299555093252en 001601 iSave 40 09 2022 iSave 40 horizontal Code no 180F7004 15 kW 6 pole IEC motor...

Page 34: ...Operation guide iSave 40 34 180R9239 AQ299555093252en 001601 iSave 40 09 2022 iSave 40 Code no 180F7011...

Page 35: ...nection Super Duplex 4 6 Bleed plug Super Duplex 5 1 Bearing PEEK 6 1 Port plate seawater Super Duplex PEEK x 7 2 Valve plate Super Duplex x 8 1 Retainer Super Duplex 9 1 Cylinder barrel Super Duplex...

Page 36: ...PEEK 109 8 Vane Super Duplex PEEK x 110 1 Sealing plate out PEEK x 111 1 Port plate out Super Duplex x 112 1 Outlet flange Super Duplex 113 1 3 Victaulic connection Super Duplex 114 1 Flange for shaft...

Page 37: ...uplex x 204 1 Spider Hytrel 6356 x 205 7 Bolt M8 x 20 1 4410 Super Duplex x 206 13 Bolt M10 x 20 A4 80 AISI 316 x 208 1 Coupling PE Super Duplex x 209 5 Pin 6 x 15 Super Duplex x 211 3 Wedge lock wash...

Page 38: ...24 mm X 10 5 6 Tool kit Note Danfoss reccommends always to use seals and screw kit for inspection and repair Pos Qnt Designation Material 180F7003 180F7005 180Z0246 Coupling kit 180Z0643 Coupling kit...

Page 39: ...Operation guide iSave 40 39 180R9239 AQ299555093252en 001601 iSave 40 09 2022 10 5 7 Exploded view vane pump iSave 40 series 04 and newer M8x20 Bolts marked A4 109...

Page 40: ...Operation guide iSave 40 40 180R9239 AQ299555093252en 001601 iSave 40 09 2022 10 5 8 Exploded view pressure exchanger series 04 and newer M8x20 Bolts marked A4 109...

Page 41: ...Operation guide iSave 40 41 180R9239 AQ299555093252en 001601 iSave 40 09 2022 10 5 9 Exploded view iSave series 04 and newer Special M8x20 bolt marked 1 4410...

Page 42: ...Operation guide iSave 40 42 180R9239 AQ299555093252en 001601 iSave 40 09 2022 10 5 10 Exploded view iSave on base plate horizontal...

Page 43: ...Operation guide iSave 40 43 180R9239 AQ299555093252en 001601 iSave 40 09 2022 10 5 11 Exploded view iSave on foot vertical...

Page 44: ...But the overload protection of the electric motors and torque limitations on the iSaves must be provided by additional equip ment This can be done by current monitoring relays see page 46 Danfoss FC...

Page 45: ...Operation guide iSave 40 45 180R9239 AQ299555093252en 001601 iSave 40 09 2022 10 6 1 Danfoss FC 300 Series with one iSave Electrical schematic diagrams according to EN60204 1 Danfoss FC 302...

Page 46: ...VDC 5 4 2 A 3 1 177HA425 10 1 Control supply model dependent 2 Outputs t u p t u o g o l a n a e l b a m m a r g o r P 8 0 7 0 t u p t u o C D V 4 2 8 0 6 1 3 Remote control inputs t u p n i e l b a...

Page 47: ...s indirectly reflecting the torque on the electric motor If the measured value exceeds the adjusted threshold value the relay sends a signal to a main switch that cuts of the power to the electric mot...

Page 48: ...nge of plan Hose assembly routing tips 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...

Page 49: ...g tips 3 180R9434 AN375455762639en 000201 07 2021 To prevent hose collapse and flow restriction hose bend radii should be kept as large as possible Tight bends can also compromise the hose reinforceme...

Page 50: ...lations 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...

Page 51: ...ard piping must be fixed rela tive to any pump iSave movements If hose is bent ensure max bending angle and distance S from each connector see table 1 on page 6 WRONG RIGHT To prevent hose collapse an...

Page 52: ...Vic OGS Super duplex EN 1 4410 50 mm 2 0 1 78 m 70 630 mm 24 8 max 180 115 mm 4 53 180Z0280 2 5 Vic OGS Super duplex EN 1 4410 50 mm 2 0 1 00 m 39 4 630 mm 24 8 max 90 115 mm 4 53 180Z0619 2 5 Vic OG...

Page 53: ...Operating guide Energy recovery device iSave 40 Appendices hpp danfoss com...

Page 54: ...eration guide iSave 40 54 180R9239 AQ299555093252en 001601 iSave 40 09 2022 Appendices 1 Service guide Disassembling and assembling 180R9242 54 2 Operating and maintenance instruction electric motor 9...

