Danfoss iSave 50 Operating Manual Download Page 3 | Manualshive

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Operating guide | iSave 50 - 70

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180R9357 | AQ265943679828en-00100

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IOM iSave 50 - 70 | 0

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.202

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8.

Service/Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

8.1

Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

8.2

Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

8.3

Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

8.4

Recommended service intervals on internal parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

8.5

Lubrication of bearings in electric motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

9.

Trouble shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

9.1

Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

10.

Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

10.1

Data sheet iSave 50-70 - (521B1378)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

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Summary of Contents for iSave 50

Page 1: ...ss com Manual del usuario Manual de instalaci n funcionamiento y mantenimiento iSave 40 Frontpage Operating guide Energy Recovery Device iSave 50 70 Installation Operation and Maintenance Manual hpp d...

Page 2: ...n 11 5 5 Dimensions and weights 11 5 6 Electrical motor data 11 5 7 How does the iSave work 11 5 8 Seawater quality 12 5 8 1 Pre filtration 12 5 8 2 Air bubbles 12 5 8 3 Chemicals 12 5 8 4 Initial sta...

Page 3: ...arings in electric motor 18 9 Trouble shooting 19 9 1 Safety regulations 19 10 Appendices 21 10 1 Data sheet iSave 50 70 521B1378 23 10 2 Start and stop procedures 180R9213 45 10 3 Membrane cleaning o...

Page 4: ...rring 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 1 Validity Document information and co...

Page 5: ...e 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 Electric...

Page 6: ...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 equipmen...

Page 7: ...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 Nord...

Page 8: ...in personal injury and or damage of the unit Lifting the iSave with electric motor vertical The two lifting belts around the bell housing before lifting the unit 4 4 Assembly iSave to electric motor...

Page 9: ...ame 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...

Page 10: ...o use high pressure 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...

Page 11: ...itive 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 corrosi...

Page 12: ...nerated 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 pr...

Page 13: ...ressure lines before making service in the HP lines or pressurised equipment To prevent such over pressurisation appropriate relief valves should be used and procedures should be implemented to assure...

Page 14: ...ation 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 betw...

Page 15: ...electric motor can lead to an irreparable fracture of the iSave s internal parts PUMP Type iSave 50 ERD Code no 180FXXXX Serial no XXXXXX02 XXX MADE IN DENMARK Danfoss A S 6430 Nordborg Denmark When c...

Page 16: ...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 an...

Page 17: ...ment 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 torq...

Page 18: ...ase 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 mo...

Page 19: ...e booster pump or iSave Clean the system 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...

Page 20: ...Operating guide iSave 50 70 20 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023...

Page 21: ...Appendices Energy Recovery Device iSave 50 70 Appendices Installation Operation and Maintenance Manual hpp danfoss com...

Page 22: ...1B1378 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...

Page 23: ...Data sheet iSave Energy Recovery Device iSave 50 iSave 70 hpp danfoss com...

Page 24: ...ion to inlet or discharge ports 33 7 4 Filtration 33 7 5 Noise 33 7 5 RO systems with an iSave 34 8 Dimensions and connections 36 8 1 iSave 50 70 without electric motor 36 8 2 iSave 50 70 with with IE...

Page 25: ...m service required Unlike a centrifugal pump it produces a similar flow at a given speed no matter what discharge pressure 2 Benefits Corrossion resistance all wetted parts are made of high corrosion...

Page 26: ...72 Max pressure LP in peak barg 10 10 psig 145 145 Min allowable working pressure LP in barg 2 2 psig 29 29 Max differential pressure LP in LP out barg 0 53 0 79 psig 7 69 11 46 Max static test pressu...

Page 27: ...cc to EN ISO 20361 section 6 2 The noise measurements are performed acc to EN ISO 3744 2010 on a motor pump unit at max pressure and rpm 9 Balanced flow The mixing rate is defined at balanced flow whe...

Page 28: ...ta Max allowable working torque Nm 170 177 lbf ft 125 130 5 Max starting torque stick slip Nm 180 180 lbf ft 132 132 Motor data Nominal speed rpm 985 985 Rated current at 400V A 37 37 Motor size kW 18...

Page 29: ...ax allowable working torque Nm 170 177 lbf ft 125 130 5 Max starting torque stick slip Nm 180 180 lbf ft 132 132 Motor data Nominal speed rpm 1180 1180 Rated current at 400V A 36 2 36 2 Motor size kW...

