Danfoss iSave 50, iSave 70 Operating guide

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Operating guide

Manual del usuario

Energy Recovery Device

Manual de instalación,

iSave 50-70 Installation, Operation and

funcionamiento y mantenimiento

Maintenance Manual

iSave 40

hpp.danfoss.com

isave.danfoss.com

Operating guide | iSave 50 - 70

Table of Contents 1. Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.2 Target group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.3 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Manufacturer and customer service address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.5 Country speciﬁc information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.5.1 United Kingdom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2.6 Additional technical documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.1 General ............................................................................... . 6

3.2 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.3 Application range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

3.4 Preferred system design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4. Arrival, inspection, handling and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.1 Arrival inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.2 Return to the supplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

4.3 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4.4 Assembly iSave on electric motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.5 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4.6 Outdoor storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

5. Technical data and design review. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

5.1 Design details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

5.2 Sound level of the iSave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

5.3 Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

5.4 Temperature and corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.5 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.6 Electrical motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5.7 How does the iSave work?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.8 Seawater quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.8.1 Pre-ﬁltration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5.8.2 Air bubbles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5.8.3 Chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5.8.4 Initial start up and ﬂushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5.9 Initial start up and setting of safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5.10 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.11 CIP or membrane cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

5.12 High pressure remains after shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

5.13 Over-pressurisation caused by low pressure isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

5.14 Over-pressurisation caused by high-pressure pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

5.15 Preferred system design and P&ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

6. On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

6.1 Design details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

6.2 Installation and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

6.3 Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

6.4 Piping and joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

6.5 Mounting of coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

6.6 Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

6.7 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

6.7.1 Electric motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

6.7.2 Speed control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

6.7.3 Starting torque on the iSave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

6.7.4 Torque overload pretection on the iSave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

7. Commissioning, start-up and shutdown ................................................16

7.1 Safety regulations......................................................................16

7.2 Support................................................................................16

7.3 Commissioning ........................................................................16

180R9357 | AQ265943679828en-001001 IOM iSave 50 - 70 | 02.2022

Operating guide | iSave 50 - 70

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

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

8.2 Support................................................................................17

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

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

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

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

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

10. Appendices............................................................................21

10.1 Data sheet iSave 50-70 - (521B1378)) ....................................................23

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

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

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

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

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

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

180R9357 | AQ265943679828en-001001 IOM iSave 50 - 70 | 02.2022

Operating guide | iSave 50 - 70

1. Validity Document information and copyright

Installation, Operation and Maintenance Manual. Danfoss can accept no responsibility for possible errors in the manual and instructions. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in speciﬁcations already agreed. All rights reserved. Contents provided herein must neither be distributed, copied, reproduced, edited or processed for any other purpose, nor otherwise translated or published without Danfoss’ express written consent.

PUMP

Type iSave 50 ERD Code no. 180FXXXX

Serial no. XXXXXX02-XXX

MADE IN DENMARK

Danfoss A/S, 6430 Nordborg, Denmark

This manual is valid for iSave 50 -70

Code No./Description Serial no.

180F7020 iSave 50 without motor

180F7021 iSave 70 without motor

180F7038 iSave 50 Vertical (IEC motor)

180F7023 iSave 50 horizontal (IEC motor)

180F704 0 iSave 70 vertical (IEC motor)

180F7025 iSave 70 horizontal (IEC motor)

XXXXXX02-XXX

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

180R9357 | AQ265943679828en-001001 IOM iSave 50 - 70 | 02.2022

Operating guide | iSave 50 - 70

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.

Ensure that these instructions are always readily available to all personnel concerned.

2.3 Symbols

Indicates something to be noted by

the reader.

Indicates a situation which will or

couldresult in damage to the iSave and its function.

Indicates a situation which will or could result in personal injury and/or damage to the iSave.