Page 55: ...ro solutions com Instruction Disassembling and assembling iSave 40 Operation guide Energy recovery device iSave 40 series 04 and newer Installation Operation and Maintenance Manual hpp danfoss com...

Page 56: ...p series 04 and newer 8 4 Basic inspection 11 5 General inspection 12 6 Assembling the booster pump series 01 03 13 6 1 Assembling the booster pump series 04 and newer 18 7 Disassembling the pressure...

Page 57: ...socket 6 mm Hex socket 8 mm Hex socket 16 mm special socket 1 M6 bolt and nut Locking tool for shaft Tool for shaft seal assenbly Tool for retainer assembly 3 press bolt set for valve plate assembly...

Page 58: ...e to disconnect the complete unit from the motor first In this case please follow step 1 5 6 and 7 afterwards Assembly of the unit in reverse order 9 After the pressure exchanger is released from the...

Page 59: ...filtered water Carefully lift the shaft seal by using 2 screwdrivers 3 If coupling has to be changed follow the next two steps 4 Unscrew the four special M8x20 bolts marked 1 4410 Use a hammer handle...

Page 60: ...ve 40 09 2022 6 Loosen all the bolts in the adapter flange 7 Carefully disassemble adapter flange and port plate from the stator ring 9 Remove the 8 vanes 8 Remove the sealing plate 10 Carefully guide...

Page 61: ...guide iSave 40 61 180R9239 AQ299555093252en 001601 iSave 40 09 2022 12 Remove the O ring from the sealing plate 13 Unscrew the bolts in the outlet flange 14 Remove the HP outlet flange 15 Remove the p...

Page 62: ...ove the key and the dust cap from the shaft 3 1 Disassembling the booster pump series 04 and newer 4 Remove the four screws in the shaft seal cover 6 Wet the shaft seal with clean filtered water caref...

Page 63: ...the rotor by lifting it out of the housing Place it in vertical position shaft upwards to avoid the pins inside rotor from falling out 9 Put the motorflange assembly and the pins aside and continue wi...

Page 64: ...Q299555093252en 001601 iSave 40 09 2022 13 Rotate the vanepump housing and remove all bolts The rotor stop may drop out but can easily be installed again 14 Lift the adapter flange off the housing 15...

Page 65: ...ish any rough areas Only polish in rotation direction 3 Inspect the side plate for cracks You don t have to remove the side plate if no visible cracks are found 4 If the rotor bearing surfaces has wea...

Page 66: ...one in the bottom groove can be replaced 3 Check the side plate thickness using a micrometer Replace if below 11 5mm Always replace the side plate and the rotor element at the same time 4 The rotor st...

Page 67: ...in conditions of absolute cleanliness All parts must be absolutely clean before mounting Lubrication To prevent cold welding Danfoss recommend to use thread lubricant for all screw threads for instal...

Page 68: ...Tighten bolts to a torque of 60 6 Nm 7 Assemble and position the two pins in the pin holes 9 Mount the O ring in the sealing plate and guide pin in flange It is important to lubricate to ensure the O...

Page 69: ...ith correct end into rotor See the arrow below 13 Fit the 8 vanes into each slot Notice vane position Place the straight site of the vane onto the pin with the mark down ward 15 Assemble the new O rin...

Page 70: ...ng on the correct sealing plate It is important to lubricate to ensure the O ring does not drop out 20 Position the sealing plate over the guide pin 21 Carefully position the adapter flange assembly i...

Page 71: ...new O ring on the flange for shaft seal and assemble the minor flange on top of the flange Tighten M8x20 bolts marked A4 to a torque of 30 3 Nm 26 Lubricate and press new ceramic ring into the shaft s...

Page 72: ...iced in conditions of absolute cleanliness All parts must be absolutely clean before mounting Lubrication To prevent cold welding Danfoss recomend to use thread lubricant for all screw threads for ins...

Page 73: ...outer surface of the side plate should be flush with the flange when pushed down Ones the push is removed the sideplate will move out a little due to the oring below 7 Install the rotor stop with the...

Page 74: ...ement in place 12 Check O ring is in place 13 Place the rotor with the shaft pointing upwards and lubricate the groves with water 15 Place the rotor element with the O ring installed in the groove and...

Page 75: ...m for the vanes Steel inside vanes should be visible clock wise to the shaft center 19 Carefully lower the rotor assembly into the housing Taking care not to damege the side plate or the bearing Spray...

Page 76: ...om on the flange 25 It is important that the inside groove in the side plates are pointing upwards 26 The outer surface of the side plate should be flush with the flange when pushed down Ones the push...

Page 77: ...ft seal with clean filtered water and mount the shaft seal over the shaft end with the carbon ring upwards 31 Install the small O ring seal for the shaftseal cover 34 Press down the shaft seal to the...

