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.

Danfoss iSave 50-70 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual