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Doc270052309985 2
Doc270052309985 2
Data sheet
Energy Recovery
Energy Recovery Device Device
iSave 21 Plus / iSave 40
iSave 21-40
Body text
www.iSave.danfoss.com
www.danfoss.com hpp.danfoss.com
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
1. General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 iSave 21 Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 iSave 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2. Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 iSave without motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 iSave with IEC motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.3 iSave with NEMA motor (can only be ordered through Danfoss US) . . . . . . . . . . . . . . . . . . . . . . 7
5. Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
7. Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8. iSave drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.1 Assembled iSave 21 Plus and iSave 40 without electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.2 Assembled iSave 21 Plus and iSave 40 with IEC electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8.3 Assembled iSave 21 Plus and iSave 40 with NEMA motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
12. Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
12.1 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
12.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
12.3 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
I
1. General information
iSave 21 Plus
iSave 40
The iSave 21 Plus and iSave 40 consists of an The vane pumps are fixed displacement pumps
isobaric pressure exchanger, a high-pressure in which the flow is proportional to the number
positive displacement booster pump and an of revolutions of the driving shaft – enabling flow
electric motor. control.
The isobaric pressure exchangers are based on The electric motor provides speed control of
the technology used in the Danfoss APP pumps, both the pressure exchanger and the high-
and the high-pressure booster pumps are based pressure booster pump on the same shaft
on the vane pump principle enabling a very light – preventing overspin/overflushing.
and compact design. The design of iSave 21 Plus
and iSave 40 ensures lubrication of the moving The iSaves need a VFD that allows the motor to
parts by the fluid itself. apply a constant torque from low speed to
maximum speed.
All parts included in the iSave 21 Plus and iSave
40 are designed to provide long service life with The sectional drawings below illustrate the main
a constant high efficiency and minimum service components of the iSave 21 Plus and iSave 40,
required. respectively
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. Vanes
12. Port plate
13. Coupling
14. Adapter flange
15. Rotor
16. Stator
17. Port flange
18. Outlet flange
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. Vanes
12.Port plate
13. Coupling
14. Adapter flange
15. Rotor
16. Stator
17. Port plate
18. Outlet flange
(HP)
High-pressure inlet
(HP)
High-pressure outlet
(LP) (LP)
Low-pressure inlet Low-pressure outlet
521B1464 | DKCFN.PD.003.4B.02 | 2018.05 5
Data sheet | Energy Recovery Device | iSave 21 Plus and iSave 40
A)
Differential pressure HP in - HP out max. is limited
to 3 bar [44 psi]
1)
Three-phase-asynchronous-motor according to 5)
The starting torque must not exceed the values
DIN-IEC and VDE 0530 standards. stated under “Max. starting torque (stick/slip)”. The
• Voltage and frequency according to IEC 38 VFD must be able to deliver 140% start torque. The
• The motors are fitted with a rating plate in Danfoss VFD type FC 301 and FC 302 can be used.
multi-tension: 380-420 V / 660-720 V, 50 Hz or For advice on VFD settings, please consult our
440-480 V, 60 Hz relevant guideline or contact Danfoss.
• Tolerance ± 5% according to VDE 0530
• Standard coating according to IEC 60721-2-1 6)
A-weighted sound pressure level at 1 meter from
the pump unit surfaces (reference box) acc. to EN
2)
If voltage is below 400 V we recommend to use ISO 20361 section 6.2. The noise measurements are
another size of electric motor. performed acc. to EN ISO 3744:2010 on ERD with
Please contact Danfoss High Pressure Pumps for motor (motor-pump unit) at max. pressure and
further information. speed.
3)
Torque load for iSave and motor see diagram 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.
3.3 iSave with NEMA motor (can only be ordered through Danfoss US)
1)
Three-phase-asynchronous-motor according to 5)
The starting torque must not exceed the values
NEMA MG-1 and UL 1004-1 standards. stated under “Max. starting torque (stick/slip)”. The
• Insulation class F, service factor 1.25. VFD must be able to deliver 140% start torque. The
• Fan-cooled TEFC (IC411). Voltage and frequency Danfoss VFD type FC 301 and FC 302 can be used.
according to NEMA MG-1 part 12. For advice on VFD settings, please consult our
• The motors are fitted with a rating plate 230 / relevant guideline or contact Danfoss.
