Danfoss iSave 50-70 Service Manual

Service guide

Energy Recovery Device

iSave 50-70 Disassembling and assembling

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Service guide | Disassembling and Assembling, iSave 50-70

1. Introduction

Table of Contents

Contents

1. Introduction .............................................................................................................................................................. 2

2. Disconnect the isave from the electric motor ............................................................................................. 3

3. Disassembling the booster / vane pump ...................................................................................................... 4

4. Disassembling the pressure exchanger .......................................................................................................12

5. Assembling the pressure exchanger ..............................................................................................................16

6. Assembling the booster/vane pump .............................................................................................................17

7. Continue assembling the pressure exchanger ...........................................................................................18

8. Continue assembling the booster/vane pump .........................................................................................20

9. Exploded view iSave 50-70 ................................................................................................................................25

10. iSave on baseplate, horizontal .........................................................................................................................26

11. iSave on foot, vertical .........................................................................................................................................27

This document illustrates instructions for disassembling and assembling the iSave 50-70.

To understand the design of the iSave, see exploded view on page 25.

Remove all hoses or pipes from the iSave connectors by loosening the Victaulic connections and disconnect the electrical cables (only needed for the vertical version.)

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 (180F4140):

• Back-up ring tool

• Bushing for valve plate

• M6 and M8 screws

• M6 and M16 washer

• Nut M6

• M8 lifting eye

• Shaft seal tool

• 24 mm crow foot socket

• 19 mm socket

• 3/8” extension

• 3/8” torque wrench

• 4 mm allen key

• Screwdrivers

• 6 mm, 10 mm and 16mm hex socket

• Nylon hammer

• 10 mm fork wrench

• Feeler gauge

• Service instruction

Parts not included in tool set:

Puller for coupling. 2 x M5 screws

To prevent cold welding, Danfoss recommend only to use a food grade lubricants for all screw threads for assembling the iSave (here after only referred to as lubricate) and rst tighten the screws by hand.

• The weight of the iSave, including a

18.5 kW IEC electric motor and base frame, is about 462 kg (1020 lb) dry.

• The weight of the iSave alone dry is

about 164 kg (362 lb).

Service guide | Disassembling and Assembling, iSave 50-70

2. Disconnect the isave from the electric motor

1. For the vertical version mounted on the Danfoss base frame, safely mount lifting straps around the electrical motor to ensure straight vertical lifting. See Operation guide, chapter 4.

3. Carefully lift the electrical motor straight up and away from the iSave.

Place the electrical motor safely horizontal or vertically between 2 brackets. (Don’t place it on the coupling ! ! !)

2. Unscrew the 4 bolts on the electrical motor using a 24 mm wrench.

4. Unscrew the 4 bolts inside the bell housing and remove the bolts and washers using a 19 mm socket and extension tool.

5. Carefully remove the bell housing from the

iSave.

6. Measure the distance between shaft seal ange and the coupling to be able to reassemble it back to the same distance.

Service guide | Disassembling and Assembling, iSave 50-70

7. Loosen the screw in the coupling using

a 4 mm allen key for a “European coupling”. Carefully remove the coupling without damaging the shaft (sometimes a puller is needed). Remove the key in the shaft.

2. If the shaft seal ange can’t be removed easily, screw in 2 x M8 bolts which will push out the shaft seal ange.

1. Disassemble the shaft seal ange by

unscrewing the 4 bolts using a 6 mm allen key or socket.

3. Lubricate the Shaft seal with clean ltered

water and carefully remove the shaft seal using 2 screwdrivers.

4. Unscrew the 15 bolts from the motor ange using a 10 mm allen key or socket.

3. Disassembling the booster / vane pump

Service guide | Disassembling and Assembling, iSave 50-70

5. Mount 2 x eyebolts in 2 of the M12 holes

and carefully remove the motor ange and place it carefully with the bearing side upwards.

6. Visually check the side plate, rotor stop and motor ange surface for wear and scratches.

7. Remove the rotor stop by hand only using

a M8 screw.

8. Carefully remove the side plates using a small screwdriver.

9. Check the rotor stop thickness using a micrometer. Replace if below 10,80 mm.

10. Check the side plates thickness using a micrometer. Replace if below 11.55 mm.

Service guide | Disassembling and Assembling, iSave 50-70

11. Put a small amount of lubricant in the hole. Lubricate the rotor stop and hole with clean ltered water and carefully by hand press in the rotor stop.

12. Lubricate the O-rings, side plate and ange with clean ltered water.

Mount the r st O-ring in the cut ou t in the ange.

