Danfoss iSave 40 User manual

isave.danfoss.com
User manual
Installation, Operation and
Maintenance Manual
iSave 40
Frontpage
Operation guide
Energy recovery device
iSave 40 series 04 and newer
Installation, Operation and
Maintenance Manual
hpp.danfoss.com

Operation guide | iSave 40
2180R9239 | AQ299555093252en-001601 | iSave 40 | 09.2022
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 specications 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.
Document information
and copyright
Validity
Code no. Serial no.
180F7001 XXXXXX04-XXX
180F7003 XXXXXX04-XXX
180F7004 XXXXXX04-XXX
180F7005 XXXXXX04-XXX
180F7011 XXXXXX04-XXX
This manual is valid for iSave 40:
The serial number is referring to the Serial no. on
the product label. The digits shown (04) indicate
the version number of the iSave.
This documentation is compatible with previous
pump versions.
Type iSave 40 ERD
Code no. 180FXXX
Serial no. XXXXXX04-XXX
ERD
Danfoss A/S, 6430 Nordborg, Denmark

Operation guide | iSave 40
3
180R9239 | AQ299555093252en-001601 | iSave 40 | 09.2022
Table of Contents
Document information and copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Validity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.2 Target group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.3 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.4 Manufacturer and customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.5 Country specic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.5.1 United Kingdom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.6 Additional technical documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. Safety instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.2 Intended use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.3 Application range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.4 Preferred system design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4. Arrival inspection, handling and storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.1 Arrival inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.2 Return to the supplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.3 Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.3.1 How to assemble the iSave and electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.3.2 Lifting the whole iSave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.3.3 Centre of mass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.4 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.5 Outdoor Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5. Technical data and design review. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.1 Design details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.2 Sound level of the iSave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.3 Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.4 Temperature and corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.5 Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.6 Electric motor data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.7 How does the iSave work?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.7.1 Pressure exchanger function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.7.2 Booster pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.7.3 Lubrication ow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.7.4 Volumetric mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
5.7.5 How does the iSave work in an RO system? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.8 Seawater quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.8.1 Pre-ltration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.8.2 Air bubbles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.8.3 Chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.9 Initial start up and ushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.10 Initial start-up and settings of safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
5.11 Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.12 CIP or membrane cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.13 High pressure remains after shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.14 Over-pressurisation caused by low pressure isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.15 Over-pressurisation caused by the high pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
5.16 Preferred system design and P&ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.17 Explanation of P&ID setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6. On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.2 Installation and alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.3 Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.4 Piping and joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.5 Flexible couplings and exible hoses.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.6 Mounting of coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.7 Accessibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.8 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.8.1 Electric motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.8.2 Speed control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.8.3 Starting torque on the iSave/ramping the electric motor.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6.8.4 Torque overload protection on the iSave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Operation guide | iSave 40
4180R9239 | AQ299555093252en-001601 | iSave 40 | 09.2022
Table of contents