460 V, 60 Hz.
• Plus or minus 10% of rated voltage, with rated 6)
A-weighted sound pressure level at 1 meter from
frequency. Standard coating according to the pump unit surfaces (reference box) acc. to EN
motor supplier specifications. ISO 20361 section 6.2. The noise measurements are
performed acc. to EN ISO 3744:2010 on ERD with
2)
Max. speed for iSave 21 is 1500 rpm. motor (motor-pump unit) at max. pressure and
speed.
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.
4. Flow at different rpm The diagram shows that the HP flow can be For accurate data please use our selection tool
changed by changing the rotation speed of the which is available on our website:
iSave. The flow/rpm ratio is constant, the www.isave.danfoss.com
required flow is obtainable by changing the
rotation speed to a required value. The iSave is delivered with a 3.1 performance
certificate according to EN10204.
35 154
30 132
25 110
m3/h
i Sa ve 21 Pl us
gpm
20 88
15 66
10 44
5 22
0 0
500 600 700 800 900 1000 1100 1200 1300 1400 1500
rpm
80 º C Duplex
70
Super Duplex
60
50
316L
40
30
20 -
100 1000 10 000 100 000 CI
ppm
160 1600 16000 160000 NaCI
ppm
6. Noise level The noise level for the iSaves is measured at max.
speed, a pressure of 80 barg and a booster Pressure:
pressure of 5 bar. Since the iSave is mounted on a • High pressure makes more noise than low
bell housing and electric motor, the noise level pressure.
can only be determined for the complete unit Mounting:
(system). • Rigid mounting makes more noise than
flexible mounting due to structure-borne
It is therefore important that a horizontal iSave vibrations.
unit is mounted correctly on a frame with Connections to iSave:
dampeners to minimize vibrations and noise. • Pipes connected directly to the iSave make
We recommend to mount a vertical iSave directly more noise than flexible hoses due to
to the floor with bolts. It is also strongly recom- structure-borne vibrations.
mended to use high-pressure flexible hoses • Variable frequency drives (VFD):
between the hard piping in the RO-plant and the Motors regulated by VFDs can increase noise
iSave or to use multiple connections with level if the VFD does not have the right
Victaulic clamps. settings.
Noise level (dB(A) measured for the iSave 21 Plus and 40 at different speed and system pressure.
Booster pressure 3 bar.
7. Filtration It is important that the incoming water is filtered support core. High Pressure Pumps does not
properly to ensure optimum service life. A true recommend cartridges requiring any type of
graded density, melt-blown depth filter cartridge 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 High Pressure Pumps. Please see section 10.0,
housing to ensure good cartridge end sealing. “RO systems with an iSave”, for installation of
If there is a high risk of water by-pass it is filter. For more information on the importance of
recommended to use a second stage filter proper filtration, please consult our publication
solution. “Filtration” (code number 521B1009), which also
will provide you with an explanation of filtration
As the various filters on the market differ greatly, definitions and a guidance on how to select the
Danfoss High Pressure Pumps recommends right filter.
using cartridges with consistent, reliable
performance and high efficiency and where
fibres are blown continuously onto a central
iSave 21 Plus
iSave 40
A: Flexible coupling
B: Bell housing
C: Motor shaft
A B C
The iSave is connected to the electric motor by a The iSave and motor must be supported without
bell housing and coupling. applying stress/overload to the bell housing.
If a horizontal iSave is delivered without base If a horizontal iSave is delivered with a baseplate,
plate it is important to support the iSave and a rigid mounting surface is required such as
motor. The bell housing is not able to carry the concrete foundation, optional base frame or a
weight of either the iSave or the motor when container with suitable steel substructure.
using horizontal mounting.
