Danfoss iSave 40 Service Manual
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Danfoss iSave 40 Service Manual

Energy recovery device
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Service guide
Instruction
Energy recovery device
Disassembling and assembling
iSave 40
iSave 40
Disassembling and assembling
ro-solutions.com
hpp.danfoss.com

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Summary of Contents for Danfoss iSave 40

  • Page 1 Service guide Instruction Energy recovery device Disassembling and assembling iSave 40 iSave 40 Disassembling and assembling ro-solutions.com hpp.danfoss.com...

  • Page 2: Table Of Contents

    Exploded view iSave on foot, vertical ...........25 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).

  • Page 3: Disconnect The Isave From Electric Motor

    Instruction Disassembling and assembling iSave 40 Disconnect the iSave Apply a light lifting force on the pressure Unscrew 10 bolts in the adapter flange from electric motor exchanger and disconnect the support between booster pump and pressure bracket between the pressure exchanger exchanger.
  • Page 4 Service guide Disassembling and assembling iSave 40 Disassemble the bell housing from the It is also possible to disconnect the booster pump by unscrewing the 4 bolts in complete unit from the motor first. In this the bell housing. case, please follow step 1, 5, 6 and 7 afterwards.

  • Page 5: Disassembling The Booster Pump

    Service guide Disassembling and assembling iSave 40 Disassembling the Disassemble the flange for shaft seal. If flange cannot be removed easily, use two booster pump M8 bolts. Wet the shaft seal first with clean filtered If coupling has to be changed, follow the water.
  • Page 6 Service guide Disassembling and assembling iSave 40 Loosen all the bolts in the adapter flange. Carefully disassemble adapter flange and port plate from the stator ring. Remove the sealing plate. Remove the 8 vanes. Carefully guide the rotor out of the stator.
  • Page 7 Service guide Disassembling and assembling iSave 40 Remove the O-ring from the sealing plate. Unscrew the bolts in the outlet flange. Remove the HP outlet flange. Remove the port flange. 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016...

  • Page 8: Assembling The Booster Pump

    Service guide Disassembling and assembling iSave 40 Assembling the booster pump WARNING: Lubrication: Do not use silicone when assembling the • To prevent seizing-up, lubricate all threads iSave. Do not reuse disassembled O-rings; with PTFE lubrication type. they might be damaged. Always use new •...
  • Page 9 Service guide Disassembling and assembling iSave 40 Tighten the bolts by using an allen key. 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.
  • Page 10 Service guide Disassembling and assembling iSave 40 Position the 8 pins in the rotor. 2 pins in Position the sealing plate on the guide pin. each hole. Ensure correct choice of sealing plate. Only one sealing plate fits the guide pin.
  • Page 11 Service guide Disassembling and assembling iSave 40 Assemble the new O-ring on the port Position the port flange in on the adapter plate-in. flange and position the two guide pins. Assemble the new O-ring on the correct Position the guide pin in the adapter sealing plate.
  • Page 12 Service guide Disassembling and assembling iSave 40 Mount two bolts in the adapter flange. Mount all bolts in the adapter flange. Tighten the bolts to a torque of 60±6 Nm. Turn the pump with shaft upwards. Using the shaft tool provided, carefully...

  • Page 13: Disassembling The Pressure Exchanger

    Service guide Disassembling and assembling iSave 40 Mount the two pins and the coupling part. Mount the four bolts and tighten them to a torque of 30 ±3 Nm. Disassembling the Unscrew the 3 coupling bolts. Remove coupling and the 3 pins.
  • Page 14 Service guide Disassembling and assembling iSave 40 Carefully take the cylinder barrel assembly Remove port plate and the two pins. out of the casing. Carefully lever the 2 valve plate assembly free with help from 2 screwdrivers. 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016...

  • Page 15: Assembling The Pressure Exchanger

    Service guide Disassembling and assembling iSave 40 Assembling the Lubrication: pressure exchanger WARNING: • To prevent seizing-up, lubricate all threads Do not use silicone when assembling the with PTFE lubrication type. iSave. Do not reuse disassembled O-rings; • It is important to lubricate ALL parts to be they might be damaged.
  • Page 16 Service guide Disassembling and assembling iSave 40 Position the port plate on the flange using Mount the provided M6 threaded rod into the two guide pins as guide. Only one port the shaft of the cylinder barrel. plate fits. Carefully guide the cylinder barrel into the Assemble the O-ring on the HP/LP flange flange bearing.
  • Page 17 Service guide Disassembling and assembling iSave 40 Position the port plate on the HP/LP flange Position the guide pin into the casing. using the two guide pins as guide. Only one port plate fits. Carefully position the flange assembly onto Carefully assemble a bolt into the casing to the guide pin in the casing.
  • Page 18 Service guide Disassembling and assembling iSave 40 Tighten the bolts to a torque of 30 ±3 Nm. Assemble booster pump and pressure exchanger. Mount the two guide pins and coupling spacer. Tighten bolts to a torque of 60 ±6 Nm.

  • Page 19: Assembling The Cylinder Drum In Pressure Exchanger

    Service guide Disassembling and assembling iSave 40 Assembling the The shaft is normally not a wear part and can cylinder barrol in only be changed by Danfoss. pressure exchanger Assemble back-up rings and O-rings on the Lubricate the O-rings and back-up rings valve plates.

  • Page 20: Changing Spring In The Rotor

    Service guide Disassembling and assembling iSave 40 Changing springs in It is basically not necessary to change the the pressure exchange springs in the rotor. If needed, follow the rotor. guidelines below: 8.1 Disassembling Replace springs in the rotor. Using the tool provided, press down the retainer and remove/cut the O-ring, and remove retainer.

  • Page 21: Exploded View Vane Pump

    Service guide Disassembling and assembling iSave 40 Exploded view vane pump 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016...

  • Page 22: Exploded Viewpressure Exchanger

    Service guide Disassembling and assembling iSave 40 10. Exploded view pressure exchanger 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016...

  • Page 23: Exploded View Isave

    Service guide Disassembling and assembling iSave 40 Exploded view iSave 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016...

  • Page 24: Exploded View Isave On Baseplate, Horizontal

    Service guide Disassembling and assembling iSave 40 12. Exploded view iSave on base plate, horizontal 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016...

  • Page 25: Exploded View Isave On Foot, Vertical

    Service guide Disassembling and assembling iSave 40 13. Exploded view iSave on foot, vertical 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016...
  • Page 26 Danfoss A/S High Pressure Pumps DK-6430 Nordborg Denmark 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 26 © Danfoss | DCS (im) | 2016.04...

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