Electrical hazard. Indicates a high-voltage warning

Safety glasses required

Hearing protection required

Safety shoes required

Safety helmet required

2.4 Manufacturer and customer service

Danfoss A/S High Pressure Pumps DK-6430 Nordborg, Dinamarca Tel.: +45 7488 2222 E-mail: highpressurepumps@danfoss.com Homepage: hpp.danfoss.com

2.2 Target group

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

2.5 Country speciﬁc information

2.5.1 United Kingdom

Danfoss Ltd. 22 Wycombe End HP9 1NB Beaconsﬁeld United Kingdom

2.6 Additional technical documents

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

Document name Content

Service guide: 180R9387 Disassembling and assembling

Design guide: 180R9367 Pipe connection

Guide line: 180R9371 Pressure safety valve in SWRO systems

Guide line: 180R9370 Review sheet P&ID

Description of how to disassemble and assemble the iSave

Design guide on how to make har piping with Victaulic clamps

Guide line on how to evaluate if a safty valve is needed in a SWRO system

Detailed description about the need for each individual component in the preferred P&ID

180R9357 | AQ265943679828en-001001 IOM iSave 50 - 70 | 02.2022

Operating guide | iSave 50 - 70

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.

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

• Improper installation can cause fatal injuries.

• The iSave must not operate outside the application range.

• During the initial start-up, slowly raise the pressure of the system and adjust the over-pressure protection equipment for proper limit settings.

• Make sure that the pressure is released from the iSave before the iSave is disconnected from any pipe or hose connections.

• Make sure that the iSave can be drained without injuring anyone and without contaminating nearby equipment or the environment.

• Before intervening in the iSave/system, the power must be shut oﬀ and the starting device must be locked. When intervening in the iSave unit, follow the instructions for Service/Maintenance, chapter 8.

• A failure not to follow the instructions can result in personal injury and/or damage to the iSave. It will also invalidate the warranty.

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 the 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

operation and maintenance personnel of the responsibility of applying normal good judgment in the operation and care of this product.

3.2 Intended use

The iSave is designed for use as energy recovery device in Sea Water Reverse Osmosis (SWRO) or Brackish Water Reverse Osmosis (BWRO) system. The iSave must not be used for other purposes than recommended and quoted for without consulting your local iSave distributor.

3.3 Application range

For application range see data sheet 521B1378 available in appendix 10.1.

Applications not suitable for the iSave can cause damages to the iSave unit, with risk of personal injury.

180R9357 | AQ265943679828en-001001 IOM iSave 50 - 70 | 02.2022

Operating guide | iSave 50 - 70

3.4 Preferred system design

Danfoss recommends building systems with a high degree of safety. Our preferred system design can be found in the data heet in appendix

10.1.

• 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 protection equipment is essential.

4. Arrival inspection, handling and storage

4.1 Arrival inspection

The iSave is packed in a wood container. The iSave ports connector are protected by plastic caps that protect the iSave against dust and particles. Do not remove the caps before the system have been ﬂushed and the iSave can be installed.

Remove all packing materials immediately after delivery. Immediately check the shipment for damage on arrival and make sure that the name plate/type designation is in accordance with the packing slip and your order.

In case of damage and/or missing parts, a report should be drawn up and presented o the carrier at once.

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

PUMP

Type iSave 50 ERD Code no. 180FXXXX

Serial no. XXXXXX02-XXX

4.2 Return to the supplier

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

MADE IN DENMARK

Danfoss A/S, 6430 Nordborg, Denmark

4.3 Transport and Handling

•

• Personnel involved in lifting and transportation of the equipment must be trained in proper handling and safety procedures.

• Observe the local regulations regarding lifting.

• Use suitable, permitted lifting equipment.

• The iSave (set) could slip the lifting arrangement.

• Be aware of individuals located in the operation area while lifting the component.

The weight of the iSave including electric motor can be found in the datasheet. All parts weighing more than 20 kg (44 lb) must be lifted using lifting slings and suitable lifting devices, e.g. an overhead crane or fork lift.

Do not use connections/nozzles for

lifting. Do not use only one sling! Make sure that the load is balanced before attempting the lift.

