Danfoss iSave 21 Plus Installation, Operation And Maintenance Manual

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Data sheet

Operating guide

Headline Myriad Pro

Energy Recovery Device

max. 26/26 pt.

iSave 21 Plus

max. 3 rows

Installation, Operation and

Maintenance Manual

and min. 18/18 pt.

180R9401_AQ261351057880en-000803

hpp.danfoss.com

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Summary of Contents for Danfoss iSave 21 Plus

Page 1 Data sheet Operating guide Headline Myriad Pro Energy Recovery Device max. 26/26 pt. and min. 18/18 pt. iSave 21 Plus max. 3 rows Installation, Operation and Maintenance Manual 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11 hpp.danfoss.com...
Page 2 Manual. consent. Original operating manual document. Validity Danfoss can accept no responsibility for This manual is valid for iSave 21 Plus possible errors in the manual and instructions. Danfoss reserves the right Code no. Serial no. to alter its products without notice. This...
Page 3 Operating guide iSave 21 Plus Table of Contents Introduction ..........6 2.1 General .
Page 4 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) .
Page 5 Operating guide iSave 21 Plus 2. Introduction 2.1 General 2.3 Symbols iSave is manufactured by Danfoss A/S, and is sold and marketed by a net of authorised Indicates something to be noted by distributors world wide. the reader. This manual contains the necessary instruc-...
Page 6 Operating guide iSave 21 Plus 2.4 Manufacturer and customer service 2.5 Country speci c information address 1.4.1 United Kingdom Danfoss A/S DK-6430 Nordborg, UK importer: Denmark Danfoss Ltd. Telephone: +45 7488 2222 22 Wycombe End Email: highpressurepumpss@danfoss.com HP9 1NB Beacons eld Home page: hpp.danfoss.com...
Page 7 • All electrical installation work must be care of this product. hazard carried out by authorised personnel in If the recommendations in the manual are not followed, Danfoss reserves the right to void the warranty. © Danfoss | 2023.11 180R9401_AQ261351057880en-000803 | 7...
Page 8 Danfoss recommends building systems with recovery device in Sea Water Reverse a high degree of safety. The P&ID in chapter Osmosis (SWRO) or Brackish Water Reverse 5.16 shows the Danfoss preferred system Osmosis (BWRO) system. design. The iSave must not be used for other purposes than recommended and quoted •...
Page 9 The last three digits of the Serial No. indicate the week and year of production. PUMP Type iSave 21 Plus ERD MADE IN DENMARK Code no. 180BXXXX Serial no. XXXXXX02-XXX Danfoss A/S, 6430 Nordborg, Denmark 4.2 Return to the supplier...
Page 10 Operating guide iSave 21 Plus Check the mass (weight) of the iSave unit. devices, e.g. an overhead crane or industrial All parts weighing more than 20 kg must be truck. All iSave units weight more than lifted using lifting slings and suitable lifting 20 kg.
Page 11 Storage temperature: 1 °C to +70 °C (33 °F to 158 °F) – provided that the pump is drained of uid 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.
Page 12 Operating guide iSave 21 Plus 5. Technical data and 5.1 Design details design review 12 12 13: Coupling 1: 2” Victaulic connections 7: Cylinder drum 14: Adapter ange 2: Shaft 8: Port ange 15: Rotor 3: Low pressure shaft seal...
Page 13 Operating guide iSave 21 Plus Depending on the NaCl concentration, the 5.3 Materials All critical parts of the iSave are made of uid temperature must be between: +2 °C to super-duplex 1.4410/UN S32750 or the like. +50 °C (+35.6 °F to 122 °F).
Page 14 Operating guide iSave 21 Plus 5.7 How does the iSave work? Figure 5.1 shows a section view of the iSave The ow through the HP side of the iSave is The iSave consists of a rotating isobargic forced and controlled by the booster pump.
Page 15 Operating guide iSave 21 Plus 5.7.2 Booster pump The booster pump is a positive displacement pump, which means that the obtained when the energy loss on LP feed is ow is controlled by the speed of the equal to or less than the energy loss caused electric motor;...
Page 16 RO system. into the HP membranes. The iSave energy As the various lters on the market recovery technology thus signi cantly di er greatly, Danfoss High Pressure reduces ow needed from the main HP Pumps recommends using cartridges pump (4).
Page 17 Operating guide iSave 21 Plus 5.8.2 Air bubbles 5.10 Initial start-up and settings of safety Large bubbles in a pressurised RO system equipment can result in damage to piping and The high-pressure pump feed water into the equipment. All air must be bleed from both...
Page 18 Operating guide iSave 21 Plus 5.11 Flushing 5.12 CIP or membrane cleaning RO membranes require periodic ushing to The purpose of membrane cleaning is to limit biological fouling. reduce scaling and fouling in the There are two types of ushing: feed water membranes.
Page 19 Operating guide iSave 21 Plus 5.14 Over-pressurisation caused by low pressure isolation 5.15 Over-pressurisation caused by the If the low-pressure side of the iSave is high pressure pump. blocked and the iSave is exposed to The HP pump may be able to generate a...
Page 20 Operating guide iSave 21 Plus 5.16 Preferred system design and P&ID Media filter Filter Filter 3 micron 10 micron nominel absolut Permeate Flowmeter Full flow cleaning LP in HP out iSave Fresh water permeate flush HP in Drain Second stage filter: If recommended housing design and cartridges are not used, a second stage filter is required Explanation of P&ID setup...
Page 21 An unlocked bolt can result in personal injury and/or damage to the iSave. Danfoss provides the iSave with a baseplate and support brackets. Although the Misalignment of the base plate may baseplate is of a sturdy design, it can ex or...
Page 22 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 in uenced by the material Misalignment of the hard pipes may used for both the Victaulic® clamps and the place stress on the iSave port hard piping.
Page 23 Operating guide iSave 21 Plus 6.5 Flexible couplings and exible hoses 6.7 Mounting of bell housing on iSave The strength of the Victaulic® connections is The gure below illustrates how to mount in uenced by the material used for both the the bell housing on the iSave.
Page 24 Operating guide iSave 21 Plus It is required to use a VFD or a soft starter. 6.9 Drives 6.9.1 Electric motor The iSave must only be driven by an electric motor. A minimum of 10 seconds is required when ramping up the Using anything other than an speed from zero to maximum.
Page 25 • Start the system according to the “Start and stop procedure” instructions in appendix. 10.1 7.2 Support Danfoss A/S o ers commissioning and service at system manufacturer’s location. Rate quotes are o ered upon request. © Danfoss | 2023.11 180R9401_AQ261351057880en-000803 | 25...
Page 26 4. Re-check bolts in all pipe connections / couplings and tighten the bolts to speci ed torque if 8.2 Support Danfoss A/S o ers commissioning and necessary. service at the system manufacturer’s 5. Replace lters if necessary. location. Rate quotes are o ered upon 6.
Page 27 Operating guide iSave 21 Plus 8,000 hours of operation after commissioning: Dimensions of the vanes 1. Re-check bolts in the foundation iSave type iSave 21 Plus and the baseplate of the iSave and Original height (H) 27 mm tighten the bolts to speci ed torque...
Page 28 Operating guide iSave 21 Plus 9. Trouble-shooting 9.1 Safety regulations The operator ensures that all Before intervening in the iSave/system; inspection and installation work is • The power must be shut o and the performed by authorised, quali ed starting device be locked.
Page 29 Operating guide iSave 21 Plus Appendices Energy Recovery Device iSave 21 Plus Installation, Operation and Maintenance Manual © Danfoss | 2023.11 180R9401_AQ261351057880en-000803 | 29 hpp.danfoss.com...
Page 30 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) .
Page 31 Data sheet Design guide Headline Myriad Pro max. 26/26 pt. iSave Energy Recovery Device and min. 18/18 pt. max. 3 rows Start and stop of the SWRO with iSave 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11 hpp.danfoss.com...
Page 32 Operating guide iSave 21 Plus Prior to start-up................................33 Table of Contents Starting up the system..............................33 Daily system shutdown..............................34 More than one day system shutdown........................35 32 | 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11...
