How it Works
Danfoss
Loading...
I
J
Loading...
Loading...
iSave 21 Plus
Data sheet
30 pgs3.01 Mb0
Data sheet [de]
28 pgs3.15 Mb0
Data sheet [es]
28 pgs3.07 Mb0
Operating guide
96 pgs12.21 Mb0
Operating guide [es]
90 pgs6.67 Mb0
Service guide
20 pgs9.04 Mb0

Danfoss iSave 21 Plus Operating guide

Download
Operating guide
Energy Recovery Device
iSave 21 Plus
Installation, Operation and Maintenance Manual
hpp.danfoss.com
Operating guide | iSave 21 Plus
Document information and copyright
Installation, Operation and Maintenance Manual. Original operating manual document.
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.
PUMP
Type iSave 21 Plus ERD Code no. 180BXXXX
Serial no. XXXXXX02-XXX
MADE IN DENMARK
Danfoss A/S, 6430 Nordborg, Denmark
Validity
This manual is valid for iSave 21 Plus
Code no. Serial no. 180F7015 XXXXXX02-XXX 180F7016 XXXXXX02-XXX 180F7017 XXXXXX02-XXX 180F7018 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.
2
Operating guide | iSave 21 Plus
Table of Contents
2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Target group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Manufacturer and customer service address . . . . . . . . . . . . . . . . . . . . . . . 7
2.5 Country specific information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5.1 United Kingdom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.6 Additional technical documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Application range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.4 Preferred system design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Arrival inspection, handling and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1 Arrival inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.2 Return to the supplier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.3 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.3.1 Centre of mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 Outdoor storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5 Technical data and design review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.1 Design details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.2 Sound level of the iSave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.4 Temperature and corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.5 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.6 Electrical motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.7 How does the iSave work? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.7.1 Pressure excharger function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.7.2 Booster pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.7.3 Lubrication flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.7.4 Mixing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.7.5 How does the iSave work in an RO system? . . . . . . . . . . . . . . . . . . . . . . . .16
5.8 Seawater quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.8.1 Pre-filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.8.2 Air bubbles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.8.3 Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.9 Initial start up and flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.10 Initial start up and settings of safety equipment . . . . . . . . . . . . . . . . . . . . .18
5.11 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.12 CIP of Membrane cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.13 High pressure remains after shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . .19
5.14 Over-pressurisation caused by low pressure isolation. . . . . . . . . . . . . . . . . .20
5.15 Over-pressurisation caused by the high pressure pump . . . . . . . . . . . . . . . .20
5.16 Preferred system design and P&ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3
Operating guide | iSave 21 Plus
6 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.2 Installation and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.3 Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.4 Piping and joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.5 Flexible couplings and flexible hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.6 Mounting of coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.7 Mounting of bell housing on iSave . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.8 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.9 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.9.1 Electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.9.2 Speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6.9.3 Starting torque on the iSave/ramping the electric motor . . . . . . . . . . . . . . .25
6.9.4 Torque overloads protection on the iSave . . . . . . . . . . . . . . . . . . . . . . . . .25
7 Commissioning, start-up and shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
7.2 Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
7.3 Commisioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
8 Service/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.2 Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.4 Tool used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
9 Trouble-shooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
9.1 Safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
10 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.1 Start and stop procedures (180R9213). . . . . . . . . . . . . . . . . . . . . . . . . . . .31
10.2 Membrane cleaning of the RO system with iSave unit (180R9214) . . . . . . . . . . 37
10.3 Data sheet iSave 21 Plus - iSave 40 (521B1464) . . . . . . . . . . . . . . . . . . . . . .43
10.4 iSave part list (521B1459) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
10.5 Hose assembly and installation (180R9434) . . . . . . . . . . . . . . . . . . . . . . . .83
10.6 Operating- and maintenance instruction, electric motor (180R9230) . . . . . . . . 91
4
Operating guide | iSave 21 Plus
2. Introduction
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:
• 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.
2.3 Symbols
Indicates something to be noted by
NB!
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
Hearing protection required
Safety shoes required
Safety helmet required
Ensure that these instructions are always readily available to all personnel concerned.
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.
5
Operating guide | iSave 21 Plus
2.4 Manufacturer and customer service address
2.5 Country specific information
1.4.1 United Kingdom
Danfoss A/S DK-6430 Nordborg, Denmark Telephone: +45 7488 2222 Email: highpressurepumpss@danfoss.com Home page: hpp.danfoss.com
UK importer:
Danfoss Ltd. 22 Wycombe End HP9 1NB Beaconsfield United Kingdom
2.6 Additional technical documents
Document name Content
Datasheet Description of the technical data and
dimensions of the iSave
iSave parts list Sectional drawings, parts list and spare part
numbers.
Instruction: start and stop of the SWRO with iSave unit
Instruction: Membrane cleaning of RO system with
Description of how to start and stop the iSave in the preferred RO system set-up.
Description of how to clean the membranes in the preferred RO system set-up.
iSave unit Instruction:
Hose assembly and installation Operating and maintenance instructions,
electric motor
Guideline for Hose assembly and installation
Operating and maintenance instructions for the standard electric motor, delivered from Danfoss.
See also appendix 10
6
Operating guide | iSave 21 Plus
3. Safety
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.
• 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 in the iSave.
• 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 to follow the instructions can result in personal injury and/or damage to the iSave. It will also invalidate the warranty.
Electrical hazard
The iSave is a rotating machine that typically operates at high pressure.
Always wear suitable safety and lifting equipment when handling the iSave.
• 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.
• 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 th motor and other electrical equipment from overloads with suitable equipment.
• The electric motors must be supplied with adequate cooling ventilation.
• 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.
Use of this manual does not relieve
NB!
operation and maintenance personnel of the responsibility of applying normal good judgment in the operation and care of this product.
7
Operating guide | iSave 21 Plus
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.
3.3 Application range
For application range see data sheet 521B1464 available in appendix 10.3.
Applications not suitable for the iSave can cause damages 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 system design.
• It is always the system builders’ 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 protectio equipment is essential.
8
Operating guide | iSave 21 Plus
4. Arrival inspection, handling and storage
4.1 Arrival inspection
The iSave is packed in a wood container with plugs in the port connections to protect the unit from damage during transport.
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 to the carrier at once.
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 21 Plus ERD Code no. 180BXXXX
Serial no. XXXXXX02-XXX
MADE IN DENMARK
Danfoss A/S, 6430 Nordborg, Denmark
4.3 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.
4.2 Return to the supplier
Flush the iSave with clean water. Drain the iSave and plug the port connections with a cap/cover.
Pack the iSave into a suitable container and make sure that it is suitably fastened to the container.
Please contact your local authorised distributor or:
Danfoss A/S DK-6430 Nordborg, Denmark Telephone: +45 7488 2222 Fax: +45 7445 3831 Email: highpressurepumps@danfoss.com Homepage: hpp.danfoss.com
9
Operating guide | iSave 21 Plus
Check the mass (weight) of the iSave unit. All parts weighing more than 20 kg must be lifted using lifting slings and suitable lifting
Secure lifting slings around the part of the iSave and the back of the electric motor. Make sure that the load is balanced before attempting the lift.
devices, e.g. an overhead crane or industrial truck. All iSave units weight more than 20 kg.
Once the lifting is done the lifting eye must be removed from the pump.
Never lift the iSave unit with only one fastening point. Incorrect lifting can result in personally injury and/or damage to the unit.
4.3.1 Centre of mass
604
Never lift the iSave in the bell housing.
Incorrect lifting can result in personally injury and/or damage to the unit.
10
Operating guide | iSave 21 Plus
4.4 Storage
Each iSave is tested before shipment and therefore holds water. Storage temperature: 1 °C to +70 °C (33 °F to 158 °F) – provided that the pump is drained of fluid and stored “plugged”.
Frost protection is required at temperatures below 1°C. Danfoss recommends using DOWFROST from DOW Chemical Company
or Chillsafe mono propylene glycol from Arco Chemical Company.
If the iSave is protected against frost, the storage temperature can be: -40 °C to +70 °C (-40 °F to 158 °F)
• The iSave is NOT delivered frost-protected from the factory.
• Only remove caps from the openings of the iSave at the time of installation.
4.5 Outdoor Storage
For outdoor storage cover the iSave (set) with waterproof material.
11
Operating guide | iSave 21 Plus
5.1 Design details5. Technical data and
design review
11
12
17
1
18
15
10 9
16
14
8
1212
1: 2” Victaulic connections 2: Shaft 3: Low pressure shaft seal 4: Port flange 5: Port plate 6: Valve plate
6
5
1
13
7: Cylinder drum 8: Port flange 9: Port plate 10: Pins 11: Van es 12: Port plate
6
7
5
1
4
2
3
1
13: Coupling 14: Adapter flange 15: Rotor 16: Stator 17: Port flange 18: Outlet flange
5.2 Sound level of the iSave
The noise level from the iSave including the electrical motor is 78 dB (A). Measurements according to EN ISO 20361. The test is made
It is therefore important that the iSave unit is mounted correctly on a frame with dampers to minimise vibrations and noise.
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 1,500 rpm
5. System pressure 60 barg and a booster pressure of 3 barg.
It is also strongly recommended to use high-pressure flexible hoses between the hard piping in the RO plant and the iSave. See “hose assembly and installation” in appendix 10.6. Alternative use multiple flexible Victaulic® couplings on the hard piping. 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
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).
12
generates more noise than flexible mounting
• Pipe mounting directly to the iSave
increases the noise level compared to flexible hoses.