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

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

180R9357 | AQ265943679828en-001001 IOM iSave 50 - 70 | 02.2022

When lifting the ERD without motor use the lifting eye

When you have ﬁnished using the lifting eyes, remove them to prevent corrosion.

Operating guide | iSave 50 - 70

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

Some motors and pumps have speciﬁc lifting eyes.

Do not use connections/nozzles for lifting! Always use two slings.

Lifting the iSave with electric motor (vertical):

The two lifting belts around the bell housing before lifting the unit.

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

4.4 Assembly iSave to electric motor

A: Elastic coupling B: Bell housing C: iSave shaft D. iSave ﬂange

1. Mount the coupling ﬂush or maximum 1 mm oﬀset from the iSave shaft end. Ensure an air gap between coupling parts of 3-5 mm (0.12-0.2 inch).

2. Mount the bell housing on iSave. Secure nuts with the right torque.

3. Measure the longest distance “A” from top of bell housing to the button of coupling claw.

4. Mount the coupling on motor shaft. Ensure the coupling and motor ﬂange are not in contact with each other.

5. Measure from motor ﬂange to the top of the coupling. That measurement “B” shall be 3-5 mm (0.12-0.2 inch) shorter than the measure me nt “A”.

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

180R9357 | AQ265943679828en-001001 IOM iSave 50 - 70 | 02.2022

Operating guide | iSave 50 - 70

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

6. Adjust respectively, verify the measure ment, and secure both couplings with the right torques on the locking screws (see coupling operation & mounting instruc tion).

7. Mount the elastic gear ring and mount the bell housing/iSave on the motor. After mounting it must be possible to move the elastic gear ring 3-5 mm (0.12 -

0.2 inch) axial “C”. The check can be done through the inspection hole of bell housing. Secure ﬂange bolts with the right torque.

2 3 1

If alternative mounting is desired, please contact Danfoss High Pressure Pumps.

Choose proper tolerances to ensure an easy mounting of the elastic coupling without use of tools.

Please take care to observe the recommended length tolerances of the chosen coupling, as an axial force on the pump will damage the pump.

(“C” can be found on the drawing below).

Thread size M5 M6 M8 M10

Torque (Nm) 2 4.8 10 17

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

4.5 Storage

When each iSave is tested before shipment in demineralized water. When tested the iSave is emptied and “plugged”, this will prevent frost damages. The storage temperature is is:

-40 °C to +70 °C (-40°F to 158 °F) – provided that the iSave is drained of ﬂuid and stored “plugged”.

Frost protection is required if the iSave is not completely drained of ﬂuids at temperatures below 1 °C .

Storage of iSave that have been in operation: For shorter periods of storage ﬂush the iSave with permeate and store. For long term storage (more than 2 months) Danfoss recommends servicing the product and clean any biological growth of the surfaces. Store the pump dry witout water inside.

3-5 mm

Danfoss recommends using DOWFROST from DOW Chemical Company or Chillsafe mono propylene glycol from Arco Chemical Company.

For further information on anti-freeze media, please contact Danfoss High Pressure Pumps.

The iSave is NOT delivered frost-protected from the factory. Only remove caps from the openings of the iSave at the time of installation.

4.6 Outdoor Storage

For outdoor storage cover the iSave (set) with waterproof material.

180R9357 | AQ265943679828en-001001 IOM iSave 50 - 70 | 02.2022

Operating guide | iSave 50 - 70

5. Technical data and design review

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

5.1 Design details

5.2 Sound level of the iSave

The A-weighted sound pressure level @ 1m, L

is for the iSave including the iSave motor.

PA, 1M

Measurement are according to EN ISO 3744:2010. The test is made under following conditions:

1. iSave and electrical motor mounted on Danfoss base plate.

2. Baseplate is isolated from concrete ground by rubber vibration dampers.

3. Flexible hoses are used on high pressure and low pressure sides of the iSave.

4. Rotation speed is max. rpm

5. System pressure max. allowable working pressure and a booster pressure of 3 barg.

Inﬂuences

Since the iSave is mounted on a base plate and connected to the electromotor by a bell housing, the noise level can only be determined for the complete unit (system). It is therefore important that the iSave unit is mounted correctly on a frame with dampers to minimise vibrations and noise.

Alternativamente, emplee acoplamientos Victaulic® ﬂexibles en la tubería rígida.

The noise level is inﬂuenced by:

• The speed of the iSave. High speed creates more noise than low speed.

• Rigid mounting of the iSave baseplate generates more noise than ﬂexible mounting

• Pipe mounting directly to the iSave increases the noise level compared to ﬂexible hoses.

• Higher pressure provides higher sound level.

5.3 Materials

All critical parts of the iSave are made of super-duplex 1.4410/UN S32750/1.4462/ UN S32205/S31803 or the like. Non-critical parts that are not in contact with sea water are made of AISI 316. The shaft to the electrical motor is sealed by a standardised mechanical seal.

It is also strongly recommended to use highpressure ﬂexible hoses between the hard piping in the RO plant and the iSave. See “Hose assembly and installation” 180R9084 in chapter10.5 and Guide line Pipe connections 180R9367. Alternative use multiple ﬂexible Victaulic® couplings on the hard piping.

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Operating guide | iSave 50 - 70

5.4 Temperature and corrosion

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

Duplex

316L

100

1000

160 1600

Depending on the NaCl concentration, the ﬂuid temperature must be between:

+2 °C y 50 °C (35,6 °F y 122°F).

Super Duplex

10 000

16000

100 000

160000

CI ppm

NaCI ppm

In order to minimise the risk of crevice

corrosion, always ﬂush the iSave according to the speciﬁed start/stop procedure.

5.5 Dimensions and weights

For dimensions and weights please refer to the iSave datasheet. See appendix 10.1

5.6 Electrical motor data

See datasheet in appendix 10.1 and “Operating and Maintenance instructions, electric motor” in appendix 10.7

5.7 How does the iSave work?

Figure 5.1 shows a section view of the iSave.

The iSave consists of a rotating isobargic pressure exchanger and a positive displacement pump, also called booster pump. The rotation speed of the pressure exchanger and the pump is exactly the same, as they are driven by the same electric motor.

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Operating guide | iSave 50 - 70

5.8 Seawater quality

5.81 Pre-ﬁltration

It is important that the incoming water is ﬁltered properly to assure optimum service life of the iSave. A true graded density melt-blown depth ﬁlter cartridge rated at 3 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 omponents in the RO system.

It is important to use a proper ﬁlter housing that allows a good seal between housing and ﬁlter cartridge. If there is a high risk of water by-pass it is recommended to use a second stage ﬁlter solution.

As the various ﬁlters on the market diﬀer greatly, Danfoss High Pressure Pumps recommends using cartridges with consistent, reliable performance and high eﬃciency, in which ﬁbres are blown continuously onto a central support core.

Danfoss High Pressure Pumps does not recommend cartridges requiring any type of binders or resins.

Filters can be purchased from Danfoss High Pressure Pumps.

5.8.3 Chemicals

The iSave can be ﬂushed with biocide like the membranes. The biocide must be compatible with the materials used in the iSave. iSave material can be found in the parts list, appendix 10.6.

5.8.4 Initial start up and ﬂushing

Prior to the initial start-up, all piping associated with the iSave unit should be thoroughly ﬂushed to assure that no impurities enter the iSave. Inadequate pre-ﬂushing will strongly aﬀect the life of the iSave and may lead to its eventual breakdown. It is essential that the water used for the ﬁnal pre-ﬂush is pre-ﬁltered to a level described in chapter 5.8 It is recommended to disconnect all connections to the iSave and to thoroughly ﬂush the piping before the iSave is connected to the inlet and outlet connections.It is recommended to install temporary basket strainers at both inlets to the iSave during the initial start-up and commissioning. Strainers do not eliminate the need for thoroughly pipe ﬂushing before commissioning.