Page 33 21 Plus Below procedures are general guidelines for the Prior to start-up start-up and shut-down functions of SWRO-sy- stems with the Danfoss iSave Energy Recovery High quality water extends the service life of the Device. whole system. Procedure details may di er depending on the Both the APP pump and iSave are sensitive to system design.
Page 34 Operating guide iSave 21 Plus Start the iSave(s). “LP-out” pressure (14) is below 1 barg/ 14.5 psig, adjust the ow by raising the In general: Only start the iSaves when the ow from the seawater supply pump (A). pressure ”HP in” (10) is below 20 barg/290 3.
Page 35 Operating guide iSave 21 Plus More than one day system shutdown If possible run the iSave at its minimum allowable speed. 1. Run the “daily system shutdown” procedure. 4. Start the APP pump(s) in a period of 5 sec. by 2.
Page 37 Data sheet Design guide Headline Myriad Pro Energy Recovery Device max. 26/26 pt. and min. 18/18 pt. iSave max. 3 rows Membrane cleaning of RO-system 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11 hpp.danfoss.com...
Page 38 Operating guide iSave 21 Plus Membrane cleaning..............................39 Table of Contents Starting up the system ..............................40 Starting up the system ................................41 38 | 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11...
Page 39 21 Plus Below procedures are general guidelines for Membrane cleaning the membrane cleaning of SWRO-systems with the Danfoss iSave. Procedure details may di er The procedures below are based on Dow’s depending on the system design. Cleaning and Sanitization: Cleaning steps described in Dow’s Form No.
Page 40 Operating guide iSave 21 Plus Feed the cleaning solution at high ow into Open valve (9) and continue ushing. the “full ow cleaning” adapter (7). The high The iSave(s) may start to rotate backward – ow rate ushes out the foulants removed this is OK.
Page 41 Operating guide iSave 21 Plus 10. Flush RO permeate or deionised water into the “full ow cleaning” adapter (7) on the feed side of the membrane. Flush out the cleaning solution. 11. When ushing is nalised – Close the high It is essential that the water used for the nal pressure “full ow cleaning”...
Page 43 Data sheet Data sheet Headline Myriad Pro max. 26/26 pt. and min. 18/18 pt. Energy Recovery Device max. 3 rows iSave 21 Plus / iSave 40 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11 hpp.danfoss.com...
Page 44 Assembled iSave 21 Plus and iSave 40 without electric motor ......52 Assembled iSave 21 Plus and iSave 40 with IEC electric motor ......54 Assembled iSave 21 Plus and iSave 40 with NEMA motor .
Page 45 21 Plus 1. General information iSave 21 Plus iSave 40 The iSave 21 Plus and iSave 40 consists of an The vane pumps are xed displacement pumps isobaric pressure exchanger, a high-pressure in which the ow is proportional to the number positive displacement booster pump and an elec- of revolutions of the driving shaft –...
Page 46 Operating guide iSave 21 Plus 1.2 iSave 40 1. 3” Victaulic connections 2. Shaft 3. Low pressure shaft seal 4. Port ange 5. Port plate 6. Valve plate 7. Cylinder barrel 8. Port ange 9. Sealing plate 10. Pins 11. Vanes 12.Port plate...
Page 47 Operating guide iSave 21 Plus iSave size iSave 21 Plus iSave 40 Technical data Code number 180F7015 180F7011 3.1 iSave without motor cm³/rev Geometric displacement In³/rev 16.7 38.2 Pressure Di erential pressure HP in - HP out max. 72.5 72.5 barg HP max.
Page 48 VFD must be able to deliver 140% start torque. The If voltage is below 400 V we recommend to use Danfoss VFD type FC 301 and FC 302 can be used. another size of electric motor. For advice on VFD settings, please consult our Please contact Danfoss High Pressure Pumps for relevant guideline or contact Danfoss.
Page 49 Operating guide iSave 21 Plus 3.3 iSave with NEMA motor (can only be ordered through Danfoss US) iSave iSave 21 Plus iSave 21 Plus iSave 40 Code number horizontal 180U0013 180U0052 180U0012 Code number vertical 180U0013 180U0052 180U0002 Motor size NEMA version...
Page 50 Operating guide iSave 21 Plus The diagram shows that the HP ow can be For accurate data please use our selection tool Flow at di erent rpm changed by changing the rotation speed of the which is available on our website: iSave.
Page 51 High rpm makes more uid/structure-borne pulsations/vibrations than low rpm due to higher frequency. Noise level (dB(A) measured for the iSave 21 Plus and 40 at di erent speed and system pressure. Booster pressure 3 bar. iSave 21 Plus iSave 40...
Page 52 Operating guide iSave 21 Plus iSave drawings 8.1 Assembled iSave 21 Plus and iSave 40 without electric motor iSave 21 Plus 52 | 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11...
Page 54 Operating guide iSave 21 Plus 8.2 Assembled iSave 21 Plus and iSave 40 with IEC electric motor iSave 21 Plus, 5.5 kW, 4 pole, IEC motor 54 | 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11...
Page 55 Operating guide iSave 21 Plus iSave 21 Plus, 7.5 kW, 4 pole, IEC motor © Danfoss | 2023.11 180R9401_AQ261351057880en-000803 | 55...
Page 56 Operating guide iSave 21 Plus iSave 40 - horizontal, 11 kW, 6 pole, IEC motor 56 | 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11...
Page 57 Operating guide iSave 21 Plus iSave 40 - horizontal, 15 kW, 6 pole, IEC motor © Danfoss | 2023.11 180R9401_AQ261351057880en-000803 | 57...
Page 58 Operating guide iSave 21 Plus iSave 40 - vertical, 11 kW, 6 pole, IEC motor 58 | 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11...
Page 59 Operating guide iSave 21 Plus iSave 40 - vertical, 15 kW, 6 pole, IEC motor © Danfoss | 2023.11 180R9401_AQ261351057880en-000803 | 59...
Page 60 Operating guide iSave 21 Plus 8.3 Assembled iSave 21 Plus and iSave 40 with NEMA motor iSave 21 Plus, 10 HP, 4 pole, NEMA motor 60 | 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11...
Page 61 Operating guide iSave 21 Plus iSave 21 Plus, 15 HP, 4 pole, NEMA motor © Danfoss | 2023.11 180R9401_AQ261351057880en-000803 | 61...
Page 62 Operating guide iSave 21 Plus iSave 40 - horizontal, 20 HP, 6 pole, NEMA motor 62 | 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11...
Page 63 Operating guide iSave 21 Plus iSave 40 - vertical, 20 HP, 6 pole, NEMA motor © Danfoss | 2023.11 180R9401_AQ261351057880en-000803 | 63...
Page 64 Note: Any axial and radial load on the shaft top of the iSave. must be avoided. The iSave 21 Plus baseplate can be used for both horizontal and vertical installations. The iSave 40 has a base when installed vertical. min. 3 - 5 mm air space...
Page 65 Thoroughly clean pipes and ush system control pressure in low-pressure out. prior to start-up. H. Although the iSave 21 Plus automatically will B. Place a monitoring pressure switch set (3) at bleed itself, there should be an air bleed valve...
Page 66 Operating guide iSave 21 Plus Performance curves 11.1 Performance and torque curves iSave 21 Plus Differential pressure vs. flow at LPin 22,0 30,8 39,6 48,4 57,2 66,0 74,8 83,7 92,5 101,3 110,1 26,1 23,2 20,3 17,4 14,5 11,6 11,0 13,0...
Page 67 Operating guide iSave 21 Plus Torque for iSave 21 and motor at 60 barg system pressure 62,7 59,0 55,3 51,6 47,9 44,3 40,6 36,9 33,2 29,5 25,8 22,1 18,4 14,8 11,1 1000 1100 1200 1300 1400 1500 1600 1700 © Danfoss | 2023.11...
Page 68 Operating guide iSave 21 Plus 11.2 Performance and torque curves iSave 40 Di erential pressure, low pressure 1.40 1.20 1.00 0.80 0.60 0.40 0.20 0.00 Lubrication ow 1.00 0.90 60 barg 0.80 0.70 0.60 0.50 30 barg 0.40 0.30 0.20 0.10...
Page 69 Operating guide iSave 21 Plus Torque for iSave 40 motor at 60 barg system pressure lbf ft 110.63 103.26 95.89 88.50 81.13 73.75 66.38 59.00 51.63 44.25 36.88 29.50 22.13 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.
Page 70 21 Plus 12. Service 12.1 Warranty Standstill The Danfoss iSave is designed for long operation, The iSave is made of Duplex or Super Duplex low maintenance and reduced lifecycle costs. materials with excellent corrosion resistance. However, it is always required to ush the iSave Provided that the iSave has been running when the system is shut down.
Page 71 Data sheet Parts list Headline Myriad Pro max. 26/26 pt. and min. 18/18 pt. max. 3 rows Energy Recovery Device iSave 21 Plus 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11 hpp.danfoss.com...
Page 72 Exploded view iSave 21 Plus ........
Page 73 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. © Danfoss | 2023.11...