7. Commissioning, start-up and shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.1 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.2 Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.3 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
8. Service/Maintnance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
8.1 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
8.2 Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
8.3 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
9. Trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
9.1 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
10. Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
10.1 General SWRO system understanding with iSave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
10.2 Instruction for start and stop of the SWRO with iSave unit (180R9213). . . . . . . . . . . . . . . . . . . .25
10.2.1 Prior to start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
10.2.2 Starting up the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
10.2.3 Daily system shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
10.2.4 2-14 days system shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
10.2.5 Long-term system shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
10.3 Membrane cleaning of the RO system with iSave unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
10.3.1 Membrane cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
10.3.2 P&ID no. 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
10.3.3 P&ID no. 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
10.4 Dimensional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
10.5 iSave parts list. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
10.5.1 Pressure exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
10.5.2 Booster pump (vane pump), partslist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
10.5.3 iSave, 180F7011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
10.5.4 iSave on base plate, horizontal, 180F7001 and 180F7004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
10.5.5 iSave on foot, vertical, 180F7003 and 180F7005 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
10.5.6 Tool kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
10.5.7 Exploded view vane pump iSave 40 series 04 and newer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
10.5.8 Exploded view pressure exchanger series 04 and newer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
10.5.9 Exploded view iSave series 04 and newer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
10.5.10 Exploded view iSave on base plate, horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
10.5.11 Exploded view iSave on foot, vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
10.6 iSave overload protection and VFD settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
10.6.1 Danfoss FC 300 Series with one iSave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
10.6.2 Danfoss Soft Starter MCD 500 Electrical schematic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
10.6.3 Protection by current monitoring relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
10.6.4 Danfoss FC 302 with two iSaves Electrical schematic diagrams according to EN60204-1.. .47
10.7 Hose assembly and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Appendices
1. Service guide - Disassembling and assembling (180R9242) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
2. Operating- and maintenance instruction, electric motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Operation guide | iSave 40
5
180R9239 | AQ299555093252en-001601 | iSave 40 | 09.2022
2. Introduction 2.1 General
iSave is manufactured by Danfoss A/S, and is sold
and marketed by a net of authorised distributors
worldwide.
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 instruc-
tions, especially the section “Safety” before:
• Transportation of the iSave unit.
• Lifting the unit.
• Installing the iSave unit on a frame.
• Connecting the iSave unit to the uid system.
• Connecting the electric motor and instrumen-
tation.
• Commissioning the unit.
• Servicing the iSave unit, mechanic and electrics-
parts.
• Decommissioning the iSave unit.
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 qualied training and experience in the
operation and maintenance of a Sea Water
Reverse Osmosis (SWRO) or Brackish Water
Reverse Osmosis (BWRO) system.
2.3 Symbols
Indicates something to be noted by the
reader
Indicates a situation which will or could
result 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, Denmark
Telephone: [phone]
Email: [email protected]
Homepage: www.hpp.danfoss.com
2.5 Country specic information
2.5.1 United Kingdom
UK importer:
Danfoss Ltd.
22 Wycombe End
HP9 1NB Beaconseld
United Kingdom
2.6 Additional technical documents
Document name Content
Instruction:
Start and stop of the SWRO with iSave unit
Description of how to start and stop the iSave in
the preferred RO system set-up
Instruction:
Membrane cleaning of RO system with iSave
unit
Description of how to clean the membranes
in the preferred RO system set-up
Dimensional drawings Description of the dimensions of the iSave
iSave parts list Sectional drawings, parts list and spare part
numbers
Instruction:
iSave overload protection
Electrical wiring diagram on how to protect the
iSave against overload / mechanical overload
protection of the iSave
Instruction:
Hose assembly and installation
Guideline for hose assembly and installation
Service instructions:
Disassembling and assembling
Description of how to assemble and disassem-
ble the iSave
Operating and maintenance instructions:
Electric motor
Operating and maintenance instructions for the
standard electric motor, delivered from Danfoss