Operating guide | iSave 21 Plus
5.3 Materials
All critical parts of the iSave are made of super-duplex 1.4410/UN S32750 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. For a detailed material/part overview see appendix
In order to minimise the risk of crevice corrosion, always flush the iSave according to the specified start/stop procedure.
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 to +50 °C (+35.6 °F to 122 °F).
5.5 Dimensions and weights
For dimensions and weights please refer to the iSave datasheet. See appendix 10.3
5.6 Electrical motor data
See datasheet in appendix 10.3 and “Operating and Maintenance instructions, electric motor” in appendix 10.6
13
Operating guide | iSave 21 Plus
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.
5.7.1 Pressure exchanger function:
The pressure exchanger consists of two port plates, one at the concentrate side and one at the seawater side. In between there is a rotor with several ducts that connect the concentrate side with the seawater side. The pressure exchanger transfers pressure from the high-pressure (HP) concentrate (HP in) to the low-pressure (LP) seawater coming from low-pressure feed pump (LP in). To separate the HP side from the LP side there is a sealing zone on both port plates. A single duct in the rotor is either on the HP side, or on the LP side or in the sealing zone. A single duct is never in contact with more than one zone at the time. When the rotor rotates a duct will go from the LP zone over the first sealing zone into the HP zone, and hereafter from the HP zone over the second sealing zone and back to the LP zone.
The flow through the HP side of the iSave is forced and controlled by the booster pump.
When the high-pressure concentrate is flowing into the iSave it pressurizes the sea water in the duct coming from “LP in”. The pressurized seawater is then pumped out of “HP out”. Just before the HP concentrate in the duct comes to the seawater port plate, the duct goes into the sealing zone and the flow in the duct stops. When the duct goes into the LP zone the concentrate water is de-pressurized. The (LP) seawater coming from the LP feed pump (LP in) forces the LP concentrate out of “LP out”. This pressure exchange process is repeated for each duct with every rotation of the rotor, and the ducts are thus continuously filling and discharging. The flow on the HP side and LP side of the iSave is nearly constant over time.
There is no physical barrier in the ducts between the concentrate and seawater. This means that there will be a small amount of mixing between the two liquids.
NB!
Fig. 5.1.
HP-out
Seawater side
LP-in
When the iSave is rotating the water always flows respectively from LP-in to HP-out, AND from HP-in to LP-out. However, if the feed flow into LP-in is higher than the flow
HP-in
Concentrate side
LP-out
into HP-in, some of the LP feed flow will flow directly to LP-out. When the iSave is not rotating the seawater can only run directly from LP-in to LP-out.
14
Operating guide | iSave 21 Plus
5.7.2 Booster pump
The booster pump is a positive displacement pump, which means that the flow is controlled by the speed of the electric motor; e.g. if the rotation speed of the electric motor is raised by 10%, the flow will be 10% higher and vice versa. The required rpm can be calculated based on the “rated flow” of the particular iSave. See datasheet in appendix 10.3.
At low speeds you may hear some minor clicking sounds from the pump. This is normal and is caused by the pins in the vane pump.
5.7.3 Lubrication flow
To lubricate the moving parts in the pressure exchanger there is a well defined leak between the port plates and the rotor, as well as in the high pressure bearing between the pressure exchanger and the booster pump. This leak is typically called “lubricating flow”. The leaks go from the high pressure side to the low pressure side of the pressure exchanger, and from the booster pump to the low pressure side of the pressure exchanger.
5.7.4 Mixing
There is no physical barrier in the ducts between the concentrate and seawater. This means that there will be a small amount of mixing between the two liquids. Because the two liquids are in contact for a short amount of time, the mixing is relatively low. On the RO market the mixing rate is defined as “balanced flow” when HP-out is equal to LP-in. Experience from the market shows that the corresponding increase in membrane operating pressure is about 1 barg.
obtained when the energy loss on LP feed is equal to or less than the energy loss caused by the excess pressure at the membrane.
5.7.5 How does the iSave work in an RO system?
The figure below illustrates a typical flow path of an SWRO or BWRO with an iSave.
The high-pressure (HP) concentrate (7) flows to the low-pressure (LP) concentrate outlet (3). The LP sea water (2) flows to the HP sea water outlet (5). The rotor, moving between the high-pressure and low-pressure streams, removes the high-pressure concentrate (7) and replaces it with feed water (2). The flow rate on the HP sea water outlet (5) is controlled by the iSave alone. The flow rate on the LP concentrate outlet (3) is controlled by the sea water feed pump (1) and the back pressure valve. This means that changing the LP feed flow (2) will not affect HP outlet flow (5) and, vice versa, that changing the HP outlet flow (5) will not af­fect the LP outlet flow (3).
As LP sea water (2) is flushing the LP concentrate to LP outlet (3), it is essential that the flow on the LP inlet (2) is equal to or slightly higher than the HP inlet (7). Otherwise there will be an “under-flush” and higher mixing will occur in the HP outlet (5). This higher mixing will result in a slightly higher pressure at the membrane.
The customer can reduce mixing by over-flushing the LP feed with excess feed water. See figure below. Over-flushing means energy loss. Optimal over-flushing is
The booster pump integrated in the iSave must only overcome the pressure drop from the high-pressure outlet (5) to the high-pressure inlet (7).
15
Operating guide | iSave 21 Plus
During the RO process operation, water is pumped into the HP-membrane feed (6) by the HP pump (4) and the iSave (5). Almost all water coming from the HP pump (4) penetrates the membranes (8). Only a slight amount of the water is used as lubrication flow in the iSave. The lubrication flow is measured as the difference between the HP pump flow rate (4) and the permeate flow rate (8). The resistance to permeate in the membrane pressurises the HP loop.
The isobaric pressure exchanger technology in an SWRO or BWRO change the HP concentrate into HP seawater that is feed into the HP membranes. The iSave energy recovery technology thus significantly reduces flow needed from the main HP pump (4). Overall energy consumption of a SWRO or BWRO plant using the iSave depends on the recovery rate.
The operator can change the recovery rate to optimise the RO system performance. Changing the recovery rate in an RO system equipped with iSave is easy. Using the VFD, change the speed of the iSave and thereby the flow in the HP flow rate. Then change the LP feed (2) flow to the iSave to minimise mixing and optimise energy consumption. Make sure that flow and pressure are within the rated parameter of the iSave in question.
5.8 Seawater quality
5.8.1 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 μm 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 components in the RO system. 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.
It is important with selection of a proper 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.
NB!
Filters can be purchased from Danfoss High Pressure Pumps.
16
Operating guide | iSave 21 Plus
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.
5.8.3 Chemicals
The iSave should not be exposed to chemicals that will damage the RO membranes.
5.9 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 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.
5.10 Initial start-up and settings of safety equipment
The high-pressure pump feed water into the high pressure line may be able to generate a pressure higher than the maximum allowable pressure in the system. There is thus a risk of personal injury and/or damage to the iSave.
Depending of the type and size of the feed pump of the RO system, this pump may be able to generate a pressure higher than the maximum allowable pressure in the LP system. There is thus a risk that the iSave or the LP equipment could be damaged by over-pressurisation.
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.
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 install temporary basket strainers at both inlets to the iSave during the initial start-up and commissioning.
Also see “Instruction for start and stop of the SWRO with iSave unit” in appendix 10.1.
17
Operating guide | iSave 21 Plus
5.11 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.
Feed water flushing is part of a normal shutdown sequence. After the HP pump has been stopped, the permeate and concen­trate production will continue until the high-pressure drops below the osmotic
pressure. Both the iSave and the LP seawater feed pump must run until the conductivity measured at point (7) and (3) are satisfac­tory. See also P&ID in chapter 5.16.
Fresh water flushing is performed before every extended shutdown of the RO plant. Permeate is simultaneously fed into the iSave at LP in (2), and either to the HP pump inlet (1) or through some other injection point such as the CIP connections or full flow cleaning connection. See also P&ID in chapter 5.16. Permeate may be produced during this flushing process.
Special attention should be given to
NB!
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 HP line (7) drops below 3 bargs. This can be avoided by reducing the speed of the iSave to about 750 rpm and keeping the pressure in the HP line at the minimum of 3 barg. At this low pressure the iSave may only run for a maximum of 10 minutes.
5.12 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 fresh water.
The flush 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 lead into the iSave. It is essential that the water used for the final pre-flush is pre-filtered to a level described in chapter 5.8. The iSave should not be exposed to chemicals that will damage the RO membranes
Also see instruction “Membrane cleaning of RO system with iSave unit” in appendix 10.2.
5.13 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.
Always check the pressure in the high-pressure lines before making service in the HP lines or pressurised equipment.
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.
18
Operating guide | iSave 21 Plus
5.14 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.
5.15 Over-pressurisation caused by the high pressure pump.
The HP pump may be able to generate a pressure higher than the maximum allowable pressure for the iSave or the system – particularly if the HP pump is a positive displacement pump, the pump will be able to generate extremely high levels of pressure.
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.
19
Operating guide | iSave 21 Plus
5.16 Preferred system design and P&ID
VFD
Media filter
1
Filter 3 micron nominel
Fresh water
permeate flush
Filter
10 micron
PIPI
19
absolut
F
12
LP in
*
2
F
HP out
11
M
VFD
PI
PS
HP in
3
iSave
4
M
18
PS
PI
5
PS
13 14
6
Full flow cleaning
7
10
PI
PI
15
20
F
* Second stage filter: If recommended housing design and cartridges are not used, a second stage filter is required
Explanation of P&ID setup
• The pressure switch (3) must stop the iSave (11) and the high-pressure pump (4) at pressures lower than the minimum inlet pressure or higher than the allowable maximum pressure.