13. Mount the second new O-ring in the bottom on the ange.

14. It is important that the inside groove in the side plates are pointing upwards

16 Remove the 2 pins in the stator housing.

15.Carefully by hand only press down the side plate.

Always change rotor stop and side plate at the same time as changing the rotor elements.

Service guide | Disassembling and Assembling, iSave 50-70

18. Carefully lift out the rotor (make sure the pins do not drop out and that the vanes do not get damaged).

17. Mount the M8 lifting eye in the rotor shaft end.

19. Remove the rotor elements in the rotor

using the small screwdriver in the 2 small cut outs in the rotor.

20. Remove by hand the rotor elements and check and replace the rotor elements if necessary.

Always change rotor stops and side plates at the same time as changing the rotor elements.

21. Lubricate the rotor elements, rotor and ‘

O-ring with clean ltered water. Replace the O-ring in the rotor elements. Make sure not to damage or twist the O-rings.

22.Mount the rotor elements by hand, by carefully pushing them into the rotor. Make sure not to damage or twist the O-rings.

Service guide | Disassembling and Assembling, iSave 50-70

23.The rotor elements can only be pushed in until the surface is slightly above the rotor surface. There is not any special placement of the grooves in the rotor elements.

24. The O-ring will try to slip out in the 2 cut out holes. Carefully press it in with a small screwdriver.

25. Remove the 8 vanes from the stator

housing.

26. Remove the green spider from the internal coupling.

27. Unscrew the 4 coupling screws using

the 6 mm allen socket.

28. Remove the coupling from the cylinder shaft. If sticking, screw in 2 x M5 bolts (not in tool kit) which will allow a better grip to pull out the coupling.

Service guide | Disassembling and Assembling, iSave 50-70

29. Remove the 2 pins in the cylinder shaft

end.

30. Mount 2 lifting eyes across from each other in the stator housing to equal the weight and use a lifting strap to lift the stator housing.

32. Remove the nuts and washers (the stud bolts may get loose and fall down).

33. Carefully lift away the stator housing incl.

the intermediate ange and port plate which is xed on the intermediate ange and the stud bolts. (The small pin may fall out).

34. Unscrew the stud bolts using a 6 mm allen key to avoid the stud bolts get bended before placing the stator housing horizontally.

31. Unscrew the stud bolt nuts below the

exchange connection ange using a 19 mm socket.

Service guide | Disassembling and Assembling, iSave 50-70

35. Unscrew and remove the lifting eyes

and lifting strap and turn the stator housing up so that the port plate is upwards to avoid damage.

36. Remove the port plate from the 2 clips using a screwdriver.

37. Visually check the port plate for wear/

scratches and using a straight edge ruler across the sealing surfaces and replace if needed.

38. Remove the 2 clips, 2 pins and the O-ring.

39. Remove the small pin for xing the exchanger housing in the intermediate ange.

Service guide | Disassembling and Assembling, iSave 50-70

40. Unscrew the 15 bolts in the intermediate ange using a 10 mm allen key or socket.

41. Mount 2 lifting eyes across from each other in the intermediate ange to equal the weight and use a lifting strap to lift the ange away from the stator housing.

42. Remove the lifting eyes and strap and

place the intermediate ange with the bearings side upwards.

45.

Remove the 2 pins from the stator housing.

43. Visually check all the intermediate ange bearings for wear/scratches. Replace the O-ring.

44. Remove, check and replace rotor stop, side plate and O-rings - see items 7 - 15 on page 5 and 6.

Service guide | Disassembling and Assembling, iSave 50-70

4. Disassembling the pressure exchanger

3. Disassemble the 2 valve plates by

screwing in 2 x M8 bolt in the 2 holes with threads which press out the valve plate.

1. Mount the M8 lifting eye on the cylinder

barrel shaft end and carefully lift the cylinder barrel out of the housing using lifting equipment. (The weight of the cylinder barrel is about 32 kg).

2. Place the cylinder barrel horizontal and secure it can’t roll and remove the lifting eye.

Changing springs in the cylinder barrel.

It is not necessary to change the springs in the cylinder barrel. If needed follow the guidelines below:

3.1 Disassemble the spring cover using 2 x M6 screws with 2 nuts and 2 washers and rst tighten the screws to max. 10 Nm. Cross tighten the nuts until the O-ring is fully visual.

3.2 Carefully disassemble or cut the O-ring with the small screwdriver and unscrew the 2 x screws, 2 nuts and 2 washers.

Service guide | Disassembling and Assembling, iSave 50-70

4. Visually check both the valve plates sealing surface for wear/scratches and use a straight edge ruler across the sealing surface and replace if needed.

3.3 Remove the spring cover by hand and check and replace springs if necessary. Assembling: Lubricate the thread holes in the cylinder barrel with lubrication and mount the spring cover by hand over the springs.