Page 78: ...ater and press the ring into the shaft seal cover using the plastic press bush tool Warning Ensure that the face with rubber seal is positioned against shoulder reces in shaft seal cover and the ceram...

Page 79: ...iSave 40 09 2022 3 Unscrew all the bolts 4 Carefully lever the flange and port plate from the casing 7 Disassembling the pressure exchanger 1 Unscrew the 3 special M8x20 bolts marked 1 4410 2 Remove c...

Page 80: ...arefully lever the 2 valve plate assembly free with help from 2 screwdrivers If the plates are hard to remove it is recommended to install the 3 M8x50 bolt from the tool kit Lubricate the ends and the...

Page 81: ...e mounting Lubrication To prevent cold welding Danfoss reco mend to use thread lubricant for all screw threads for installing the iSave and first tighten the screws by hand It is important to lubricat...

Page 82: ...flange and position the two guide pins into the flange 9 Position the port plate on the HP LP flange using the two guide pins as guide Only one port plate fits 10 Position the guide pin into the casin...

Page 83: ...install the bolts Cross tighten with torque according to the setting specified in the exploded view 14 Mount the 3 pins in shaft and place the coupling part 15 Place the wedge lock washers on the thr...

Page 84: ...anged by Danfoss 1 Assemble new back up rings and O rings on the valve plates Back up rings first 2 Lubricate the O rings and back up rings with clean filtered water and position the two valve plates...

Page 85: ...iameter Distance 4 5 mm 10 Changing springs in the pressure exchange rotor It is basically not necessary to change the springs in the rotor If needed follow the guidelines below 9 1 Disassembling Usin...

Page 86: ...ver the springs 3 Assemble the O ring over the retainer 4 Using the tool provided press down the retainer by tightening the nut until the O ring is placed in the recess If needed use a small screwdriv...

Page 87: ...Operation guide iSave 40 87 180R9239 AQ299555093252en 001601 iSave 40 09 2022 11 Exploded view vane pump iSave 40 series 01 03 M8x20 Bolts marked A4 80...

Page 88: ...Operation guide iSave 40 88 180R9239 AQ299555093252en 001601 iSave 40 09 2022 12 Exploded view vane pump iSave 40 series 04 and newer M8x20 Bolts marked A4 109...

Page 89: ...Operation guide iSave 40 89 180R9239 AQ299555093252en 001601 iSave 40 09 2022 13 Exploded view pressure exchanger series 01 03 M8x20 Bolts marked A4 80...

Page 90: ...Operation guide iSave 40 90 180R9239 AQ299555093252en 001601 iSave 40 09 2022 14 Exploded view pressure exchanger series 04 and newer M8x20 Bolts marked A4 109...

Page 91: ...Operation guide iSave 40 91 180R9239 AQ299555093252en 001601 iSave 40 09 2022 15 Exploded view iSave series 01 03 Special M8x20 bolt marked 1 4410...

Page 92: ...Operation guide iSave 40 92 180R9239 AQ299555093252en 001601 iSave 40 09 2022 16 Exploded view iSave series 04 and newer Special M8x20 bolt marked 1 4410...

Page 93: ...Operation guide iSave 40 93 180R9239 AQ299555093252en 001601 iSave 40 09 2022 17 Exploded view iSave on base plate horizontal...

Page 94: ...Operation guide iSave 40 94 180R9239 AQ299555093252en 001601 iSave 40 09 2022 18 Exploded view iSave on foot vertical...

Page 95: ...Danfoss A S High Pressure Pumps Nordborgvej 81 DK 6430 Nordborg Denmark Danfoss DCS im 2019 03 180R9239 AQ299555093252en 000901 95...

Page 96: ...M a n u a l Electric Motors Motor Manual hoyermotors com...

Page 97: ...hat the mounting conditions do not cause resonance with the rotational frequency and the doubled supply frequency Only mount or remove drive components pulley coupling etc using suitable tools never h...

Page 98: ...lues The table values are based on an ambient temperature of 25 C The values must be halved for every 15K increase in bearing temperature Higher speed operations e g frequency converter drive will req...

Page 99: ...100 180R9379 AQ188686503004en 000801 PAH 2 12 5 07 2022 Connection diagram Anschlu diagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexi n Collegamento Schemat polacsen...

Page 100: ...101 180R9379 AQ188686503004en 000801 PAH 2 12 5 07 2022...

Page 101: ...sberger Stra e 155 80687 M nchen T 49 89 700 88 235 F 49 89 543 56 333 germany hoyermotors com hoyermotors com Sweden Liljeholmsstranden 5 PO box 44017 SE 100 73 Stockholm T 46 8 446 877 13 sweden hoy...

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