Danfoss iSave 40 Service Manual
Energy recovery device
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Also See for iSave 40:
- Operation manual (101 pages) ,
- Service manual (26 pages) ,
- User manual (106 pages)
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Summary of Contents for Danfoss iSave 40
- Page 1 Service guide Instruction Energy recovery device Disassembling and assembling iSave 40 Disassembling and assembling iSave 40 ro-solutions.com hpp.danfoss.com...
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Page 2: Table Of Contents
Exploded view vane pump iSave 40 series 04 and newer ....... -
Page 3: Disconnect The Isave From Electric Motor
Service guide | Disassembling and assembling iSave 40 Parts not included in tool set: • 2 screwdrivers Tools needed to disassemble the iSave: • Torque wrench 10 - 60 Nm Parts included in tool set (180F4112): To prevent cold welding, Danfoss recommend to •... - Page 4 Service guide | Disassembling and assembling iSave 40 To disconnect the bell housing, unscrew Carefully pull and lift the booster pump the 4 bolts on the electric motor. from the electric motor. It is also possible to disconnect the Disassemble the bell housing from the complete unit from the motor rst.
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Page 5: Disassembling The Booster Pump Series 01-03
Service guide | Disassembling and assembling iSave 40 Disassembling the M8x20 bolts marked A4 booster pump series 01 - 03 If ange cannot be removed easily, use two Disassemble the ange for shaft seal. M8 bolts. If coupling has to be changed, follow the next two steps. - Page 6 Service guide | Disassembling and assembling iSave 40 Loosen all the bolts in the adapter Carefully disassemble adapter ange ange. and port plate from the stator ring. Remove the sealing plate. Remove the 8 vanes. Carefully guide the rotor out of the Remove the sealing plate and pin.
- Page 7 Service guide | Disassembling and assembling iSave 40 Remove the O-ring from the sealing Unscrew the bolts in the outlet ange. plate. Remove the HP outlet ange. Remove the port ange. 180R9242 | AX073186502910en-000801 | 09.2022...
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Page 8: Disassembling The Booster Pump Series 04 And Newer
Service guide | Disassembling and assembling iSave 40 3. 1 Disassembling the booster pump series 04 and newer Install the locking tool to prevent the Remove the coupling by unscrewing shaft from rotating. the four special M8 x 20 bolts marked with 1.4410... - Page 9 Service guide | Disassembling and assembling iSave 40 Carefully move the motor ange. The rotor stop may drop out of its sleeve Remove all bolts from the motor ange. when lifting the ange, but can easily be installed again. Carefully remove the rotor by lifting it Put the motor ange assembly and out of the housing.
- Page 10 Service guide | Disassembling and assembling iSave 40 Rotate the vanepump housing and remove all bolts. The rotor stop may drop out but can easily be installed Lift the adapter ange o the housing. again. The vanepump is now fully disassembled 180R9242 | AX073186502910en-000801 | 09.2022...
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Page 11: Basic Inspection
Service guide | Disassembling and assembling iSave 40 Basic inspection Inspect the stator for scratches on the Inspect the vanes. Note the position of wear surface. Use sandpaper grid 800 to the scratches and be extra observant at polish any rough areas. Only polish in these areas when inspecting the stator. -
Page 12: General Inspection
Service guide | Disassembling and assembling iSave 40 General inspection The side plate in the adapter ange and rotor ange should only be inspected if there is reason to believe they are broken or if the seals behind them needs to be changed. -
Page 13: Assembling The Booster Pump Series 01-03
Service guide | Disassembling and assembling iSave 40 Assembling the Lubrication: booster pump series WARNING: • To prevent cold welding, Danfoss 01 - 03 Do not use silicone when assembling the recommend to use thread lubricant for iSave. Do not reuse disassembled O-rings;... - Page 14 Service guide | Disassembling and assembling iSave 40 Tilt the ange and stator; assemble and Tighten the bolts by using an allen key. screw in the rest of the bolts in the ange. Tighten bolts to a torque of 60 ±6 Nm.
- Page 15 Service guide | Disassembling and assembling iSave 40 By using the handle tool provided, Fit the 8 vanes into each slot. carefully lever the rotor into Notice vane position. Place the the stator. straight site of the vane onto the pin with the mark down ward.
- Page 16 Service guide | Disassembling and assembling iSave 40 Assemble the new O-ring on the correct Position the guide pin in the adapter sealing plate. ange. It is important to lubricate to ensure the O-ring does not drop out. Position the sealing plate over the guide pin.
- Page 17 Service guide | Disassembling and assembling iSave 40 Using the shaft tool provided, Turn the pump with shaft upwards. carefully press down the shaft Lubricate the shaft and shaft seal with seal to the shoulder of the shaft. clean ltered water. Mount the shaft seal with the carbon ring upwards.
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Page 18: Assembling The Booster Pump Series 04 And Newer
Service guide | Disassembling and assembling iSave 40 6.1 Assembling the Lubrication: booster pump series WARNING: • To prevent cold welding, Danfoss 04 and newer Do not use silicone when assembling the recomend to use thread lubricant for all iSave. Do not reuse disassembled O-rings;... - Page 19 Service guide | Disassembling and assembling iSave 40 Carefully by hand press down the sideplate. The outer surface of the side Lubricate the O-rings in the plate should be ush with the ange port ange with water and install when pushed down. Ones the push is sideplate.