6. Calibrate the back up rings using the plastic tool from the tool set, before mounting the O-rings. Proper mounting is very important!!!

5. Lubricate the back-up rings, O-rings and the valve plates with clean ltered water. Replace the back-up rings and O-rings on the valve plates (back-up ring rst).

Make sure back-up rings are not

twisted.

3.4 Screw in the 2 x M6 screws with 2 x nuts and 2 washers and tighten the screws to max. 10 Nm. Cross tighten the nuts to press down the spring cover

3.5 Lubricate the new O-ring and cylinder shaft with clean ltered water and mount the new O-ring by hand in the O-ring groove. Remove the 2 x M6 screws with nuts and washers.

Service guide | Disassembling and Assembling, iSave 50-70

8. Mount the 2 x M6 nuts, 2 x M6 washers and bushings for valve plate on the 2 x M6 screws and then mount them (only by hand) in the holes with the undercut. Mount 2 x M16 washers equally between the 2 screws at the big shaft end.

7. Lubricate the back-up rings, O-rings and the holes in the cylinder barrel with clean ltered water. Place the valve plates with the 2 holes with the undercut over the 2 thread holes in the cylinder barrel.

10. Remove the exchanger housing from the port ange by carefully using a plastic hammer and remove the small pin. (The pin may fall out).

11. Remove the port plate from the 2 clips

using a screwdriver.

12.

Visually check the port plate for wear and scratches using a straight edge ruler across the sealing surfaces and replace if needed.

9. Cross tighten the 2 x M6 nuts to press down the valve plates equally. The valve plate at the small shaft end should be pressed all the way in until you feel a small resistance (max. 10 Nm). The valve plate at the big shaft end should only be pressed in until it is still possible to remove the 2 x M16 washers (2-3 mm space left).Remove the 2 x M6 screws with the nuts, washers and the bushings for valve plate.

Service guide | Disassembling and Assembling, iSave 50-70

12. Replace the 2 clips, the 2 pins and the O-ring.

13. Replace the small pin in the intermediate ange.

Service guide | Disassembling and Assembling, iSave 50-70

WARNING: Do not use silicone when assembling the iSave. Do not reuse disassembled O-rings and the shaft seal as 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 completely clean before mounting.

Lubrication:

• To prevent seizing-up, lubricate all threads.

• It is important to lubricate ALL parts to be assembled with clean ltered water (Especially all PEEK parts).

5. Assembling the pressure exchanger

1. Lubricate the port ange and port plate with clean ltered water. Mount the port plate (brine) over the new clips and pins on the port ange. Make sure that the clips are below the

port ange surface.

3.

Mount the lifting eye on the cylinder barrel big shaft end and carefully lower the cylinder barrel straight into the exchanger housing using lifting equipment. (The weight of the cylinder barrel is about 32 kg).

Afterwards remove the lifting eye.

WARNING: If the cylinder barrel is dropped or

lowered too fast into housing, the bearing in the Port ange might be damaged. Replacement can only be done at Danfoss, DK-Nordborg.

2. Check that the new small pin is still placed in the port ange and place the exchanger housing carefully over the small pin.

Service guide | Disassembling and Assembling, iSave 50-70

6. Assembling the booster/vane pump

1. Mount the 2 pins and a new O-ring. Place the intermediate ange with 1 or 2 screw holes over the edge on a desk.

2. Mount 2 lifting eyes across from each other in the stator housing to equal the weight and use a lifting strap to place it over the 2 pins in the intermediate ange with the bearing upwards.

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 completely clean before mounting.

Lubrication:

• To prevent seizing-up, lubricate all threads.

• It is important to lubricate ALL parts to be assembled with clean ltered water (Especially all PEEK parts).

3.

Lubricate the screws. Mount by hand only a few screws from below and tilt the stator housing and intermediate ange. Mount the remaining screws and cross tighten all to the torque according to exploded view.

Service guide | Disassembling and Assembling, iSave 50-70

2. Mount 2 lifting eyes across from each other in the stator housing to equal weight. Carefully lower the stator housing into the 6 stud bolt holes and small pin.

Remove the 2 lifting eyes and the lifting

strap.

1. Lubricate the stud bolt. Tilt the stator housing and the intermediate ange with the port plate mounted horizontally. Mount the stud bolts in the intermediate ange and tighten to the torque according to exploded view.

7. Continue assembling the pressure exchanger

5. Lubricate the intermediate ange and port plate (feed) with clean ltered water and mount the port plate (feed) over the clips and pins.

Make sure that the clips are below the port ange surface.