• The non-return valve (18) prevents the high pressure flow from the membrane to flow back through the HP pump and into the low pressure piping. This may occur when the high pressure pump stops.
• The pressure relief valve (6) protects the
• Inlet filters assure proper water quality. High quality water extends the service life of the whole system.
• It is important with selection of a proper 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.
• The pressure switch (13) must stop the iSave when the pressure is lower than the minimum inlet pressure or higher than the maximum pressure.
entire 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
See “Start and stop” procedure, “Membrane cleaning” procedure instruction in appendices
10.1 and 10.2
build up a very high pressure that will exceed the mechanical strength of the membrane housing, pipes and other accessories.
• The valve (8) bleeds the air out of the system. The valve must be placed at the highest point in the system.
• The pressure relief valve (19) protects the low pressure pipes against pressure overload and relieves the water if the pressure exceeds the maximum allowable pressure.
17
Permeate
F
Flowmeter
8
9
16
28
CIP
27
Drain
20
Operating guide | iSave 21 Plus
6. On-site installation
6.1 General
For safety instructions see chapter 3.1
6.2 Installation and alignment
The figure below illustrates the major iSave components. Fig. 1
Motor
Bolts
Flexible coupling
Bell housing
iSave
Base plate
Port connection
Support bracket (AISI 316)
The iSave is connected to the electric motor by the bell housing and a coupling. The bell housing is not suitable for bearing the weight of either the iSave or the motor. Both the iSave and motor must be supported without applying stress/load to the bell housing.
Danfoss provides the iSave with a baseplate and support brackets. Although the baseplate is of a sturdy design, it can flex or bend when it is bolted to the foundation. The baseplate thus requires a solid foundation such as concrete or rigid steel frame. The baseplate itself must be aligned to avoid bending caused by bolting to an uneven foundation.
A rigid foundation for the iSave assembly is important, and the iSave assembly must be bolted to the foundation.
Bolts
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.
An unlocked bolt can result in personal injury and/or damage to the iSave.
Misalignment of the base plate may cause stress and/or damage to the bell housing.
6.3 Orientation
The iSave can be mounted horizontally and vertically.
When mounted vertically, the electric motor must be placed above the iSave.
The bolts used must be of proper design and must be installed in accordance with the bolt manufacturer’s recommendations.
21
Operating guide | iSave 21 Plus
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 connections must be aligned as shown in the figures below. Don’t use the iSave as a strain for hard piping.
Misalignment of the hard pipes may place stress on the iSave port connection and may damage the iSave
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 to the iSave.
Correct piping alignment Incorrect piping alignment
Incorrect piping alignment
22
Operating guide | iSave 21 Plus
6.5 Flexible couplings and flexible hoses
The strength of the Victaulic® connections is influenced by the material used for both the Victaulic® clamps and hose couplings. The flexible hose and connections used must be of proper design and must be installed in accordance with the manufacturer’s recommendations.
See also “Hose assembly and installation” in appendix 10.5
The flexible hose 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 to the iSave.
6.6 Mounting of coupling
The figure below illustrates how to mount the flexible coupling between the iSave and to connect it to the electric motor.
Any axial and radial load on the shaft must be avoided.
A: Flexible coupling B: Bell housing C: Motor shaft
6.7 Mounting of bell housing on iSave
The figure below illustrates how to mount the bell housing on the iSave. Screw the 4 bolts through the bell housing and into the iSave and tighten them to 30 Nm.
6.8 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.
23
Operating guide | iSave 21 Plus
6.9 Drives
6.9.1 Electric motor
The iSave must only be driven by an electric motor.
Using anything other than an electric motor can lead to an irreparable fracture of the iSave’s internal parts.
6.9.2 Speed control
The rotation speed on the electric motor can be controlled by a VFD. The direction of rotation is engraved with an arrow on the iSave.
Checking the direction of rotation 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 assembly the iSave on the electrical motor, check the rotation of the shaft on the electrical motor.
It is required to use a VFD or a soft starter.
A minimum of 10 seconds is required when ramping up the speed from zero to maximum. Otherwise, the torque on the iSave will exceed the maximum limit and may lead to an irreparable fracture of the iSave’s internal parts.
6.9.4 Torque overloads protection on the iSave
The electric motor and iSave must always be protected against overload. Both at start-up and at continues operation the maximum torque on the iSave must be monitored.
The electric motor must be shut of if the maximum torque of the iSave exceeds the defined limit. The response time of the power shutoff to the iSave must be of maximum 1 second.
If more electric motors are powered by the same soft starter or VFD, each electric motor must be equipped with “torque limit equipment” to protect the iSave against overload.
Special attention has to be on NON PROTECTED – FREE ROTATING shaft on the electrical motor. Ignorance will or could result in personal injury.
• Running the iSave in the wrong direction for more than a few min­utes can cause un-intended 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.
6.9.3 Starting torque on the iSave/ramp­ing the electric motor
Because of the inertia of the iSave internal parts and the fact that the iSave includes a positive displacement pump, the torque will exceed the maximum allowable torque for the iSave when the speed is not ramped up from zero to maximum.
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.
3. Torque limiter coupling.
See also examples of “iSave overload protection” equipment in appendix 10.5
The electric motor and iSave must always be protected against overload. Otherwise, the torque will exceed the maximum limit and may lead to an irreparable fracture of the iSave’s internal parts.
24
Operating guide | iSave 21 Plus
7. Commissioning, start-up and shutdown
7.1 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 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 equipped with all protection devices in accordance with EN60204-1.
• Check that all motor protections are properly set.
• All safety equipment, auxiliary equipment and connections required are proper 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. Rate quotes are offered upon request.
7.3 Commissioning
Before starting up the iSave and the high pressure pump make sure that the following requirements are met:
• 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 bargs, 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 for leakage.
• 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 externa leakage for all connections.
• At low pressure, start the iSave and
check direction of rotation.
• Start the system according to the
“Start and stop procedure” instructions in appendix. 10.1
25
Operating guide | iSave 21 Plus
8. Service/ Maintenance
8.1 Safety regulations
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 starting device 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
• When saftey equipment has been adjusted make sure that proper re-adjustment has been made before start-up.
• When the system is re-started after service and maintenance follow the instructions in chapter 7 and in “Start and stop procedures” in appendix. 10.1
8.2 Support
Danfoss A/S offers commissioning and service at the system manufacturer’s location. Rate 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:
1. Re-check bolts in the foundation and the baseplate 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 necessar y.
4. Replace filters if necessary
5. Clean the filter housing and reinstall filters. Make sure no debris enters the system.
Three months after commissioning:
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
baseplate 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.
5. Replace filters if necessary.
6. Clean the filter elements and install the new filters. Make sure no debris enters the system.
7. Audibly inspect the iSave assembly. If there is irregular sounds or vibrations inspect the internals parts of the iSave and replace if necessary.
26
Operating guide | iSave 21 Plus
8,000 hours of operation after commissioning:
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 baseplate 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.
5. Replace filters if necessary.
6. Clean the filter elements and install the new filter. Make sure no debris enters the system.
7. Audibly inspect the iSave assembly. If there is irregular sounds or vibrations inspect the internals parts of the iSave and replace if necessary.
8. Visually inspect pump coupling and replace if necessary.
9. Audibly inspect the iSave assembly. If there is irregular sounds or vibrations inspect the internals parts of the iSave and replace if necessary.
10.Check power consumption and flow out of the iSave. If there is irregular performances inspect the internals parts of the iSave and replace if necessary.
11.Inspect and replace, if necessary, the vanes in the vane pump.
Dimensions of the vanes
iSave type iSave 21 Plus Original height (H) 27 mm Change when H is less than 26 mm Original length (L) 79.84 mm Change when L is less than 79.64 mm
Annually:
1. See above section: “8,000 hour of operation after commissioning”.
2. See “Operating- and maintenance instruction, electric motor” in appendix 10.6
Follow manufacturer’s recommendations for electric motor service and maintenance.
27
Operating guide | iSave 21 Plus
9. Trouble-shooting
9.1 Safety regulations
The operator ensures that all inspection and installation work is performed by authorised, qualified 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 low-pressure side.
• The water in all connected pipes must be drained.
The numbers in () correspond to the preferred system design and P&ID
Problem Possible cause Action VFD can’t start the iSave
at initial start-up.
VFD is not designed for con­stant torque.
Ramp-up settings in the VFD is not correct. VFD is tilting.
Choose a VFD that is designed for constant torque.
Set Ramp-up parameters correct.
Valve (9) is closed Open valve (9)
Torque on iSave too high during operation
Pressure in the HP line (5) is too high
Pressure difference from HP­out (5) to HP-in (10) is too high.
Start the iSave only when the pressure in the HP line is low.
Clean or change membranes.
Debris in the booster pump or iSave.
Wear in the booster pump or iSave.
Design of the basic plant doesn’t fit the performance of the iSave.
Permeate production is too low (17).
Valves (6), (7), (8) or (16) are leaking.
Repair or change valve.
Internal leakage in iSave Repair iSave HP pump flow (2) is to small Incorrect speed on the HP
pump. Check the HP pump and repair
if necessary.
Pressure on the mem-
Fouling on the membranes Clean the membranes
branes (5) is too high.
Mixing in the iSave is too high. Check flow on LP-in (12) and
adjust flow.
Flow out of the iSave is too low, causes a recovery rate
Check speed on iSave and change if necessary.
that is too high.