Page 74 Operating guide iSave 21 Plus Pressure exchanger Note: The parts listed are not sold seperately, only in various kits Exploded view, see following pages. 180F4101 180F4102 180F4155 180F4156 180F4157 Pos. Qnt. Designation Material Valve Port plate, Port plate, Sealing plate...
Page 75 Operating guide 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 180F4157 180F4162 180F4158 Sealing kit Vane kit Side plate Stator ring «Super Duplex PEEK»...
Page 76 Operating guide iSave 21 Plus Exploded view, see following pages. iSave 21 Plus on base plate Pos. Qnt. Designation Coupling 180Z0244 iSave 21 Base plate Bell housing Electric motor Coupling Bolt M10 × 30 A4 Washer Bolt M6 × 16 A4...
Page 77 Operating guide iSave 21 Plus Exploded view Vane pump © Danfoss | 2023.11 180R9401_AQ261351057880en-000803 | 77...
Page 78 Operating guide iSave 21 Plus Exploded view Pressure exchanger 78 | 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11...
Page 79 Operating guide iSave 21 Plus Exploded view iSave 21 Plus © Danfoss | 2023.11 180R9401_AQ261351057880en-000803 | 79...
Page 81 Data sheet Instruction Headline Myriad Pro max. 26/26 pt. and min. 18/18 pt. Right and wrong max. 3 rows Hose assembly routing tips 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11 hpp.danfoss.com...
Page 82 Correct hose installation is essential for safe and Hose routing tips: satisfactory performance. The size of the hoses Danfoss recommends installing hose whip impacts the installation recommendations. This restraints whenever your pressurized hose manual has therefore been split in recommenda- assemblies are in proximity to personnel or tion for hoses up to 2”...
Page 83 Operating guide iSave 21 Plus WRONG RIGHT WRONG RIGHT To prevent hose collapse and ow 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 speci cation table on page 6 for minimum bend radii.
Page 84 Operating guide iSave 21 Plus Whenever possible, high pressure hoses should Danfoss 3” HP hoses are nylon reinforced; when Hoses larger than 2” always be connected directly to Danfoss pro- using hoses that are not steel reinforced the vided adapters and check valves. Elbows and...
Page 85 Operating guide iSave 21 Plus MAX. BENDING ANGLE The use of pipe or ttings between pump and iSave connectors and hoses should be avoided. Such con gurations can apply excessive loads on the connectors and can cause connector and/or connector bolt failure.
Page 86 Operating guide iSave 21 Plus Hose speci cation table High pressure hoses Pipe Hose size Hose length Code Pipe connection connection Inner ISO 1436 Bending radius number material diameter 1.5" Vic. OGS Super duplex 180Z0228 25.4 mm (1.0") 0.66 m (26") 152 mm (6.08"), max.
Page 89 Operating guide iSave 21 Plus Electric Motors Motor Manual hoyermotors.com M a n u a l © Danfoss | 2023.11 180R9401_AQ261351057880en-000803 | 89...
Page 90 Operating guide iSave 21 Plus Motor Manual General etc.) using suitable tools, never hit the drive components with a hammer as this will cause damage to the bearing. This manual concerns the following types of standard The motor are balancing with half key, ensure that the drive induction motors from Hoyer: components are also the same.
Page 91 Operating guide iSave 21 Plus Motor Manual connections must be checked and tightened if necessary. The table values are based on an ambient temperature of Bearing size and type are speciﬁed on the rating plate. Motor 25°C. The values must be halved for every 15K increase in types HMA3 and HMC3 is as standard with lifetime greased bearing temperature.
Page 92 Operating guide iSave 21 Plus Connection diagram Anschlußdiagram Anslutningdiagramm Forbindelsesdiagram Aansluitdiagram Connection Conexión Collegamento Schemat polacsen 92 | 180R9401_AQ261351057880en-000803 © Danfoss | 2023.11...
Page 94 T +86 574 26 28 15 77 · F + 86 574 2628 1573 sweden@hoyermotors.com korea@hoyermotors.com hoyermotors@hoyermotors.cn hoyermotors.com hoyermotors.com hoyermotors.cn Important notice. Text and data in this catalogue are not binding and we reserve the right to implement changes without further notice. 94 | 180R9401_AQ261351057880en-000803 © Danfoss | DCS-SGDPT/SI | 2023.11...

This manual is also suitable for:

180f7015 180f7016 180f7017 180f7018