4. Lubricate small pin and the small pin hole and mount 2 new clips, 2 new pins and a new O-ring on the intermediate ange.

Service guide | Disassembling and Assembling, iSave 50-70

4. Lubricate the stud bolt threads. Mount the 6 Stud bolt washer and nuts below the exchange connection ange.

6. Mount the 2 pins in the cylinder shaft end.

5. Cross tighten to the torque according to exploded view.

7. Lubricate the coupling screw. Mount one internal coupling part and mount 4 coupling screws.

8. Cross tighten to the torque according to exploded view.

3. Check that the small pin is in correct position.

Service guide | Disassembling and Assembling, iSave 50-70

9. Mount the green spider inside the internal coupling.

1. Mount a lifting eye in the rotor shaft end and mount the 8 pins inside the rotor.

3. Remove the lifting eyes and mount the 2 pins in the stator housing.

4. Lubricate the vanes and the rotor slides with clean ltered water.

2. Carefully lower the rotor straight into the

stator housing, internal coupling and green spider.

8. Continue assembling the booster/vane pump

Service guide | Disassembling and Assembling, iSave 50-70

5.

Mount the 8 vanes. (Steel inside vanes should be visible clock wise to the shaft center.)

8.

Mount 2 x eyebolts in 2 of the M12 holes in the motor ange and carefully lower the motor ange on the stator housing and the 2 pins. (Be carefully not to scratch the bearings).

6.

Apply a thin layer of lubrication (not water) on the O-ring for the motor ange.

7. Make sure to

mount the O-ring correctly in the groove so that it does not twist. Remove excess lubrication from the motor ange. This is to keep the O-ring in place when turning the ange upside down.

9. Lubricate all the screws but rst mount only 4 screws that are evenly placed around the motor ange.

10. By hand only carefully cross tighten the 4 screws (max. 10 Nm) to ensure the motor anges are tightened evenly onto the stator housing.

Service guide | Disassembling and Assembling, iSave 50-70

15. Remove the ceramic ring of the shaft seal in the shaft seal cover using a screwdriver.

14. Press down the shaft seal to the shoulder/ recess of the shaft using the plastic press bush tool.

13. Only lubricate the new shaft seal with clean ltered water and mount the shaft seal over the shaft end with the carbon ring upwards.

12. Mount the remaining 11 screws in the motor ange and cross tighten all the screws to the torque according to exploded view.

11. Check with a 0.05 mm feeler gauge that there is no gap between the motor ange and stator housing. If there is a gap loosen one or more screws and retighten them again.

16. Lubricate the new shaft seal with clean ltered water and press the new ceramic ring into the shaft seal cover using the plastic press bush tool. Warning:

Ensure that the face with rubber seal is

positioned against shoulder/recess

in shaft seal

cover and the

ceramic ring upwards.

Service guide | Disassembling and Assembling, iSave 50-70

20. Mount the spider and the bell housing over the shaft seal cover outside diameter.

18. Lubricate the shaft. Mount the key in the shaft end and mount the coupling. Adjust the coupling and ange distance to the same as measured before the disassembling.

19. Tighten the screw inside the coupling to the torque according to exploded view.

21. Lubricate the 4 screws and mount the washers and screws inside the bell housing. Tighten the screws to the torque according to exploded view.

17. Lubricate the screws. Mount a new O-ring on the shaft cover and mount it on the motor ange. Tighten the screws to the torque according to exploded view.

22. Carefully lift the electrical motor from the support.

Service guide | Disassembling and Assembling, iSave 50-70

23. Carefully lower it onto the iSave ( turn the electrical motor coupling using a screwdriver through the inspection hole in the bell housing so it ts into the spider and the other coupling).

25. Lubricate the screws. Mount the 4 screws and washers and tighten to the torque according tothe drawings in chapter 10 and 11.

26. Remove the lifting straps. Mount all hoses or pipes to the iSave connectors and connect the electric cables correctly again.

24. Check through the inspection hole in the bell housing that the coupling distance still has 3 - 5 mm free space.

3 - 5 mm

Also remember to retighten all the screws and nuts on the base frame with the torque according to chapter 10 and 11.

Service guide | Disassembling and Assembling, iSave 50-70

9. Exploded view iSave 50-70

Service guide | Disassembling and Assembling, iSave 50-70

10. iSave on baseplate, horizontal

Service guide | Disassembling and Assembling, iSave 50-70

11. iSave on foot, vertical

Danfoss A/S High Pressure Pumps DK-6430 Nordborg Denmark

180R9387 | 521B1430 | DKCFN.PI.013.1H.02 | 28

Danfoss iSave 50-70 Service Manual

Specifications and Main Features

Frequently Asked Questions

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