Booster pump in the iSave is worn out. Perform service on the VP.
Pressure on the mem­branes (5) is too low.
Valves (6), (7), (8) or (16) are leaking.
Repair or change valve (s).
Internal leakage in iSave Repair iSave HP pump flow (2) is too small Incorrect speed on the HP
pump. Check the HP pump and repair
if necessary.
28
Appendices
Energy Recovery Device
iSave 21 Plus
Installation, Operation and Maintenance Manual
hpp.danfoss.com
Operating guide | iSave 21 Plus
10. Appendix
Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.1 Start and stop procedures (180R9213). . . . . . . . . . . . . . . . . . . . . . . . . . . .31
10.2 Membrane cleaning of the RO system with iSave unit (180R9214) . . . . . . . . . . 37
10.3 Data sheet iSave 21 Plus - iSave 40 (521B1464) . . . . . . . . . . . . . . . . . . . . . .43
10.4 iSave part list (521B1459) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
10.5 Hose assembly and installation (180R9434) . . . . . . . . . . . . . . . . . . . . . . . .83
10.6 Operating- and maintenance instruction, electric motor (180R9230) . . . . . . . . 91
30
Design guide
iSave Energy Recovery Device
Start and stop of the SWRO with iSave
hpp.danfoss.com
Design guide | Start and stop of the SWRO with iSave unit
Table of Contents Prior to start-up................................................................................................................................................................33
Starting up the system...................................................................................................................................................33
Daily system shutdown.................................................................................................................................................34
More than one day system shutdown........................................................................................................................35
32
Design guide | Start and stop of the SWRO with iSave unit
Below procedures are general guidelines for the start-up and shut-down functions of SWRO­systems 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) discon- nected 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).
33
Design guide | Start and stop of the SWRO with iSave unit
4. Start the iSave(s). In general: Only start the iSaves when the
pressure ”HP in” (10) is below 20 barg/290 psig. Always start the iSave unit before the high-pressure pump is started.
There are in principle two ways to start multi ple iSaves:
- Slowly ramp up all the iSaves at the same time.
- Slowly ramp up one by one.
Starting sequence - one by one: a) Start iSave #1. b) After 5 sec. start iSave #2. c) In a sequence of 5 sec. start the remaining iSaves. Comments:
- Ramp up time on iSaves is set between 10 –15 sec.
Starting sequence - Start all iSaves at the same time. Comments:
- Ramp up time on iSaves is set between 10 –15 sec.
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 min. within a period of 6 hours. If possible run the iSave at its min allowable speed to reduce cavitation.
“LP-out” pressure (14) is below 1 barg/
14.5 psig, adjust the flow by raising the flow from the seawater supply pump (A).
3. If the “LP-in” flow (12) is too high, reduce flow by closing the pressure control valve (15) or the flow from the seawater supply pump (A).
10. For iSave 50 and iSave 70: 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-in” pressure (21) is higher than 2 barg/29 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 “LP-in” pressure (21) is below 2 barg/ 29 psig, adjust the flow by raising the flow from the seawater supply pump (A).
3. If the “LP-in” flow (12) is too high, reduce flow by closing the pressure control valve (15) or the flow from the seawater supply pump (A).
Daily system shutdown
1. The system is running in normal operation and producing permeate flow.
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.
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.
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
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. If possible run the iSave at its minimum allowable speed to reduce cavitation.
4. Stop the iSave(s)(11).
5. Stop the seawater supply pump (A).
34
Design guide | Start and stop of the SWRO with iSave unit
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. If possible run the iSave at its minimum allowable speed.
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 high- pressure line is equal to the TDS in the low- pressure line.
7. Stop iSave(s) and permeate water supply.
VFD
22
M
4
2
26
Media filter
A
B C
Filter 3 micron nominel
PI
Fresh water
permeate flush
Filter
10 micron
absolut
PI
F
*
12
PI
PS
21
24
19
3
PI
PS
F
1
LP in
HP out
11
M
4
26
iSave
HP in
M
VFD
23 23
25
18
25
18
HP out
HP in
M
VFD
VFD
5
PI
PS
13
14
PS
PI
6
7
20
F
22
Full flow
cleaning/CIP
1011
PI
15
17
Permeate
F
Flowmeter
8
9
16
28
CIP
27
Drain
35
© Danfoss | DCS (im) | 2020.01
180R9213 | 521B1164 | DKCFN.PI.003.F8.02 | 36
Design guide
Energy Recovery Device iSave Membrane cleaning of RO-system
hpp.danfoss.com
Design guide Membrane cleaning of the RO-system with iSave ERD
Table of Contents Membrane cleaning......................................................................................................................................................39
Starting up the system .................................................................................................................................................40
Starting up the system .......................................................................................................................................................... 41
38
Design guide Membrane cleaning of the RO-system with iSave ERD
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.
39
Design guide Membrane cleaning of the RO-system with iSave ERD
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.
P&ID no. 1
4
2
26
Media filter
A
B C
Filter 3 micron nominel
PI
Fresh water
permeate flush
10 micron
absolut
PI
F
*
PI
PS
21
24
19
3
Filter
PI
PS
F
1
12
LP in
HP out
11
iSave
HP in
M
VFD
23 23
4
26
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)
VFD
22
M
25
18
M
25
18
HP out
HP in
M
VFD
VFD
22
5
PI
6
PS
Flowmeter
Full flow
cleaning/CIP
7
1011
9
PI
13
14
PS
PI
15
20
F
8
16
28
27
Drain
17
Permeate
F
CIP
*
Second stage filter: If recommended housing design an d 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.
40
Design guide Membrane cleaning of the RO-system with iSave ERD
P&ID no. 2
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.
M
4
2
26
Media filter
A
B C
Filter 3 micron nominel
PI
Fresh water
permeate flush
10 micron
PI
F
*
PI
PS
21
24
19
3
Filter
PI
PS
absolut
F
1
12
LP in
HP out
11
HP in
M
VFD
23 23
26
iSave
18
M
4
18
M
VFD
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
VFD
25
25
HP out
HP in
5
PI
PS
PS14PI
22
6
Full flow
cleaning/CIP
7
1011
PI
9
13
15
20
F
Flowmeter
8
16
Drain
17
Permeate
F
28
CIP
v
27
*
Second stage filter: If recommended housing design and car tridges are not used, a second stage filter is required
VFD
22
M
4
2
26
Media filter
A
B C
Filter 3 micron nominel
PI
PI
*
PI
PS
21
Fresh water
permeate flush
24
19
*
Second stage filter: If recommended housing design and car tridges are not used, a second stage filter is required
3
Filter
PI
10 micron
PS
absolut
F
1
F
12
LP in
HP out
11
HP in
M
VFD
23 23
4
26
iSave
25
18
M
25
18
HP out
HP in
M
VFD
VFD
22
5
PI
6
PS
Full flow
cleaning/CIP
7
1011
PI
9
13
15
20
PS14PI
F
Flowmeter
8
16
Drain
17
Permeate
F
28
CIP
27
41
Danfoss A/S High Pressure Pumps Nordborgvej 81 SK-6430 Nordborg Denmark
© Danfoss | DCS (im) | 2017.09
521B1165 | DKCFN.PI.00.G6.02 | 42
Data sheet
Data sheet
Energy Recovery Device
Energy Recovery Device
iSave 21 Plus / iSave 40
iSave 21-40
Body textBody textBody textBody text
www.danfoss.com
www.iSave.danfoss.com
hpp.danfoss.com
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
Table of Contents Contents
1. General information....................................................................45
1.1 iSave 21 Plus ...........................................................................45
1.2 iSave 40................................................................................46
2. Benefits................................................................................46
3. Technical data .........................................................................47
3.1 iSave without motor ...................................................................47
3.2 iSave with IEC motor ...................................................................48
3.3 iSave with NEMA motor (can only be ordered through Danfoss US) ......................49
4. Flow at different rpm...................................................................50
5. Corrosion..............................................................................50
5.1 Oper atio n..............................................................................50
6. Noise level.............................................................................51
7. Filtration...............................................................................51
8. iSave drawings .........................................................................52
8.1 Assembled iSave 21 Plus and iSave 40 without electric motor ...........................52
8.2 Assembled iSave 21 Plus and iSave 40 with IEC electric motor ...........................54
8.3 Assembled iSave 21 Plus and iSave 40 with NEMA motor ................................60
9. Installation.............................................................................64
10. RO systems with an iSave...............................................................65
11. Performance curves....................................................................66
11.1 Performance and torque curves iSave 21 Plus ...........................................66
11.2 Performance and torque curves iSave 40................................................68
12. Service.................................................................................70
12.1 Warranty...............................................................................70
12.2 Maintenance...........................................................................70
12.3 Re p air .................................................................................70
44
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
1. General information
iSave 21 Plus
iSave 40
1. 2” Victaulic connections
2. Shaft
3. Low pressure shaft seal
4. Port flange
5. Port plate
6. Valve plate
7. Cylinder drum
8. Port flange
9. Port plate
10. Pins
11. Vane s
12. Port plate
13. Coupling
14. Adapter flange
15. Rotor
16. Stator
17. Port flange
18. Outlet flange
The iSave 21 Plus and iSave 40 consists of an isobaric pressure exchanger, a high-pressure positive displacement booster pump and an electric motor.
The isobaric pressure exchangers are based on the technology used in the Danfoss APP pumps, and the high-pressure booster pumps are based on the vane pump principle enabling a very light and compact design. The design of iSave 21 Plus and iSave 40 ensures lubrication of the moving parts by the fluid itself.
