Danfoss iSave 40 Service guide

Service guide

Energy recovery device iSave 40

Disassembling and assembling

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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.	• The weight of the iSave, including
			electric motor, is about 260 kg (573 lb).
		To understand the design of the iSave, see	• The weight of the pressure exchanger
		exploded views starting on page 21.	alone is about 75 kg (165 lb).
		Always use suitable lifting equipment.	• The weight of the booster pump
			alone is about 50 kg (110 lb).

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

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.

5.To disconnect the bell housing, unscrew the 4 bolts on the electric motor.

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.

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

1.Disassemble the flange for shaft seal.

3.If coupling has to be changed, follow the next two steps.

2.Wet the shaft seal first with clean filtered water. Carefully lift the shaft seal by using 2 screwdrivers.

If flange cannot be removed easily, use two M8 bolts.

4 x special M8x20 bolts marked 1.4410

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.

8.Remove the sealing plate.

10.Carefully guide the rotor out of the stator.

7.Carefully disassemble adapter flange and port plate from the stator ring.

9.Remove the 8 vanes.

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 plate.

14.Remove the HP outlet flange.

13.Unscrew the bolts in the 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.

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.

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).

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.

7.Assemble and position the two pins in the pin holes.

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.

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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