Danfoss iSave 40 Manuel utilisateur
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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
3
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
5
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
7
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 identication
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
9
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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2
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