Also see “Instruction for start and stop of the SWRO with iSave unit” - 180R9213 in appendix 10.2.

5.9 Initial start up and settings of safety equipment

The system designer is responsible to design the equipment according to the local regulations where the equipment is running. According to PED 2014/68/ EU a risk assessment must be made to identify and evaluate hazards which apply to his equipment on account of pressure.

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

5.8.2 A ir 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.

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

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

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Operating guide | iSave 50 - 70

To prevent such over-pressurisation, appropriate relief valves should be used and procedures should be implemented to safeguard the HP and LP sides of the iSave and/or the RO system.

5.12 High pressure remains after shutdown

The HP line of the RO system equipped with an iSave can remain pressurised for a long time after shutdown. Pressure decreases as water slowly leaks through the iSave. If more rapid system depressurisation is required, the system should be bled through a suitable valve on the HP concentrate line.

trado HP.

5.10 Flushing

RO membranes require periodic ﬂushing to limit biological fouling. There are two types of ﬂushing: feed water (Seawater) ﬂush and fresh water (Permeate) ﬂush. Regardless of the ﬂush water used, the water must be pre-ﬁltered to the level described in chapter 5.8. All parts of the iSave must be ﬂushed, i.e. LP- and HP ﬂow channels.

Follow the guide line 180R9213 “Start and stop of the SWRO with iSave in appendix 10.2.

It is required to ﬂush with permeate:

• After chemical treatment

• For stop more than 1 day the iSave must be rotated during permeate ﬂush

• Before long time shut down

It is required to ﬂush with fresh sea water prior to every shut down.

Special attention should be given to the pressure in the HP line (7) as the iSave may start to cavitate when it runs at high speed and the pressure in the P line (7) drops below 2 bargs. This can be avoided by reducing the speed of the iSave and keeping the pressurein the HP line at the minimum of 2 barg. At this low pressure the iSave may only run for a maximum of 10 minutes.

Always check the pressure in the high-pressure lines before making service in the HP lines or pressurised equipment.

5.13 Over-pressurisation caused by low pressure isolation

If the low-pressure side of the iSave is blocked and the iSave is exposed to high-pressure, there is a risk that the iSave or the LP piping could be damaged by over-pressurisation.

To prevent such over-pressurisation, appropriate relief valves should be used and procedures should be implemented to assure that the HP of the iSave is depressurised prior to the isolation of the LP side..

5.14 Over-pressurisation caused by the high-pressure pump.

Discharge pressure on the pump is generated only by the restriction in the pipelines, valves and membranes. The pump can build up pressure that will exceed the mechanical strength of the membrane vessels, pipes and other accessories. The pressure rise can be fast and may exceed the response time for electrical safety equipment, like pressure switch and control loop.

Failing to ﬂush the iSave with fresh water before extended shutdowns may result in extensive biological growth and cause corrosion in the iSave and other equipment in the RO system.

5.11 CIP or membrane cleaning

The purpose of membrane cleaning is to reduce scaling and fouling in the membranes. For optimal performance speciﬁc chemicals are required, depending on the cause of the pollution. After chemical treatment the system must be ﬂushed with permeate.

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

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

180R9357 | AQ265943679828en-001001 IOM iSave 50 - 70 | 02.2022

To prevent such over-pressurisation, appropriate relief valves should be used and procedures should be implemented to assure that the HP of the iSave is protected against excess pressure.

5.15 Explanation of P&ID set-up

See data sheet in appendix 10.1.

Operating guide | iSave 50 - 70

6. On-site installation 6.1 Design details

For safety instruction see chapter 3.

6.2 Installation and alignment

The ﬁgure below illustrates the major iSave components.

An unlocked bolt can result in personal injury and/or damage to the iSave

Misalignment of the base frame to the iSave may cause stress and/or damage.

6.3 Orientation

The iSave can be mounted horizontally and vertically.