All parts included in the iSave 21 Plus and iSave 40 are designed to provide long service life with a constant high efficiency and minimum service required.
1.1 iSave 21 Plus
10 9
11
12
17
1
18
15
16
14
8
1212
The vane pumps are fixed displacement pumps in which the flow is proportional to the number of revolutions of the driving shaft – enabling flow control.
The electric motor provides speed control of both the pressure exchanger and the high­pressure booster pump on the same shaft – preventing overspin/overflushing.
The iSaves need a VFD that allows the motor to apply a constant torque from low speed to maximum speed.
The sectional drawings below illustrate the main components of the iSave 21 Plus and iSave 40, respectively
6
5
1
13
6
7
5
1
4
2
3
1
45
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
1.2 iSave 40
1. 3” Victaulic connections
2. Shaft
3. Low pressure shaft seal
4. Port flange
5. Port plate
6. Valve plate
7. Cylinder barrel
8. Port flange
9. Sealing plate
10. Pins
11. Vane s
12.Port plate
13. Coupling
14. Adapter flange
15. Rotor
16. Stator
17. Port plate
18. Outlet flange
2. Benefits
• One of the smallest and lightest energy recovery devices on the market
• Few components
• High efficiency
• No need for high-pressure flow meters
• No expensive high-pressure mechanical seal
• No risk of over spin/over flushing
• Easy modular service
• All parts of the device are made of high
corrosion-resistant materials e.g. Super Duplex
(HP) High-pressure outlet
(LP) Low-pressure inlet
(HP) High-pressure inlet
(LP) Low-pressure outlet
46
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
3. Technical data
3.1 iSave without motor
iSave size iSave 21 Plus iSave 40
Code number 180F7015 18 0F 7011
Geometric displacement
Pressure
Differential pressure HP in - HP out max.
HP max. outlet pressure
HP min. inlet pressure
HP max. inlet pressure
HP inlet min. pressure, intermittent
2) 3)
LP inlet max. pressure
LP inlet max. pressure intermittent
3)
LP outlet min. pressure
LP differential LP in - out at HP max. flow
Speed
Min. speed rpm 500 600
Max. speed rpm 1500 120 0
Typical flow
HP outlet flow range
4)
at max. differential pressure
Lubrication flow at 60 barg (871 psig) max.
LP inlet max. flow
Torque
Torque at max. differential pressure operation
1)
Max. starting torque (stick/slip)
Media temperature
5)
Ambient temperature
Filtration requirements (nominal)
6)
Salinity increase at membrane at 40% recovery rate 2-3 %
Weight
1)
Continuous torque a bove max. differential pre ssure
will reduce the lifetime of the iSave.
2)
Pressure can reach this pressure level at start-up
and permeate flush.
3)
Intermittent pressure is acceptable for less than 10
cm³/rev 273 626
In³/r ev 16.7 38.2
bar 5 5
1)
psi 72.5 72.5
barg 83 83
psig 120 0 120 0
barg 15 20
psig 217 290
barg 83 83
psig 120 0 120 0
barg 3 3
psig 44 44
barg 5 5
psig 72 72
barg 10 10
psig 145 145
barg 1 1
psig 14. 5 14. 5
bar 0.9 1.2
psi 13 17.5
m³/h 6-22 21-41
gpm 26-96 92-180. 5
m³/h 0.4 0.8
gpm 1.8 3.5
m³/h 33 67
gpm 145 295
Nm 49 102
lbf-ft 36 75
Nm 50 150
lbf-ft 37 110
o
C 2-40 2-40
o
F 36 -122 36 -122
o
C 0-50 0-50
o
F 32-104 32-10 4
3 micron melt-blow
kg 47 123
lb 103 271
minutes within a period of 6 hours.
4)
Typical average flow at 60 bar.
5)
Dependent on NaCI concentation.
6)
Please see section 7. filtration.
47
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
3.2 iSave with IEC motor
iSave iSave 21 Plus A)iSave 21 Plus iSave 40
Code number horizontal 180F7016 180F7 017 180 F7001 18 0F7004 Code number vertical 180F7016 18 0F7017 180F7003 180F7005
Motor size IEC version IEC 400 V,
1)
50 Hz
Frame size
Motor data
Nominal speed rpm 1450 1450 970 970
Min. speed at 400 V rpm 500 Max. speed at 400 V rpm 150 0 150 0 Rated current at 400 V A 11 15.2 22 30 Torque
Motor torque at norminal speed
Motor torque at min. speed
3)
Motor ambient temperature, max.
Motor insulation Class B B B B
Motor degrees of protection IP 55 55 55 55
Sound pressure level max.
6)
Weight
Footprint (horizontal/vertical)
kW 5.5 7.5 11 15 HP 7. 5 10 15 20 IEC 132 S 132 M 160 L 180 L pole 4 4 6 6
Nm 36 49
3) 4)
lbf-ft 26.5 36 80 107.7 Nm 27 36 95 129 lbf-ft 20 27 70 95
o
C 40 40 40 40
o
F 122 122 12 2 12 2
dB(A) 78 79 84 84
kg 105 116 254 305
lb 231 255 560 672
m² 0.31 0.32 0.5/0.16 0.54/0.17
foot² 3.34 3.45 5.38/1.72 5.81/1.83
2)
500 600 600
3)
110 0 12 00
5)
108 146
A)
Differential pressure HP in - HP out max. is limited
to 3 bar [44 psi]
1)
Three-phase-asynchronous-motor according to
DIN-IEC and VDE 0530 standards.
• Voltage and frequency according to IEC 38
• The motors are fitted with a rating plate in multi-tension: 380-420 V / 660-720 V, 50 Hz or 440-480 V, 60 Hz
• Tolerance ± 5% according to VDE 0530
• Standard coating according to IEC 60721-2-1
2)
If voltage is below 400 V we recommend to use another size of electric motor. Please contact Danfoss High Pressure Pumps for further information.
3)
Torque load for iSave and motor see diagram on
page 23 and 25.
4)
Due to iner tia and stick-slip frictio n of the iSave, the torque may exceed the maximum allowable operation torque for the iSave when it is taken into use and/ or speed is ramped up from zero to maximum. A VFD or a soft starter must be used for ramp up.
5)
The starting torque must not exceed the values stated under “Max. starting torque (stick/slip)”. The VFD must be able to deliver 140% start torque. The Danfoss VFD type FC 301 and FC 302 can be used. For advice on VFD settings, please consult our relevant guideline or contact Danfoss.
6)
A-weighted sound pressure level at 1 meter 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 ERD with motor (motor-pump unit) at max. pressure and speed.
48
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
3.3 iSave with NEMA motor (can only be ordered through Danfoss US)
iSave iSave 21 Plus A)iSave 21 Plus iSave 40
Code number horizontal 180U0013 180U0052 180U0012 Code number vertical 180U0013 180U0052 180U0002
Motor size NEMA version
1)
High efficiency 460 V, 60 Hz
Frame size
Motor data
Nominal speed rpm
Min. speed continuous at 400 V rpm 500 500 600 Max. speed continuous at 400 V rpm 150 0 1500 1200 Motor rated current 460 V A 12 .4 18 24.2 Torque
Motor torque at norminal speed
Motor torque at min. speed
4)
Motor ambient temperature, max. 3,300 feet above sea level
Motor degrees of protection IP 55 55 55
Sound pressure level max.
6)
Weight
Footprint (horizontal/vertical)
A)
Differential pressure HP in - HP out max. is limited
to 3 bar [44 psi]
kW 7.5 11 15 HP 10 15 20 NEMA 215TC 254 286TC pole 4 4 6
Nm
3) 4)
(lbf-ft) 29.4 44 Nm 20 31 95 (lbf-ft) 14. 7 23 70
o
C 40 40 40
(oF) 122 122 122
dB(A) 78 79
kg 152 206 324
(lb) 335 454 715
m² 0.38 0.45/0.16 0.65/0.23
foot² 4.09 4.85/1.72 7.0/2.48
2)
1760 1765 1175
40 59.7 119
*)
Tested with IEC motor
5)
88.2
*)
84
1)
Three-phase-asynchronous-motor according to
NEMA MG-1 and UL 1004-1 standards.
• Insulation class F, service factor 1.25.
• Fan-cooled TEFC (IC411). Voltage and frequency according to NEMA MG-1 part 12.
• The motors are fitted with a rating plate 230 / 460 V, 60 Hz.
• Plus or minus 10% of rated voltage, with rated frequency. Standard coating according to motor supplier specifications.
2)
Max. speed for iSave 21 is 1500 rpm.
3)
Torque load for iSave and motor see diagramme on
page 23 and 25.
4)
Due to inertia and stick-slip friction of the iSave, the
torque may exceed the maximum allowable operation torque for the iSave when it is taken into use and/ or speed is ramped up from zero to maximum. A VFD or a soft starter must be used for ramp up.
5)
The starting torque must not exceed the values stated under “Max. starting torque (stick/slip)”. The VFD must be able to deliver 140% start torque. The Danfoss VFD type FC 301 and FC 302 can be used. For advice on VFD settings, please consult our relevant guideline or contact Danfoss.
6)
A-weighted sound pressure level at 1 meter 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 ERD with motor (motor-pump unit) at max. pressure and speed.
49
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
ppm
iSave 21 Plus
iSave 40
0
22
44
66
88
110
132
154
176
198
0
5
10
15
20
25
30
35
40
45
500 600 700 800 900 1000 1100 1200 1300 1400 1500
gpm
m3/h
rpm
Flow at HP out vs. rpm
4. 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 please use our selection tool which is available on our website: www.isave.danfoss.com
The iSave is delivered with a 3.1 performance certificate according to EN10204.
