Danfoss iSave 40 Service Manual
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Danfoss iSave 40 Service Manual

Energy recovery device, disassembling and assembling
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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

    Service guide | Disassembling and assembling iSave 40 Table of Contents General information..............2 Disconnect the iSave from electric motor .

  • Page 3: Disconnect The Isave From Electric Motor

    Instruction Disassembling and assembling iSave 40 Disconnect the iSave from electric motor Apply a light lifting force on the pressure Unscrew 10 bolts in the adapter flange 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 complete unit from the motor first. In this in the bell housing.

  • Page 5: Disassembling The Booster Pump

    Service guide | Disassembling and assembling iSave 40 Disassembling the booster pump Disassemble the flange for shaft seal. If flange cannot be removed easily, use two M8 bolts. If coupling has to be changed, follow the next two steps. Wet the shaft seal first with clean filtered Unscrew the 4 coupling bolts.
  • 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 Unscrew the bolts in the outlet flange. plate. Remove the HP outlet flange. Remove the port flange. 180R9242 | AX073186502910 en-000501 | 08.2019...

  • 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 Tilt the flange and stator; assemble and Tighten the bolts by using an allen key. 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 sealing plate on the guide Position the 8 pins in the rotor. 2 pins in 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 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 Mount the four bolts and tighten them to part. a torque of 30 ±3 Nm. Disassembling the pressure exchanger 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 assem- bly out of the casing. Remove port plate and the two pins. Carefully lever the 2 valve plate assembly free with help from 2 screwdrivers. 180R9242 | AX073186502910 en-000501 | 08.2019...

  • 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 Mount the provided M6 threaded rod into using the two guide pins as guide. Only the shaft of the cylinder barrel. one port plate fits.
  • Page 17 Service guide | Disassembling and assembling iSave 40 Carefully assemble a bolt into the casing Carefully position the flange assembly to ensure that flange assembly stays in onto the guide pin in the casing. place. Assemble all the bolts and tighten them to Mount the 3 pins in shaft and place the a torque of 30 ±3 Nm.
  • Page 18 Service guide | Disassembling and assembling iSave 40 Tighten bolts to a torque of 60 ±6 Nm. Assembling the cylinder barrol in pressure exchanger O-ring Back-up ring The shaft is normally not a wear part and can only be changed by Danfoss.

  • Page 19: Assembling The Cylinder Drum In Pressure Exchanger

    Service guide | Disassembling and assembling iSave 40 Small shaft diameter: No distance. Large shaft diameter: Distance 4-5 mm. Changing springs in the pressure exchange rotor. It is basically not necessary to change the springs in the rotor. If needed, follow the guidelines below: 8.1 Disassembling...

  • Page 20: Changing Spring In The Rotor

    Service guide | Disassembling and assembling iSave 40 Assemble the retainer over the springs. Assemble the O-ring over the retainer. Using the tool provided, press down the Carefully lever the bolt and tool assembly retainer by tightening the nut until the and check the O-ring assembly.

  • Page 21: Exploded View Vane Pump

    Service guide | Disassembling and assembling iSave 40 Exploded view vane pump 180R9242 | AX073186502910 en-000501 | 08.2019...

  • Page 22: Exploded Viewpressure Exchanger

    Service guide | Disassembling and assembling iSave 40 10. Exploded view pressure exchanger 180R9242 | AX073186502910 en-000501 | 08.2019...

  • Page 23: Exploded View Isave

    Service guide | Disassembling and assembling iSave 40 Exploded view iSave 180R9242 | AX073186502910 en-000501 | 08.2019...

  • Page 24: Exploded View Isave On Baseplate, Horizontal

    Service guide | Disassembling and assembling iSave 40 12. Exploded view iSave on base plate, horizontal 180R9242 | AX073186502910 en-000501 | 08.2019...

  • Page 25: Exploded View Isave On Foot, Vertical

    Service guide | Disassembling and assembling iSave 40 13. Exploded view iSave on foot, vertical 180R9242 | AX073186502910 en-000501 | 08.2019...
  • Page 26 Service guide | Disassembling and assembling iSave 40 180R9242 | AX073186502910 en-000501 | 08.2019...
  • Page 27 Service guide | Disassembling and assembling iSave 40 180R9242 | AX073186502910 en-000501 | 08.2019...
  • Page 28 Danfoss A/S High Pressure Pumps DK-6430 Nordborg Denmark 180R9242 | AX073186502910 en-000501 | 28 © Danfoss | DCS (im) | 2019.08...

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