When mounted vertically, the electric motor must be placed above the iSave.

6.4 Piping and joints

Piping material and schedule is of high importance. The strength of the Victaulic® connections is inﬂuenced by the material used for both the Victaulic® clamps and the hard piping.

The hard piping and connections used must be of proper design and must be installed in accordance with the manufacturer’s recommendations.

Hard piping to the iSave must be properly aligned to avoid stress on the iSave port connections. Pipe connection must be aligned as shown in the ﬁgures next page. Don’t use the iSave as a strain for hard piping.

The iSave is connected to the electric motor by the bell housing and a ﬂexible coupling. If not using Danfoss base frame both the iSave and the motor must be supported without applying stress/load to the bell

Ccrrect piping alignment Incorrect piping alignment

housing. Danfoss provides the iSave with a base frame and support brackets. Although the base frame is of a sturdy design, it can ﬂex or bend when it is bolted to the foundation. The base frame thus requires a solid foundation such as concrete or rigid steel frame. The base frame itself must be aligned to avoid bending caused by bolting to an uneven foundation.

Incorrect piping alignment

A rigid foundation for the iSave assembly is important, and must fulﬁl Eurocode 2: EN1992-1-1, and the iSave assembly must be bolted to the foundation with M12 bolts. The bolts used must be of proper design and must be installed in accordance with bolt manufacturer’s recommendations. To reduce noise it is recommended to use resilient mounts between the baseplate and

The hard piping and connections used must

be of proper design and must be installed in accordance with the manufacturer’s recom-

mendations. the foundation. Make sure that the bolts are properly locked and will stay locked over time.

A failure to comply with this will or may result

in personal injury and/or damage the iSave.

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Operating guide | iSave 50 - 70

Misalignment of the hard pipes may place stress on the iSave port connections and may damage the iSave.

6.5 Mounting of coupling

The ﬁgure below illustrates how to mount the ﬂexible coupling between the iSave and to connect it to the electric motor..

100 NM ± 10 NM

Min. 3 -5 mm air space

PUMP

Type iSave 50 ERD Code no. 180FXXXX

Serial no. XXXXXX02-XXX

MADE IN DENMARK

Danfoss A/S, 6430 Nordborg, Denmark

When connecting to the power supply, check the direction of rotation. The rotation can only be checked with water connected and iSave bleeded. This can be made by:

1. Looking at the fan in the end of the electric motor.

2. Removing the plug in the bell housing and watch the rotation of coupling.

3. Before assembling the iSave on the electric motor, check the rotation of the shaft on the electric motor.

A: Flexible coupling

40 NM ± 4 NM

B: Bell housing C: Motor shaft

Any axial and radial load on the shaft must be avoided.

6.6 Accessibility

With respect to the service and replacement of the complete iSave unit, it is recommended to maintain suﬃcient space around the unit.

The space must be suﬃcient enough to allow for safe lifting of the equipment, with no risk for personal injury and/or damage to the iSave.

6.7 Drives

6.7.1 Electric motor

The iSave must only be driven by an electric motor.

Special attention has to be on NON PROTECTED - FREE ROTATING shaft on the electric motor. Ignorance will or could result in personal injury.

Running the iSave in the wrong direction for more than a few minutes can cause unintended wear on the iSave. If the electric motor is running at a lower speed, extra care must be taken to ensure that the electric motor is NOT overheated. External cooling may be necessary.

6.7.3 Starting torque for the iSave

Because of the inertia and stick-slip friction of the iSave internal parts, the torque may exceed the maximum allowable operation torque for the iSave when the speed is ramped up from zero to maximum.

It is required to use a VFD. See Danfoss guide line 180R9372 “APP pumps and iSave overload protection”.

Using anything other than an electric motor can lead to an irreparable fracture of the iSave’s internal parts.

6.7.2 Speed control

The rotation speed on the electric motor can be controlled by a VFD. The VFD must be able to operate at constant torque over the whole range of speed. The direction of rotation can be seen on the identiﬁcation label.