Operation guide | iSave 40
6180R9239 | AQ299555093252en-001601 | iSave 40 | 09.2022
3. Safety instruction 3.1 General
The iSave must not be used for other purposes
than those described in 3.2 “Intended use”
without rst consulting your local iSave distribu-
tor.
This manual must be read and completely
understood by the responsible specialist
personnel prior to installation and commission-
ing.
Use of this manual does not relieve operation
and maintenance personnel of the responsibility
of applying normal good judgement in the
operation and care of this product and its
components.
The 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 ocer 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.
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 sup-
ported. 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.
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.
• 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 overpressure 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 o 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.
The iSave must never run dry. Dry
running produces heat and will cause
damage to internal parts.
If the iSave does not function satisfacto-
rily, contact your local iSave distributor.
Use of this manual does not relieve opera-
tion and maintenance personnel of the
responsibility of applying normal good
judgment in the operation and care of
this product.

Operation guide | iSave 40
7
180R9239 | AQ299555093252en-001601 | iSave 40 | 09.2022
3.3 Application range
The iSave should only be used within the
following limits:
1) Continuous torque above max. dierential pressure will harm the iSave
2) Pressure can reach this pressure level at start-up and permeate ush.
3) Intermittent pressure is acceptable for less than 10 minutes within a period of 6 hours.
4) Typical average ow at 60 barg
5) Dependent on NaCI concentration
6) Please see section 5.8.1 ltration
iSave size iSave 40
Code number 180F7011
Geometric displacement cm³/rev
in³/rev
626
38.2
Pressure
Dierential pressure HP in - HP out max. 1) bar 5
psi 72.5
HP min. inlet pressure barg 20
psig 290
HP max. inlet pressure barg 83
psig 1200
HP inlet min. pressure,
intermittent 2) 3)
barg 3
psig 43.5
LP inlet max. pressure barg 5
psig 72.5
LP inlet max. pressure intermittent 3) barg 10
psig 145
LP oulet min. pressure barg 1
psig 14.5
LP dierential LP in - out at HP max. ow bar 1.2
psi 17.5
Speed
Min. speed rpm 600
Max. speed rpm 1200
Typical ow
HP outlet ow range 4)
at max. dierential pressure
m³/h 21-41
gpm 92.4-180.5
Lubrication ow at 60 barg (871 psig) max. m³/h 0.8
gpm 3.5
LP inlet max. ow m³/h 67
gpm 295
Torque
Torque at max. dierential pressure
operation 1)
Nm 102
lbf-ft 75
Max. starting torque (stick/slip) Nm 150
lbf-ft 110
Media temperature 5)
oC2-40
oF36-104
Ambient temperature
oC0-50
oF32-122
Filtration requirements (nominal) 6) 5 micron melt-blow 85% ecient
Salinity increase at membrane at 40% recovery rate 2-3%
Weight kg 123
lb 271

Operation guide | iSave 40
8180R9239 | AQ299555093252en-001601 | iSave 40 | 09.2022
Asynchronous motor according to DIN-IEC and
VDE 0530 standards.
Voltage and frequency according to IEC 38.
The motors are tted 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
If delivered with NEMA motor see separate Data
sheet 521B1164
Insulation according to DIN-IEC 34 Class F
Ambient temperature 40°C, 1000 m above sea
level
Class B
Degrees of protection, minimum IP55
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 protection
equipment is essential.
The iSave 40 with code no 180F7001 and
180F7003 are delivered with a 11 kW
(15HP), 6 pole motor. If supply voltage is
maximum 400 V and the iSave shall
operate above 1100 rpm and boost at a
pressure of up to 5 bar, the motor shall be
sized up to a 15 kW (20 HP) (Code no.:
180F7004 and 180F7005) to ensure no
overload of motor.

Operation guide | iSave 40
9
180R9239 | AQ299555093252en-001601 | iSave 40 | 09.2022
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 identication label on the iSave states the
specic type, the serial number and the code
number of the iSave; see label below.
The last three digits of the Serial No. indicate the
week and year of production.
4.2 Return to the supplier
Flush the iSave with clean ltered water. Drain
the iSave and plug the port connections with a
cap/cover. Pack the iSave into a suitable con-
tainer and make sure that it is suitably fastened
to the container.
Please contact your local authorised distributor
or:
Danfoss A/S
High Pressure Pumps
DK-6430 Nordborg, Denmark
Telephone: [phone]
Fax: [phone]
Email: [email protected]
Homepage: www.hpp.danfoss.com
The weight of the iSave, including electric motor,
is between 260 -305 kg (573 lb-672 lb.) The
weight of the electric motor is about 110 kg
(242 lb). 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.
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.
Never lift the iSave unit with only one
fastening point.
Incorrect lifting can result in personally
injury and/or damage to the unit.
Never lift the iSave in the bell housing.
Incorrect lifting can result in personally
injury and/or damage to the unit.
• Personnel involved in lifting and
transporting 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.
4.3 Handling

Operation guide | iSave 40
10 180R9239 | AQ299555093252en-001601 | iSave 40 | 09.2022
4.3.1 How to assemble the iSave and electric
motor
1) The driver coupling is pre-mounted from
factory. Do not move the coupling.
2) Insert the coupling element into the coupling
in the bell housing.
3) Position the electric motor on the bell
housing. Make sure that the two coupling
parts are connected properly.
4) Tighten the 4 bolts.
Lift the electric motor ONLY in the lifting
eyes provided. The lifting eyes on the
motor must only be used for lifting the
motor – and not the whole unit.
4.3.2Lifting the whole iSave
Tie two lifting belts around the bell housing
before lifting the whole iSave.
Once the lifting is done the lifting
eye must be removed from the
pump.