5. Corrosion
5.1 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.
º
80
C
70
60
50
40
316L
30
20
100
160 1600
1000
Always flush the iSave with fresh water at operation stop in order to minimize the risk of crevice corrosion.
Duplex
Super Duplex
10 000
16000
100 000
160000
CI ppm
NaCI
-
50
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
6. Noise level The noise level for the iSaves is measured at max. speed, a pressure of 80 barg and a booster pressure of 5 bar. Since the iSave is mounted on a bell housing and electric motor, the noise level can only be determined for the complete unit (system).
It is therefore important that a horizontal iSave unit is mounted correctly on a frame with dampeners to minimize vibrations and noise. We recommend to mount a vertical iSave directly to the floor with bolts. It is also strongly recom­mended to use high-pressure flexible hoses between the hard piping in the RO-plant and the iSave or to use multiple connections with Victaulic clamps.
The noise level is influenced by: Speed:
• High rpm makes more fluid/structure-borne
pulsations/vibrations than low rpm due to higher frequency.
Noise level (dB(A) measured for the iSave 21 Plus and 40 at different speed and system pressure. Booster pressure 3 bar.
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.
7. Filtration
iSave 21 Plus iSave 40
barg/psig
rpm
500 60 62 68 1000 69 72 74 150 0 77 78 78
20/290 60/870 80/1160
It is important that the incoming water is filtered properly to ensure optimum service life. A true graded density, melt-blown depth filter cartridge
barg/psig
rpm
support core. High Pressure Pumps does not recommend cartridges requiring any type of binders or resins.
rated at 3 μm is therefore recommended.
Filters can be purchased from Danfoss It is important with selection of a proper 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.
High Pressure Pumps. Please see section 10.0,
“RO systems with an iSave”, for installation of
filter. 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 As the various filters on the market differ greatly, Danfoss High Pressure Pumps recommends
definitions and a guidance on how to select the
right filter. using cartridges with consistent, reliable performance and high efficiency and where fibres are blown continuously onto a central
30/435 60/870 80/1160
800 73 77 78 1000 76 79 81 120 0 78 82 84
51
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
8. iSave drawings 8.1 Assembled iSave 21 Plus and iSave 40 without electric motor
iSave 21 Plus
52
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
iSave 40
53
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
8.2 Assembled iSave 21 Plus
and iSave 40 with IEC electric motor
iSave 21 Plus, 5.5 kW, 4 pole, IEC motor
54
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
iSave 21 Plus, 7.5 kW, 4 pole, IEC motor
55
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
iSave 40 - horizontal, 11 kW, 6 pole, IEC motor
56
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
iSave 40 - horizontal, 15 kW, 6 pole, IEC motor
57
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
iSave 40 - vertical, 11 kW, 6 pole, IEC motor
58
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
iSave 40 - vertical, 15 kW, 6 pole, IEC motor
59
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
8.3 Assembled iSave 21 Plus and iSave 40 with NEMA motor
iSave 21 Plus, 10 HP, 4 pole, NEMA motor
60
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
iSave 21 Plus, 15 HP, 4 pole, NEMA motor
61
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
iSave 40 - horizontal, 20 HP, 6 pole, NEMA motor
62
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
iSave 40 - vertical, 20 HP, 6 pole, NEMA motor
63
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
9. Installation
Orientation
iSave 21 Plus and iSave 40 can be mounted horizontal and vertical. iSave 40 can be mounted horizontally and vertically - when mounted vertically, the electric motor must be placed at the top of the iSave. The iSave 21 Plus baseplate can be used for both horizontal and vertical installations. The iSave 40 has a base when installed vertical.
A: Flexible coupling B: Bell housing C: Motor shaft
The iSave is connected to the electric motor by a bell housing and coupling.
If a horizontal iSave is delivered without base plate it is important to support the iSave and motor. The bell housing is not able to carry the weight of either the iSave or the motor when using horizontal mounting.
Mounting
The figure below illustrates how to mount the iSave and connect it to the electric motor.
Note: Any axial and radial load on the shaft must be avoided.
min. 3 - 5 mm air sp ace
A B C
The iSave and motor must be supported without applying stress/overload to the bell housing.
If a horizontal iSave is delivered with a baseplate, a rigid mounting surface is required such as concrete foundation, optional base frame or a container with suitable steel substructure.
64
1: Motor 2: Flexible coupling 3: Bell housing 4: Base plate
5: Pressure exchanger 6: Booster pump 7: Port connection
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
10. RO systems with an iSave
P&ID setup
VFD
Media filter
1
Filter 3 micron nominel
Fresh water
permeate flush
Filter
10 micron
PIPI
19
*
Second stage filter: If recommended housing design and cartridges are not used, a second stage filter is required
absolut
F
12
LP in
*
2
F
HP out
11
M
VFD
PI
PS
HP in
3
iSave
4
M
18
PS
Explanation of P&ID setup
A. Place inlet filters on LP string in front of the
iSave (11). Inlet filters assure proper water
quality. High quality water extends the service life of the whole system. It is impor tant with selection of a proper filter housing to ensure good cartridge end sealing. If there is a high risk of water by-pass it is recom mended to use a second stage filter solution. Please consult section 7, “Filtration” for guidance on how to select the right filter. Thoroughly clean pipes and flush system
prior to start-up.
B. Place a monitoring pressure switch set (3) at
minimum inlet pressure between filter and
pump inlet. The monitoring switch must stop
the iSave (11) and the high-pressure pump (4)
at pressures lower than minimum inlet
pressure.
C. Dimension the piping to obtain minimum
pressure loss (large flow, minimum pipe
length, minimum number of bends/connec-
tions and fittings to prevent pressure loss and
flow turbulence). Use flexible hoses to
minimize vibrations and noise.
D. To balance the flow between high-pressure
out and low-pressure in, place a variable area
flow meter (12) on low-pressure inlet to the
iSave.
E. In order to eliminate the risk of damage and
cavitation, a positive pressure at the
PI
5
PS
13 14
6
Full flow cleaning
7
10
PI
PI
20
F
9
15
17
Permeate
F
Flowmeter
8
16
28
CIP
27
Drain
low- pressure outlet from the iSave is always to be maintained at minimum 1 barg (14.5 psig) and maximum 10 barg (145 psig). It is recommen ded to install monitoring pressure switch (13) in order to prevent high/low-pres sure.
F. Install a VFD to control the speed of the iSave.
G. Install a pressure and flow control valve (15) to
control pressure in low-pressure out.
H. Although the iSave 21 Plus automatically will bleed itself, there should be an air bleed valve (8) installed on the highest point of the high-pressure piping to ensure proper bleeding of the RO system.
I. 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.
J. The pressure relief valve (19) protects the
low-pressure pipes against pressure overload and relieves the water if the pressure exceeds the maximum allowable pressure.
For alternative P&ID setup, please contact Danfoss High Pressure Pumps sales organisation.
65
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
22,0 30,8 39,6 48,4 57,2 66,0 74,8 83,7 92,5 101,3 110,1
0,0
2,9
5,8
8,7
11,6
14,5
17,4
20,3
23,2
26,1
0,0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
1,8
5,0 7,0 9,0 11,0 13,0 15,0 17,0 19,0 21,0 23,0 25,0
gpm
psi
bar
m3/h
Differential pressure vs. flow at LPin
60 ba rg
22,0 30,8 39,6 48,4 57,2 66,0 74,8 83,7 92,5 101,3 110,1
30 ba rg
0,00
0,22
0,44
0,66
0,88
1,10
1,32
1,54
1,76
0,00
0,05
0,10
0,15
0,20
0,25
0,30
0,35
0,40
5,0 7,0 9,0 11,0 13,0 15,0 17,0 19,0 21,0 23,0 25,0
gpm
gpm
m3/h
m3/h
Lubrication flow vs. flow at HPout
11. Performance curves
11.1 Performance and torque curves iSave 21 Plus
66
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
0,0
3,7
7,4
11,1
14,8
18,4
22,1
25,8
29,5
33,2
36,9
40,6
44,3
47,9
51,6
55,3
59,0
62,7
0
5
10
15
20
25
30
35
40
45
50
400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700
lb ft
Nm
rpm
Torque for iSave 21 and motor at 60 barg system pressure
67
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
11.2 Performance and torque curves iSave 40
Differential pressure, low pressure
bar
1.40
psi100 140 180
20
1.20
1.00
15
0.80
10
0.60
0.40
5
0.20
0.00
20.0
22.0
24.0
26.0
28.0
30.0
32.0
34.0
36.0
38.0
40.0
42.0
m
44.0
Lubrication flow
m3/h gpm
1.00
3
/h
0.90
60 barg
0.80
3
0.70
0.60
0.50
30 barg
0.40
1.5
0.30
0.20
0.10
0.00
42
40
38
36
34
32
30
28
26
24
22
20
m3/h
44
68
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
Torque for iSave 40 motor at 60 barg system pressure
Nm lbf ft
150
140
130
120
110
100
90
80
70
60
50
40
30
20
600
650
X
700
750
800
850
110.63
103.26
95.89
88.50
X
900
950
X
X
i
s
p
5
.
2
7
r
a
b
5
r
a
b
4
r
a
b
3
b
2
b
1
1000
i
s
p
8
5
i
s
p
5
.
3
4
i
s
p
9
2
r
a
r
a
1050
i
s
p
5
.