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Operating guide | iSave 50 - 70

7. Commissioning, start-up and shutdown

6.7.4 Torque overload protection on the iSave

The electric motor and iSave must always be protected against overload.

As continuously operation the maximum torque on the iSave must be monitored.

The electric motor must be shut oﬀ if the maximum torque of the iSave exceeds the deﬁned limit.

If more electric motors are powered by the same VFD, each electric motor must be equipped with “torque limit equipment” to protect the iSave against overload.

Below are examples of equipment which can measure the load on the electric motor or limit the torque on the iSave.

7.1 Safety regulations

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

• Before starting up the iSave and the high-pressure pump, make sure that the following requirements are met:

• The iSave has been properly connected to the electric power supply and is quipped with all protection devices in accordance with EN 60204-1

• Check that all motor protections are properly set.

• All safety equipment, auxiliary equipment and connection required are properly connected and operational.

• Check all bolts in all connections and in the foundation of the iSave and the pumps.

7.2 Support

Danfoss A/S oﬀers commissioning and service at system manufacturer’s location. Rated quotes are oﬀered upon request.

1. VFD with integrated current monitoring relays.

2. External current monitoring relays suitablefor VFD control.

The electric motor and iSave must always be protected against overload. See Danfoss guide line 180R9372 “APP pumps and iSave overload protection” in the appendix

10.4.

If torque exceeds the maximum operation torque, it may lead to an irreparable fracture of the iSave’s internal parts.

7.3 Commissioning

Before starting up the iSave and the highpressure pump, make sure 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 that 10 barg, check the system for leakage.

Slowly raise the pressure in the system and set all pressure switches to the correct limit and continually check all connections.

• If pressure relief valve is present, set pressure relief valve on both low and high-pressure at the maximum system pressure.

• Check high-pressure hoses for proper assembly and inspect for external leakage for all connections.

• At low pressure, start the iSave and check direction of rotation.

• “Start and stop procedure” Guide line 180R9213. - appendix 10.2.

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Operating guide | iSave 50 - 70

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 main switch must be locked.

• The pressure in the high-pressure lines must be drained to the low-pressure side.

• The water in all connected pipes must be drained.

Always use suitable safety and lifting equipment when handling the iSave, and follow the instructions in chapter 4.3.

• Assure correct settings of safety equipment before start-up.

• When the system is re-started after service and maintenance follow the instruction in chapter 8 and in “Start and stop procedures” in guide line 180R9213 in appendix 10.2.

Three months after commissioning:

1. Re-check bolts in the foundation and the base plate of the iSave and tighten the bolts to speciﬁed torque if necessary.

2. Re-check alignment of the iSave base plate and iSave.

3. Visually inspect all pipe connections/ couplings for external leakage.

4. Re-check bolts in all pipe connections/ couplings and tighten the bolts to speciﬁed torque if necessary.

1. Replace ﬁlters if necessary.

2. Clean the ﬁlter housing and install the new ﬁlter. Make sure no debris enters the system.

3. Audibly inspect the iSave assembly. If there is irregular sounds or vibration inspect the internal parts of the iSave and replace if necessary.

Half year:

For vertical mounted electric motor lubricate motor bearings.

8.2 Support

Danfoss A/S oﬀers commissioning and service at the system manufacturer’s location. Tates/quotes are oﬀered upon request.

8.3 Maintenance schedule

The schedule of preventive maintenance below will help ensure that the iSave provides years of trouble-free performance.

One day after commissioning:

1. Re-check bolts in the foundation and the base plate of the iSave and tighten the bolts to speciﬁed torque if necessary.

2. Visually inspect all pipe connections/ couplings for external leakage.

3. Re-check bolts in all pipe connections/ couplings and tighten the bolts to speciﬁed torque if necessary.

1. Replace ﬁlters if necessary.

2. Clean the ﬁlter housing and reinstall ﬁlters. Make sure no debris enters the system.

Annually:

1. Re-check bolts in the foundation and the baseplate of the iSave and tighten the bolts to speciﬁed torque if necessary.

