Danfoss iSave 40 Service guide
Service guide
Instruction
Energy recovery device
iSave 40
Disassembling and assembling
Disassembling and assembling
iSave 40
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Service guide | Disassembling and assembling iSave 40
Table of Contents
1. General information.....................................................................2
2. Disconnect the iSave from electric motor ................................................3
3. Disassembling the booster pump .......................................................5
4. Assembling the booster pump ..........................................................8
5. Disassembling the pressure exchanger .................................................13
6. Assembling the pressure exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7. Assembling the cylinder drum in pressure exchanger ...................................19
8. Changing spring in the rotor ...........................................................20
8.1 Disassembling .........................................................................20
9. Exploded view vane pump .............................................................21
10. Exploded viewpressure exchanger .....................................................22
11. Exploded view iSave ...................................................................23
12. Exploded view iSave on baseplate, horizontal ...........................................24
13. Exploded view iSave on foot, vertical ...................................................25
1. General information
This document illustrates instructions for
disassembling and assembling the iSave 40.
To understand the design of the iSave, see
exploded views starting on page 21.
Always use suitable lifting equipment.
Important!
It is essential that the iSave is serviced in
conditions of absolute cleanliness.
Tools needed to disassemble the iSave:
Parts included in tool set (180F4112):
• 6 mm and 8 mm allen key
• C-wrench 24 mm
• 1 M6 bolt and nut
• Handel for rotor assembly
• Tool for shaft seal assembly
• Tool for retainer assembly
• 3 press bolt-set for valve plate assembly
Parts not included in tool set:
• 2 screwdrivers
• Torque wrench 10-60 Nm
• The weight of the iSave, including
electric motor, is about 260 kg (573 lb).
• The weight of the pressure exchanger
alone is about 75 kg (165 lb).
• The weight of the booster pump
alone is about 50 kg (110 lb).
To prevent cold welding, lubricate threads of the
screws with PTFE lubrication type and screw
them into the component and tighten by hand.
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Instruction Disassembling and assembling iSave 40
2. Disconnect the iSave
from electric motor
1. Apply a light lifting force on the pressure
exchanger and disconnect the support
bracket between the pressure exchanger
and base plate.
3. Unscrew the 2 upper bolts.
2. Unscrew 10 bolts in the adapter flange
between booster pump and pressure
exchanger. Leave the 2 upper bolts
tighten.
4. Carefully pull and lift the pressure
exchanger from the booster pump.
5. To disconnect the bell housing, unscrew
the 4 bolts on the electric motor.
180R9242 / 521B1213 / DKCFN.PI.003.R2.02 / 09.2013
6. Carefully pull and lift the booster pump
from the electric motor.
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Service guide | Disassembling and assembling iSave 40
7. Disassemble the bell housing from the
booster pump by unscrewing the 4 bolts
in the bell housing.
9. After the pressure exchanger is released
from the booster pump, remove the two
guide pins.
8. It is also possible to disconnect the
complete unit from the motor first. In this
case, please follow step 1, 5, 6 and 7
afterwards.
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Service guide | Disassembling and assembling iSave 40
3. Disassembling the
booster pump
M8x20 bolts marked A4
If flange cannot be removed easily, use two
M8 bolts.
1. Disassemble the flange for shaft seal.
3. If coupling has to be changed, follow the
next two steps.
4 x special M8x20 bolts
marked 1.4410
2. Wet the shaft seal first with clean filtered
water. Carefully lift the shaft seal by using
2 screwdrivers.
4. Unscrew the four special M8x20 bolts
marked 1.4410. Use a hammer handle at
the opposite end to prevent the shaft from
turning.
5. Remove coupling and the two pins.
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Service guide | Disassembling and assembling iSave 40
6. Loosen all the bolts in the adapter flange. 7. Carefully disassemble adapter flange and
port plate from the stator ring.
9. Remove the 8 vanes.8. Remove the sealing plate.
10. Carefully guide the rotor out of the stator. 11. Remove the sealing plate and pin.
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Service guide | Disassembling and assembling iSave 40
12. Remove the O-ring from the sealing
13. Unscrew the bolts in the outlet flange.
plate.
14. Remove the HP outlet flange. 15. Remove the port flange.
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Service guide | Disassembling and assembling iSave 40
4. Assembling the
booster pump WARNING:
Do not use silicone when assembling the
iSave. Do not reuse disassembled O-rings;
they might be damaged. Always use new
O-rings.
Important:
It is essential that the pump is serviced in
conditions of absolute cleanliness. All parts
must be absolutely clean before mounting.
Lubrication:
• To prevent seizing-up, lubricate all threads
with PTFE lubrication type.
• It is important to lubricate ALL parts to be
assembled with clean filtered water
(Especially all PEEK parts).
1. Place the HP outlet flange on the desk
and mount the O-ring and 2 pins.
3. Turn the stator with the two holes for the
lifting eye closest to the port plate and
position the stator on the 2 pins.
2. Align the port plate-out on the two pins
and mount the O-ring on the port plate.
4. From down side up and by hand, screw in
two bolts in the stator.
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Service guide | Disassembling and assembling iSave 40
5. Tighten the bolts by using an allen key.
6. Tilt the flange and stator; assemble and
screw in the rest of the bolts in the flange.
Tighten bolts to a torque of 60 ±6 Nm.
7. Assemble and position the two pins in the
pin holes.
9. Mount the O-ring in the sealing plate and
guide pin in flange.
It is important to lubricate to ensure the
O-ring does not drop out.
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