4
1
1100
1150
81.13
73.75
66.38
59.00
51.63
44.25
36.88
29.50
22.13
rpm
1200
Important:
The marked area at 1100-1200 rpm shows the operation area which cannot be reached with a 11 kW motor at 400 voltage supply. A 15 kW is needed if max rpm (1100-1200) and max differential pressure (4 to 5 bar) is required.
Max motor torque for 15 kW, IEC180L-6, 50 Hz, 400 V
Max motor torque for 20 HP, NEMA286TC-6, 60 Hz, 460 V
Max motor torque for 11 kW, IEC160L-6, 50 Hz, 400 V
X
Max motor torque for 11 kW, IEC160L-6, 60 Hz, 480 V
The straight pressure lines (1 to 5 bar) show the needed shaft torque for the iSave at different pressures.
69
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
12. Service
12.1 Warranty
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 8,000 hours service-free operation, however, max. 18 months from date of produc­tion.
The life of an iSave may be greatly shortened if Danfoss recommendations concerning system design are not followed.
Standstill
The iSave is made of Duplex or Super Duplex materials with excellent corrosion resistance. However, it is always required to flush the iSave when the system is shut down.
12.2 Maintenance
In our experience, poor filtration is the number one cause of iSave damage. Danfoss recom­mends an periodic inspection where worn parts, if any, must be replaced. This is done in order to to prevent a potential breakdown of the iSave.
12.3 Repair
In case of irregular function of the iSave, please contact Danfoss High Pressure Pumps.
70
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
71
Danfoss A/S
High Pressure Pumps DK-6430 Nordborg Denmark
Danfoss ca n accept no respons ibility for pos sible errors in ca talogues, bro chures and other pr inted material. Da nfoss reserve s the right to alter its p roducts with out notice. This also a pplies to produc ts already on ord er provided that su ch alterations ca n be made without su bsequential cha nges being nece ssary in speci fications alread y agreed. All trade marks in this mate rial are proper ty of the respec tive companies . Danfoss and the Danf oss logotyp e are trademark s of Danfoss A/S. Al l rights reserv ed.
© Danfoss | DCS (im) | 2018.05
521B1464 | DKCFN.PD.003.4B.02 | 72
Parts list
Energy Recovery Device
iSave 21 Plus
hpp.danfoss.com
Parts list | Energy Recovery Device iSave 21 Plus
Table of Contents
iSave 21 Plus ......................................................................................75
Pressure exchanger................................................................................76
Booster Pump (vane pump)........................................................................77
iSave 21 Plus ......................................................................................77
iSave 21 Plus on base plate ........................................................................78
Exploded view Vane pump ........................................................................79
Exploded view Pressure exchanger ................................................................80
Exploded view iSave 21 Plus .......................................................................81
74
Parts list | Energy Recovery Device iSave 21 Plus
iSave 21 Plus
This part list provides an overview of the content of various service sets for the iSave 21 Plus as well as exploded views of the iSave, pressure exchanger and booster pump.
75
Parts list | Energy Recovery Device iSave 21 Plus
Pressure exchanger
Note: The parts listed are not sold seperately, only in various kits
Exploded view, see following pages.
Pos. Qnt. Designation Material
Valve
plate
101 1 PE Housing Duplex
180 F4101
102 1
103 1
104 1
105 1
106 2 Int. Valve plate Super Duplex X
107 1 Cylinder barrel Super Duplex
108 1 Shaft Super Duplex
109 1 Spring stop Super Duplex
110 2
111 1
112 1 Cover Super Duplex
113 1
114 1 Clips iSave PPS HP V X
115 2 Pin Ø6 x 10 PEEK X X X
116 2 Pin Ø6 × 10 AISI 316 X
117 29
118 12
119 1 Shaft seal Ø18 AISI 316 X
120 3
121 4
122 2
123 3
124 1
125 1
126 24 Backup ring PTFE X
127 24
128 1
129 1 Bush/Bearing PEEK
130 1 Key 5 × 5 × 20 AISI 316Ti X
131 1
Mounting
flange
Intermediate
flange
Port plate Sea water
Port plate
Brinea
Victaulic studs
2”
2” victaulic
studs
Ass. HP Be aring
support
Screw
M8 × 45,0,
A4-80
Screw M6 × 16
CS RS A4
Compression spring ø1,4 ×
ø9,5
Screw
M10 × 30 A4-80
O-rin g 135,00
× 3,00
O-rin g 50,00
× 2,00
O-rin g 40,00
× 2,00
O-rin g Ø30,00
× 2,00
O-rin g 18,00
× 2,00
O-rin g 17,00 ×
3,00 NBR 70
Liftin g eye M8
(DIN 580E)
Super Duplex
Super Duplex
«Super Duplex
PEEK»
«Super Duplex
PEEK»
Super Duplex
Super Duplex
«Super Duplex
PEEK»
AISI 316 X
AISI 316 X
Hastelloy C276
AISI 316 X
NBR 70 X
NBR 70 X
NBR 70 X
NBR 70 X X
NBR 90 X
NBR 70 X
AISI 316
180 F4102
Port plate,
brine
X
180 F4155
Port plate,
sea water
X
180 F4156
HP
bearing
X
180 F4157
Sealing
kit
76
Parts list | Energy Recovery Device iSave 21 Plus
Booster Pump (vane pump)
Note: The parts listed are not sold seperately, only in various kits
Exploded view, see following pages.
Pos. Qnt.. Designation Material 180 F4157
Sealing kit
1 1 Stator ring «Super Duplex PE EK»
2 1 Int. Flange «Super Du plex PEEK»
3 1 Connection flange «Super D uplex PEEK»
4 1 Port flange
5 1 Side plate OU T «Super Duplex PEEK» X
6 1 Rotor Super Duplex
7 8 Van e «Sup er Duplex PEEK» X
8 4 Pin Ø6,9 PEEK
9 1 Side plate I N «Su per Duplex PEEK» X
10 2 Pin Ø 4 × 9 PEEK X X
11 1 Pin Ø6 × 10 AISI 316 X
12 12 Screw M 8 × 30 A4-80 AISI 316 X
13 1 Pin Ø6 × 16 A4 AISI 316 X
14 3
15 13
O-ring
112,00 × 2,50
Screw M8 × 150
A4-80
«Super Duplex
PMC TRIBO 180»
NBR 70 X
AISI 316 X
180 F4162
Vane k it
180 F4158
Side plate
iSave 21 Plus
Exploded view, see following pages.
Pos. Qnt. Designation Material 180 F4157
Sealing kit
201 1 Booster pump
202 1 Pressure exchanger
203 1 PE Coupling Super Duplex X
204 1 Spider softex 24/30 Green Hytrel X
205 1 VP Coupling Super Duplex X
206 2 Screw M8 × 30 Super Duplex X X
16 1 O -ring 60 × 2 NBR 70 X X
17 1 O-rin g 80 × 2 NB R 70 X X
18 1 Pin Ø6 × 10 AISI 316 X X
180 F4159
Coupling kit
77
Parts list | Energy Recovery Device iSave 21 Plus
iSave 21 Plus on base plate
Exploded view, see following pages.
Pos. Qnt. Designation Coupling 180Z0244
1 1 iSa ve 21
2 1 Base p late
3 1 Bell housing
4 1 Electric motor
5 1 Coupling X
6 4 Bolt M10 × 30 A4
7 4 Washer
8 6 Bolt M6 × 16 A4
9 1 Plug
10 8 Washer
11 4 Bolt M8 × 20 A4
12 1 Rubber plate
13 1 Support
78
Parts list | Energy Recovery Device iSave 21 Plus
Exploded view Vane pump
79
Parts list | Energy Recovery Device iSave 21 Plus
Exploded view Pressure exchanger
80
Parts list | Energy Recovery Device iSave 21 Plus
Exploded view iSave 21 Plus
81
© Danfoss | DCS (im) | 2019.10
AX321034532238en-000301 | 521B1459_DKCFN.PI.003.Q3.02 | 82
Instruction
Instruction
Right and wrong
Right and wrong
Hose assembly routing tips
Hose assembly routing tips
danfoss.high-pressurepumps.com
hpp.danfoss.com
Instruction | Right and wrong - Hose assembly routing tips
HOSES & HOSE COUPLINGS
GS-HYDRO PRODUCT CATALOGUE
Assembly and installation
When hose installation is straight, allow enough slack in hose line to provide for length changes which will occur when pres- sure is applied.
Prevent twisting and distortion by bending hose in same plane as the motion of the boss to which hose is connected.
User proper angle adaptors to avoid sharp twist or bend in hose. Adequate hose length is necessary to distribute movement on
flexing applications and to avoid abrasion.
When radius is below the required minimum, use an angle adap- tor to avoid sharp bends.
Avoid twisting of hose lines bent in two planes by clamping hose at change of plane.
Hose assembly routing tips
HOSES & HOSE COUPLINGS
GS-HYDRO PRODUCT CATALOGUE
Assembly and installation
When hose installation is straight, allow enough slack in hose line to provide for length changes which will occur when pres- sure is applied.
Prevent twisting and distortion by bending hose in same plane as the motion of the boss to which hose is connected.
Avoid twisting of hose lines bent in two planes by clamping hose at change of plane.
Hose assembly routing tips
HIGH
PRESSURE
NO
PRESSURE
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”.
1. Hoses up to 2” When installing hoses, avoid twisting the hose as the hose will try to straighten under pressure.
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.
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.
This can cause hose failure via hose blowout from the fitting and/or hose burst at the point of strain.