VFD
Media filter 4
Filter Filter PI PI
3 micron 10 micron 3 5 6
M
PI nominel PI absolut 2 PS PS 17
1 Permeate
F
F
18 Flowmeter
F
12 Full flow
cleaning 8
LP in 7
HP out
* 11 10
Fresh water iSave PI 9
permeate flush
HP in
M
16 28
CIP
VFD 13 14
PS PI 20 15 27
F
Drain
19
* Second stage filter: If recommended housing design and cartridges are not used, a second stage filter is required
Explanation of P&ID setup E. In order to eliminate the risk of damage and
cavitation, a positive pressure at the low-
A. Place inlet filters on LP string in front of the pressure outlet from the iSave is always to be
iSave (11). Inlet filters assure proper water maintained at minimum 1 barg (14.5 psig) and
quality. High quality water extends the maximum 10 barg (145 psig). It is recommen-
service life of the whole system. It is impor ded to install monitoring pressure switch (13)
tant with selection of a proper filter housing in order to prevent high/low-pressure.
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. F. Install a VFD to control the speed of the iSave.
Please consult section 7, “Filtration” for
guidance on how to select the right filter. G. Install a pressure and flow control valve (15) to
Thoroughly clean pipes and flush 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
minimum inlet pressure between filter and (8) installed on the highest point of the
pump inlet. The monitoring switch must stop high-pressure piping to ensure proper
the iSave (11) and the high-pressure pump (4) bleeding of the RO system.
at pressures lower than minimum inlet
pressure. I. The pressure relief valve (6) protects the
whole system against pressure overload and
C. Dimension the piping to obtain minimum relieves the water if the pressure exceeds the
pressure loss (large flow, minimum pipe maximum set pressure.
length, minimum number of bends/connec- If the high-pressure pump is a positive
tions and fittings to prevent pressure loss and displacement pump, the pump can built up a
flow turbulence). Use flexible hoses to very high pressure that will exceed mechani-
minimize vibrations and noise. cal strength of the membrane housing, pipes
and other accessories.
D. To balance the flow between high-pressure
out and low-pressure in, place a variable area J. The pressure relief valve (19) protects the
flow meter (12) on low-pressure inlet to the low-pressure pipes against pressure overload
iSave. and relieves the water if the pressure exceeds
the maximum allowable pressure.
1,6 23,2
1,4 20,3
1,2 17,4
1,0 14,5
bar
psi
0,8 11,6
0,6 8,7
0,4 5,8
0,2 2,9
0,0 0,0
5,0 7,0 9,0 11,0 13,0 15,0 17,0 19,0 21,0 23,0 25,0
m3/h
0,35 1,54
0,30 1,32
0,25 1,10
60 ba rg
m3/h
gpm
0,20 0,88
0,15 0,66
30 ba rg
0,10 0,44
0,05 0,22
0,00 0,00
5,0 7,0 9,0 11,0 13,0 15,0 17,0 19,0 21,0 23,0 25,0
m3/h
50 62,7
59,0
45
55,3
51,6
40
47,9
35 44,3
40,6
30 36,9
33,2
lb ft
Nm
25
29,5
20 25,8
22,1
15 18,4
14,8
10
11,1
7,4
5
3,7
0 0,0
400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700
rpm
1.20
15
1.00
0.80
10
0.60
0.40
5
0.20
0.00 m3/h
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
20
22
24
26
28
30
32
34
36
38
40
42
44
Lubrication flow
m3/h gpm
1.00
0.90
60 barg
0.80 3
0.70
0.60
0.50
0.40 30 barg
1.5
0.30
0.20
0.10
0.00 m3/h
40
42
44
20
22
24
26
28
30
32
34
36
38
20 rpm
00
50
00
50
00
0
0
60
65
70
75
80
85
90
95
10
10
11
11
12
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.
12. Service
12.1 Warranty
The Danfoss iSave is designed for long operation, Standstill
low maintenance and reduced lifecycle costs. The iSave is made of Duplex or Super Duplex
materials with excellent corrosion resistance.
Provided that the iSave has been running However, it is always required to flush the iSave
according to the Danfoss specifications, Danfoss when the system is shut down.
guarantees 8,000 hours service-free operation,
however, max. 18 months from date of produc- 12.2 Maintenance
tion. In our experience, poor filtration is the number
one cause of iSave damage. Danfoss recom-
The life of an iSave may be greatly shortened if mends an periodic inspection where worn parts,
Danfoss recommendations concerning system if any, must be replaced. This is done in order to
design are not followed. 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.
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. 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 trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.