- Page 20 Service guide | Disassembling and assembling iSave 40 Carefully press the rotor element in Check O-ring is in place. place. Place the rotor with the shaft pointing Install the O-ring on the rotor element. upwards and lubricate the groves with water.
- Page 21 Service guide | Disassembling and assembling iSave 40 Spray the inside of the housing with Install the 8 pins inside the rotor. clean ltered water before installing Two pins per hole. the rotor. Carefully lower the rotor assembly into Install the vanes. Use a screwdriver to the housing.
- Page 22 Service guide | Disassembling and assembling iSave 40 Lubricate the O-rings, side plate and Mount the second new O-ring ange with clean ltered water. (pos. 137) in the bottom on the ange. Mount the rst O-ring (pos. 139) in the cut out in the ange.
- Page 23 Service guide | Disassembling and assembling iSave 40 Lubricate the surfaces with water and The pins ensures correct orientation carefully lower the ange on the of the housing. stator. Cross tighten the screws (max. 10 Nm) to ensure the motor anges are...
- Page 24 Service guide | Disassembling and assembling iSave 40 Lubricate the stationary part of the shaft seal with clean ltered water and press the ring into the shaft seal cover using the plastic press bush tool. When it is placed in the center it can...
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Page 25: Disassembling The Pressure Exchanger
Service guide | Disassembling and assembling iSave 40 Disassembling the 3 x special M8x20 bolts pressure exchanger marked 1.4410 Unscrew the 3 special M8x20 bolts marked Remove coupling and the 3 pins. 1.4410. Unscrew all the bolts. Carefully lever the ange and port plate from the casing. - Page 26 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. If the plates are hard to remove it is recommended to install the 3 M8x50 bolt from the tool kit..
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Page 27: Assembling The Pressure Exchanger
Service guide | Disassembling and assembling iSave 40 Assembling the Lubrication: pressure exchanger WARNING: • To prevent cold welding, Danfoss reco Do not use silicone when assembling the mend to use thread lubricant for all screw iSave. Do not reuse disassembled O-rings;... - Page 28 Service guide | Disassembling and assembling iSave 40 Position the port plate on the ange Mount the provided M6 threaded rod into using the two guide pins as guide. Only the shaft of the cylinder barrel. one port plate ts.
- Page 29 Service guide | Disassembling and assembling iSave 40 Carefully assemble a bolt into the casing Carefully position the ange assembly to ensure that ange assembly stays in onto the guide pin in the casing. place. Lubricate and install the bolts. Cross...
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Page 30: Assembling The Cylinder Barrol In Pressure Exchanger
Service guide | Disassembling and assembling iSave 40 Special tool Install the screws and cross tighten them to the torque speci ed in the exploded view. Use the special tool when using the torque wrench. Assembling the cylinder barrol in... -
Page 31: Changing Springs In The Pressure Exchange Rotor
Service guide | Disassembling and assembling iSave 40 Small shaft diameter: No distance. Large shaft diameter: Distance 4-5 mm. 10. Changing springs in the pressure exchange rotor It is basically not necessary to change the springs in the rotor. If needed, follow the... - Page 32 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 retainer by tightening the nut until the Carefully remove the tool assembly and O-ring is placed in the recess.
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Page 33: Exploded View Vane Pump Isave 40 Series 01-03
Service guide | Disassembling and assembling iSave 40 Exploded view vane pump iSave 40 series 01-03 180R9242 | AX073186502910en-000801 | 09.2022... -
Page 34: Exploded View Vane Pump Isave 40 Series 04 And Newer
Service guide | Disassembling and assembling iSave 40 12. Exploded view vane pump iSave 40 series 04 and newer 180R9242 | AX073186502910en-000801 | 09.2022... -
Page 35: Exploded View Pressure Exchanger Series 01-03
Service guide | Disassembling and assembling iSave 40 13. Exploded view pressure exchanger series 01-03 180R9242 | AX073186502910en-000801 | 09.2022... -
Page 36: Exploded View Pressure Exchanger Series 04 And Newer
Service guide | Disassembling and assembling iSave 40 14. Exploded view pressure exchanger series 04 and newer 180R9242 | AX073186502910en-000801 | 09.2022... -
Page 37: Exploded View Isave Series 01-03
Service guide | Disassembling and assembling iSave 40 15. Exploded view iSave series 01-03 180R9242 | AX073186502910en-000801 | 09.2022... -
Page 38: Exploded View Isave Series 04 And Newer
Service guide | Disassembling and assembling iSave 40 16. Exploded view iSave series 04 and newer 180R9242 | AX073186502910en-000801 | 09.2022... -
Page 39: Exploded View Isave On Base Plate, Horizontal
Service guide | Disassembling and assembling iSave 40 Exploded view iSave on base plate, horizontal 180R9242 | AX073186502910en-000801 | 09.2022... -
Page 40: Exploded View Isave On Foot, Vertical
Service guide | Disassembling and assembling iSave 40 18. Exploded view iSave on foot, vertical 180R9242 | AX073186502910en-000801 | 09.2022... - Page 41 Service guide | Disassembling and assembling iSave 40 180R9242 | AX073186502910en-000801 | 09.2022...
- Page 42 © Danfoss | DCS-SGDPT/SI | 09.2022 180R9242 | AX073186502910en-000801 | 42...
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