Page 30: ...uired 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 Performance curves 5 1 Flow at diff...

Page 31: ...cal values 0 20 40 60 80 100 120 140 160 180 200 525 645 765 875 Torque Nm Motor speed rpm Torque on iSave50 and iSave70 Starting torque delta P 1 bar delta P 2 bar delta P 3 bar delta P 4 bar delta P...

Page 32: ...per 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 6 Temperature and corrosion 7 Insta...

Page 33: ...ystem 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...

Page 34: ...xing 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 contr...

Page 35: ...ief 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...

Page 36: ...Data sheet iSave 50 and iSave 70 36 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023 8 1 iSave 50 70 without electric motor 8 Dimensions and connections...

Page 37: ...Data sheet iSave 50 and iSave 70 37 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023 8 2 iSave 50 70 with with IE3 motor 18 5 kW on base frame vertical_front mounted...

Page 38: ...Data sheet iSave 50 and iSave 70 38 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023 8 3 iSave 50 70 with with IE3 motor 18 5 kW on base frame vertical_back mounted...

Page 39: ...Data sheet iSave 50 and iSave 70 39 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023 8 4 iSave 50 70 with with IE3 motor 18 5 kW on base frame horizontal...

Page 40: ...Data sheet iSave 50 and iSave 70 40 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023 8 4 iSave 50 70 with NEMA motor 30 HP on base frame vertical front mounted...

Page 41: ...Data sheet iSave 50 and iSave 70 41 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023 8 5 iSave 50 70 with NEMA motor 30 HP on base frame vertical back mounted...

Page 42: ...Data sheet iSave 50 and iSave 70 42 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023 8 5 iSave 50 70 with NEMA motor 30 HP on base frame horizontal...

Page 43: ...ining the frequency of the inspections Danfoss recom mends yearly inspections It is recommended to order the purpose designed tool kit 9 4 Repair assistance In case of irregular function of the Danfos...

Page 44: ...der provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies D...

Page 45: ...Design guide iSave Energy Recovery Device Start and stop of the SWRO with iSave hpp danfoss com...

Page 46: ...stop of the SWRO with iSave unit 46 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023 Table of Contents Prior to start up 47 Starting up the system 48 Daily system shutdown 48 More than one da...

Page 47: ...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 r...

Page 48: ...0 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 b...

Page 49: ...ave 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 iSav...

Page 50: ...Danfoss DCS im 2020 01 180R9213 521B1164 DKCFN PI 003 F8 02 50...

Page 51: ...Design guide Energy Recovery Device iSave Membrane cleaning of RO system hpp danfoss com...

Page 52: ...Design guide Membrane cleaning of the RO system with iSave ERD 52 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023 Table of Contents Membrane cleaning 53 P ID No 1 54 P ID No 2 55...

Page 53: ...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 Fo...

Page 54: ...are not used a second stage filter is required 1 21 2 PS PI PS PI PS 14 PI PI PI PI PI 3 A B C 22 22 PS 24 23 23 25 25 26 26 16 CIP 28 Below procedure is according P ID no 2 1 Stop the high pressure...

Page 55: ...Flowmeter VFD M HP in HP out VFD M HP in HP out VFD Fresh water permeate flush Full flow cleaning CIP 6 7 17 8 15 13 10 11 11 12 19 Filter 3 micron nominel Filter 10 micron absolut Drain 4 18 5 M 4 18...

Page 56: ...Danfoss DCS im 2017 09 521B1165 DKCFN PI 00 G6 02 56...

Page 57: ...ro solutions com Design Guide APP pumps and iSave overload protection hpp danfoss com...

Page 58: ...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 an...

Page 59: ...ngoing 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 torq...

Page 60: ...utomatic motor adaption AMA Run full AMA Remember to fuse termi nals 12 and 27 Push hand on Remove fuse after AMA Parameter 1 71 Start delay Set in sec See chapter 5 3 Parameter 1 72 Start function Se...

Page 61: ...r 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 ch...

Page 62: ...80B3056 851 Nm 738 Nm 527 Nm 80 barg 700 rpm 1200 rpm APP 26 1500 180B3057 851 Nm 596 Nm 426 Nm 80 barg 700 rpm 1500 rpm APP 24 1200 180B3054 851 Nm 685 Nm 489 Nm 80 barg 700 rpm 1200 rpm APP 24 1500...

Page 63: ...108 101 100 Operational speed Min Parameter 4 11 500 500 600 600 600 Operational speed Max Parameter 4 13 1500 1500 1200 1200 1200 Delay torque limit Parameter 14 25 30 sec 30 sec 30 sec 30 sec 30 se...

Page 64: ...Design Guide APP and iSave overload protection 64 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023 5 3 Time delay before start...

Page 65: ...Design Guide APP and iSave overload protection 65 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023...

Page 66: ...Danfoss DCS im 2018 08 180R9372 521B1412 DKCFN PI 003 O2 02 66...

Page 67: ...danfoss high pressurepumps com Instruction Right and wrong Hose assembly routing tips Instruction Right and wrong Hose assembly routing tips hpp danfoss com...

Page 68: ...ovide 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 1 Hoses...

Page 69: ...Save 50 70 03 2023 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 fai...

Page 70: ...se 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 pl...

Page 71: ...ive 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 WRONG RIGHT To prevent hose collapse and flow restriction hose bend ra...

Page 72: ...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 OGS Super duplex EN 1 4410 65 mm...

Page 73: ...Instruction Right and wrong Hose assembly routing tips 73 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023...

Page 74: ...Danfoss DCS im 2019 05 180R9084 521B0540 DKCFN PI 000 D7 02 74...

Page 75: ...Parts list Energy recovery device iSave 50 70 hpp danfoss com...

Page 76: ...its for the iSave 50 70 as well as exploded view of the iSave Contents 1 General 76 2 Parts list iSave 50 70 77 3 Exploded view iSave 50 70 79 4 Assembly unit iSave 50 70 Vertical mounting 80 5 Assemb...

Page 77: ...ge Super Duplex PEEK 10 2 O ring NBR X 11 2 Rotor stop mashined PEEK X 12 2 O ring NBR X 13 2 Side plate Ceramic X 14 2 O ring NBR X 15 2 Rotor element Ceramic X 16 2 O ring NBR X 17 1 Rotor Super Dup...

Page 78: ...X 111 1 Cylinder barrel Super Duplex 112 1 Port plate Brine PEEK Super Duplex X X 113 2 Pin AISI 316 X 114 1 Housing Duplex 115 6 Stud bolt M12 Duplex 116 6 Washer M12 AISI 316 X 117 6 Nut AISI 316 X...

Page 79: ...Parts list Energy recovery device iSave 50 70 Danfoss DCS im 2023 03 180R9357 AQ265943679828en 001002 IOM iSave 50 70 79 3 Exploded view iSave 50 70...

Page 80: ...80U0006 iSave 50 70 without motor 1 1 iSave 50 180F7020 1 1 iSave 70 180F7021 Motor 2 1 Motor 18 5 kW IEC200 6 pole 3x400 V IE3 180Z0530 2 1 Motor 324TC 30 HP 3PH 1200 230 460 380 180U2370 5 4 Screw n...

Page 81: ...Parts list Energy recovery device iSave 50 70 Danfoss DCS im 2023 03 180R9357 AQ265943679828en 001002 IOM iSave 50 70 81 5 Assembly unit drawing iSave 50 70 Vertical mounting...

Page 82: ...0 180F7020 1 1 iSave 70 180F7021 Motor 2 1 Motor 18 5 kW IEC200 6 pole 3x400 V IE3 180Z0530 2 1 Motor 324TC 30 HP 3PH 1200 230 460 380 180U2370 5 4 Screw not inluded in kit 6 4 Washer not included in...

Page 83: ...Parts list Energy recovery device iSave 50 70 Danfoss DCS im 2023 03 180R9357 AQ265943679828en 001002 IOM iSave 50 70 83 7 Assembly unit drawing iSave 50 70 Horizontal mounting...

Page 84: ...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...

Page 85: ...Parts list Energy recovery device iSave 50 70 Danfoss DCS im 2023 03 180R9357 AQ265943679828en 001002 IOM iSave 50 70 85...

Page 86: ...86 Danfoss DCS im 2021 03 180R9392_AX299849991270en 000701...

Page 87: ...M a n u a l Electric Motors Motor Manual hoyermotors com...

Page 88: ...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 etc using suitable tools never...

Page 89: ...values 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...

Page 90: ...90 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023 Connection diagram Anschlu diagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexi n Collegamento Schemat polacsen...

Page 91: ...91 180R9357 AQ265943679828en 001002 IOM iSave 50 70 03 2023...

Page 92: ...ndsberger 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 h...

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