WRONG
RIGHT
When radius is below the required minimum, use an angle adap- tor to avoid sharp bends.
At radius below required minimum, angle adapters should be used to prevent sharp hose bends.
NO PRESSURE
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.
HIGH PRESSURE
WRONG
RIGHT
Use proper angle adapters to avoid sharp twist or bend of hose.
84
Instruction | Right and wrong - Hose assembly routing tips
WRONG
WRONG RIGHT
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
85
Instruction | Right and wrong - Hose assembly routing tips
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.
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.
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
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.
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.
WRONG
RIGHT
Hoses should not be twisted and should only have one bend.
86
Instruction | Right and wrong - Hose assembly routing tips
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.
MAX. BENDING ANGLE
If hose is bent, ensure max. bending angle and distance S from each connector (see table 1 on page 6).
WRONG
WRONG RIGHT
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.
NO
NO
PRESSURE
PRESSURE
RIGHT
HIGH
HIGH
PRESSURE
PRESSURE
WRONG
RIGHT
The hose must have a distance S before bending starts.
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.
87
Instruction | Right and wrong - Hose assembly routing tips
S
3. Hose specification
table
High pressure hoses
Code
number
180Z0228
Pipe connection1
[A]
1.5" Vic. OGS Super duplex
Pipe
connection
material
EN 1.4410
Hose size
Inner
diameter
25.4 mm (1.0") 0.66 m (26") 152 mm (6.08"), max. 90° 79 mm (3.11”)
Hose length
ISO 1436
[B]
Bending radius S
180Z0229 1.5" Vic. OGS
180Z0167
180Z0140
180Z0263 2.5" Vic. OGS
180Z0280
180Z0619
180Z0618
180Z0612
18 0Z0 611
180Z1000
180Z1001
Low pressure hoses
180Z0298 2.0” Vic. OGS
180Z0144 3.0” Vic. OGS
1.5" Vic. OGS Super duplex
2.0" Vic. OGS Super duplex
2.5" Vic. OGS Super duplex
2.5" Vic. OGS Super duplex
2.5" Vic. OGS Super duplex
3.0" Vic. OGS Super duplex
3.0" Vic. OGS Super duplex
3.0" Vic. OGS Super duplex
3.0" Vic. OGS Super duplex
Super duplex EN 1.4410
EN 1.4410
EN 1.4410
)
Super duplex EN 1.4410
EN 1.4410
EN 1.4410
EN 1.4410
EN 1.4410
EN 1.4410
EN 1.4410
EN 1.4410
Super duplex EN 1.4410
Super duplex EN 1.4410
25.4 mm (1.0")
38.0 mm (1.5") 1.16 m (45.7") 250 mm (9.84"), max. 180° 85 mm (3.35”)
50 mm (2.0") 1.25 m (49") 630 mm (24.8"), max. 90° 115 mm (4.53”)
50 mm (2.0") 1.78 m (70") 630 mm (24.8"), max. 180° 115 mm (4.53”)
50 mm (2.0") 1.00 m (39.4") 630 mm (24.8"), max. 90° 115 mm (4.53”)
65 mm (2.5") 1.78 m (70") 200 mm (7.87"), max. 270° 150 mm (5.90”)
65 mm (2.5")
76 mm (3.0") 1.79 m (70.5") 250 mm (9.84"), max. 270° 150 mm (5.90”)
76 mm (3.0") 1.00 m (39.4") 250 mm (9.84"), max. 90° 150 mm (5.90”)
76 mm (3.0") 1,25 m (49") 250 mm (9.84"), max. 180° 150 mm (5.90”)
76 mm (3.0") 1,6 m (63") 250 mm (9.84"), max. 180° 150 mm (5.90”)
1.16 m (45.7")
1.00 m (9.4")
2.0 m (79”)
2.0 m (79”)
152 mm (6.08"), max. 180° 79 mm (3.11”)
200 mm (7.87"), max. 90° 150 mm (5.90”)
1)
The installation instuction for Style 77DX is located in the Victaulic document I-100 Field Installation Handbook (htpp://static.victaulic.com)
O. D.
r
α
88
S
When using flexible hoses, it is recommened to use Hose Whip Restraint.
Instruction | Right and wrong - Hose assembly routing tips
89
Danfoss A/S High Pressure Pumps • danfoss.com • +45 7488 2222 • E-mail: highpressurepumps@danfoss.com
Any information, including, but not limited to information on selection of product, its application or use, product design, weight, dimensions, capacity or any other technical data in
product manuals, catalogues descriptions, advertisements, etc. and whether made available in writing, orally, electronically, online or via download, shall be considered informative, and is only binding if and to the extent, explicit reference is made in a quotation or order confirmation. Danfoss cannot accept any responsibility for possible errors in catalogues, brochures, videos and other material. Danfoss reserves the right to alter its products without notice. This also applies to products ordered but not delivered provided that such alterations can be made without changes to form, fit or function of the product. All trademarks in this material are property of Danfoss A/S or Danfoss group companies. Danfoss and the Danfoss logo are trademarks of Danfoss A/S. All rights reserved.
© Danfoss | DCS (im) | 2021.07
180R9434 | AN375455762639en-000201 | 90
Electric Motors
Motor Manual
hoyermotors.com
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 ≤ 10MΩ 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,
92
180R9401 | AQ261351057880en-000801 | 01.2022
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
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 Poles Typical lifetime
56 - 160 2 - 8 40,000h
180 2 35,000h
200 2 27,000h
225 2 23,000h
180 - 225 4 - 8 40,000h
Motors with a re-greasing system must be lubricated with high quality lithium complex grease, NLGI grade 2 or 3, with a temperature range of between -40°C to +150°C. Motors are normal fitted with a data plate with greasing information; if it is missing use the following re-greasing intervals.
Frame
size
160 20 4200 7000 8500 8500
180 20 4200 7000 8500 8500
200 25 3100 6500 8500 8500
225 25 3100 6500 8500 8500
250 35 2000 6000 7000 7000
280 35 2000 6000 7000 7000
315 50 1500 5500 6500 6500
355 60 1000 4000 5000 6000
400 80 800 3000 4000 6000
Grease
(g)
2 pole
(h)
4 pole
(h)
6 pole
(h)
8 pole
(h)
Grease the motor while running, open the grease outlet plug and let the motor run 1-2 hours before the outlet grease plug is closed again. Grease the motor for the first time during commissioning.
The following applies in general for both lifetime lubricated and re-lubricated bearings: At 60Hz the time will be reduced by app. 20%. Data for vertically mounted motors are half of the above 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 require shorter greasing intervals. Typically, doubling the speed will reduce the values by 50%.
Special note for Atex Zone 22 and nA motors
Designation of motor according to IEC standard: II 3D Ex tc IIIB T120°C II 3G Ex nA IIC T3
The hazardous 3-phase asynchronous motors are in accordance with International standard IEC 60079-31 and IEC 60079-15. Only one electrical installation may be installed in one specified area (zone).
Only certificated cable glands may be used. Unused glands must be closed. 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 earth connection. Installations must be in accordance with actual standards for installation in hazardours area.
It is recommended that the IEC standard is followed according to temperature and dust on the motor surface. The use of motors with so much surface dust that the motor temperature increases is not permitted. Regularly cleaning is recommended. The radial shaft sealing ring is part of the ATEX certification. It is important that the ring is always intact. The shaft sealing must be regularly checked, and if dry it must be lubricated. It is recommended that the seal is re­lubricated regularly. Always use the original seal ring when replaced. Replacing bearings also means replacing the seals.
All machines must be inspected regularly for mechanical damage. The user is responsible for changing parts in accordance with the lifetime of parts, in particular: bearings, grease and lubrication of shaft sealing.
Maintenance, repairs and replacement on this type must only be carried out by qualified specialists.
180R9401 | AQ261351057880en-000801 | 01.2022
93
Connection diagram Anschlußdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexión Collegamento Schemat polacsen
94
180R9401 | AQ261351057880en-000801 | 01.2022
180R9401 | AQ261351057880en-000801 | 01.2022
95
Hoyer Motors, Motor Manual, April 2019
Head Offices
Over Hadstenvej 42 · DK-8370 Hadsten
T +45 86 98 21 11 · F +45 86 98 17 79
hoyermotors@hoyermotors.com
19 Jingwu Middle Road · Beilun District
T +86 574 26 28 15 77 · F + 86 574 2628 1573
hoyermotors@hoyermotors.cn
Important notice.
Denmark
CVR no. 17 63 06 95
hoyermotors.com
China
Ningbo 315821 · Zhejiang
hoyermotors.cn
Text and data in this catalogue are not binding and we reserve the right to implement changes without further notice.
© Danfoss | DCS (im) | 2022.01
Branch Offices
Landsberger Straße 155 · 80687 München
T +49 89 700 88 235 · F +49 89 543 56 333
Liljeholmsstranden 5 · PO box 44017
Germany
germany@hoyermotors.com
hoyermotors.com
Sweden
SE-100 73 Stockholm
T +46 8 446 877 13
sweden@hoyermotors.com
hoyermotors.com
Vasteland 78 · 3011 BN, Rotterdam
Tel. +31 10 420 35 20 · Fax.+31 10 420 44 51
302ho · Code square · 3150-1 · Daejeo 2-dong
T +82 51 996 0251 · F +82 51 996 0252
Benelux
benelux@hoyermotors.com
hoyermotors.com
Korea
Gangseo-gu · Busan · Korea
korea@hoyermotors.com
hoyermotors.com
180R9401 | AQ261351057880en-000801 | 96
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use