2. Re-check alignment of iSave base plate and iSave.

3. Visually inspect all pipe connections/ couplings for external leakage.

4. Re-check bolts in all pipe connections/ couplings and tighten the bolts to speciﬁed torque if necessary.

1. Replace ﬁlters if necessary.

2. Clean the ﬁlter housing and nstall the new ﬁlter. Make sure no debris enters the system.

3. Visually inspect iSave coupling and replace if necessary.

4. Audibly inspect the iSave assembly. If there is irregular sounds or vibrations inspect the internals parts of the iSave and replace if necessary.

5. Check power consumption. If there are irregular parts of the iSave and replace if necessary.

6. Lubricate motor bearings.

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Operating guide | iSave 50 - 70

8.4 Recommended service intervals on internal parts

Se below table. For detailed information on parts see Service guide 180R9392 Parts list.

Description Service interval Service interval (2nd, 3rd)

Tool kit Screw and seal kit 32.000 hours 26.000 hours Shaft seal kit 32.000 hours 26.000 hours Coupling kit 56.000 hours 56.000 hours

Port plate kit (PE), iSave 50

32.000 hours 26.000 hours

Port plate kit (PE), iSave 70 32.000 hours 26.000 hours Vane kit (8 pcs) Valve kit, Pressure exchanger 32.000 hours 26.000 hours Rotor element and sealing plates kt 32.000 hours 26.000 hours

8.5 Lubrication of bearings in electric

motor

Motors with a re-greasing system must be lubricated with high quality lithium complex grease, NLGI grade 2 or 3 with a temperature range between -40 °C to 150 °C.

For electric motors in vertical mount; grease every 6 months.

For electric motor in horizontal mount; grease every 12 months.

If the motor has increased vibrations or sound check the bearings.

Follow manufacturer’s recommendations for electric motor service and maintenance, see appendix 10.7.

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Operating guide | iSave 50 - 70

9. Trouble-shooting 9.1 Safety regulations

Before intervening in the iSave/system: The operator ensures that all inspection and installation work is performed by authorised, qualiﬁed specialist personnel who are thoroughly familiar with the manual.

• The power must be shut oﬀ and the starting device be locked.

• The pressure in the high-pressure lines must be drained to lowpressure side.

• The water in all connected pipes must be drained.

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

Problem Possible cause Action

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

VFD cannot deliver suﬃcient start torque

Ramp-up settings in the VFD are not correct. VFD is tilting

Choose a VFD that is designed for constant torque

Choose a VFD that is designed for suﬃcient start torque. See guide line 180R9372

Set ramp-up parameters correct. See guide line 180R9372

Valve (9) is closed Open valve (9)

Start the iSave only when the pressure in the HP line is low

Clean or change membranes

Torque on iSave is too high during operation

Pressure in the HP line (5) is too high

Pressure diﬀerence from HP-out (5) to HPin (10) is too high

Debris in the booster pump or iSave Clean the system

Wear in the booster pump or iSave Repair or change the parts

Design of the basic plant does not ﬁt the performance of the iSave

Change design to ﬁt the iSave performance

Permeate production is too low (17) 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 Correct speed on the HP pump

Check the HP pump and repair if necessary

Pressure on the membranes (5) is too high

Fouling on the membranes Clean the membranes Mixing in the iSave is too high Check ﬂow on LP-in (12) and adjust ﬂow

Flow out of the iSave is too low and causes a recovery rate that is too high

Check speed on iSave and change if necessary

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 Pressure on the membranes (5) is too low Incorrect speed on the HP pump

Check the HP pump and repair, if necessary

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Operating guide | iSave 50 - 70

180R9357 | AQ265943679828en-001001 IOM iSave 50 - 70 | 02.2022

Appendices

Energy Recovery Device

iSave 50-70 Appendices - Installation, Operation and Maintenance Manual

hpp.danfoss.com