Danfoss ISave 40 Bedienungsanleitung

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Instruction

Disassembling and assembling

iSave 40

Service guide

Energy recovery device

iSave 40

Disassembling and assembling

hpp.danfoss.com

Service guide Disassembling and assembling iSave 40

2180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016

Table of Contents

This document illustrates instructions for

disassembling and assembling the iSave 40.

To understand the design of the iSave, see

exploded views starting on page 21.

Always use suitable lifting equipment.

Important!

It is essential that the iSave is serviced in

conditions of absolute cleanliness.

• The weight of the iSave, including

electric motor, is about 260 kg (573 lb).

• The weight of the pressure exchanger

alone is about 75 kg (165 lb).

• The weight of the booster pump

alone is about 50 kg (110 lb).

Tools needed to disassemble the iSave:

Parts included in tool set (180F4112):

• 6 mm and 8 mm allen key

• C-wrench 24 mm

• 1 M6 bolt and nut

• Handel for rotor assembly

• Tool for shaft seal assembly

• Tool for retainer assembly

• 3 press bolt-set for valve plate assembly

Parts not included in tool set:

• 2 screwdrivers

• Torque wrench 10-60 Nm

To prevent cold welding, lubricate threads of the

screws with PTFE lubrication type and screw

them into the component and tighten by hand.

1. General information

1. General information.....................................................................2

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

3. Disassembling the booster pump........................................................5

4. Assembling the booster pump ..........................................................8

5. Disassembling the pressure exchanger .................................................13

6. Assembling the pressure exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

7. Assembling the cylinder drum in pressure exchanger ...................................19

8. Changing spring in the rotor ...........................................................20

8.1 Disassembling .........................................................................20

9. Exploded view vane pump .............................................................21

10. Exploded viewpressure exchanger .....................................................22

11. Exploded view iSave ...................................................................23

12. Exploded view iSave on baseplate, horizontal...........................................24

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

Instruction Disassembling and assembling iSave 40

180R9242 / 521B1213 / DKCFN.PI.003.R2.02 / 09.2013

2. Unscrew 10 bolts in the adapter ange

between booster pump and pressure

exchanger. Leave the 2 upper bolts tighten.

3. Unscrew the 2 upper bolts.

1. Apply a light lifting force on the pressure

exchanger and disconnect the support

bracket between the pressure exchanger

and base plate.

2. Disconnect the iSave

from electric motor

4. Carefully pull and lift the pressure

exchanger from the booster pump.

5. To disconnect the bell housing, unscrew

the 4 bolts on the electric motor.

6. Carefully pull and lift the booster pump

from the electric motor.

Service guide Disassembling and assembling iSave 40

4180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016

7. Disassemble the bell housing from the

booster pump by unscrewing the 4 bolts in

the bell housing.

8. It is also possible to disconnect the

complete unit from the motor rst. In this

case, please follow step 1, 5, 6 and 7

afterwards.

9. After the pressure exchanger is released

from the booster pump, remove the two

guide pins.

Service guide Disassembling and assembling iSave 40

180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016

1. Disassemble the ange for shaft seal.

2. Wet the shaft seal rst with clean ltered

water. Carefully lift the shaft seal by using

2 screwdrivers.

3. Disassembling the

booster pump

3. If coupling has to be changed, follow the

next two steps.

4. Unscrew the 4 coupling bolts. Use a

hammer handle at the opposite end to

prevent the shaft from turning.

5. Remove coupling and the two pins.

If ange cannot be removed easily, use two

M8 bolts.

Service guide Disassembling and assembling iSave 40

6180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016

6. Loosen all the bolts in the adapter ange. 7. Carefully disassemble adapter ange and

port plate from the stator ring.

9. Remove the 8 vanes.8. Remove the sealing plate.

10. Carefully guide the rotor out of the stator. 11. Remove the sealing plate and pin.

Service guide Disassembling and assembling iSave 40

180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016

12. Remove the O-ring from the sealing plate. 13. Unscrew the bolts in the outlet ange.

14. Remove the HP outlet ange. 15. Remove the port ange.

Service guide Disassembling and assembling iSave 40

8180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016

1. Place the HP outlet ange on the desk and

mount the O-ring and 2 pins.

2. Align the port plate-out on the two pins

and mount the O-ring on the port plate.

4. Assembling the

booster pump 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 absolutely clean before mounting.

Lubrication:

• To prevent seizing-up, lubricate all threads

with PTFE lubrication type.

• It is important to lubricate ALL parts to be

assembled with clean ltered water

(Especially all PEEK parts).

3. Turn the stator with the two identication

rings closest to the port plate and position

the stator on the 2 pins.

4. From down side up and by hand, screw in

two bolts in the stator.

Service guide Disassembling and assembling iSave 40

180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016

5. Tighten the bolts by using an allen key. 6. Tilt the ange and stator; assemble and

screw in the rest of the bolts in the ange.

Tighten bolts to a torque of 60 ±6 Nm.

7. Assemble and position the two pins in the

pin holes.

9. Mount the O-ring in the sealing plate and

guide pin in ange.

It is important to lubricate to ensure the

O-ring does not drop out.

Service guide Disassembling and assembling iSave 40

10 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016

10. Position the sealing plate on the guide pin.

Ensure correct choice of sealing plate.

Only one sealing plate ts the guide pin.

11. Position the 8 pins in the rotor. 2 pins in

each hole.

12. By using the handle tool provided, carefully

lever the rotor into the stator.

14. Orient the vanes with correct end into

rotor. See the arrow below.

13. Fit the 8 vanes into each slot. Notice vane

position. Place the straight site of the vane

onto the pin with the mark downward.

15. Assemble the new O-ring on the adapter

ange.

No mark on

this side.

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