Danfoss iSave 40 User manual

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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
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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
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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
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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.

Service guide Disassembling and assembling iSave 40
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180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016
16. Assemble the new O-ring on the port
plate-in.
17. Position the port ange in on the adapter
ange and position the two guide pins.
19. Position the guide pin in the adapter
ange.
18. Assemble the new O-ring on the correct
sealing plate.
It is important to lubricate to ensure the
O-ring does not drop out.
20. Position the sealing plate over the guide
pin.
21. Carefully position the adapter ange
assembly into the two guide pin holes.

Service guide Disassembling and assembling iSave 40
12 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016
22. Mount two bolts in the adapter ange. 23. Mount all bolts in the adapter ange.
Tighten the bolts to a torque of 60±6 Nm.
24. Turn the pump with shaft upwards.
Lubricate the shaft and shaft seal with
clean ltered water. Mount the shaft seal
with the carbon ring upwards.
25. Using the shaft tool provided, carefully
press down the shaft seal to the shoulder of
the shaft.
27. Mount a new O-ring on the ange for shaft
seal and assemble the minor ange on top
of the ange. Tighten bolts to a torque of
30 ±3 Nm.
26. Lubricate and press new ceramic ring into the
shaft seal cover by using the press bush tool.
WARNING:
Ensure that the face with rubber seal is
positioned against shoulder in shaft seal
ange.

Service guide Disassembling and assembling iSave 40
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180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016
29. Mount the four bolts and tighten them to a
torque of 30 ±3 Nm.
3. Unscrew all the bolts. 4. Carefully lever the ange and port plate
from the casing.
5. Disassembling the
pressure exchanger
1. Unscrew the 3 coupling bolts. 2. Remove coupling and the 3 pins.
28. Mount the two pins and the coupling part.

Service guide Disassembling and assembling iSave 40
14 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016
5. Carefully take the cylinder barrel assembly
out of the casing.
7. Carefully lever the 2 valve plate assembly
free with help from 2 screwdrivers.
6. Remove port plate and the two pins.

Service guide Disassembling and assembling iSave 40
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180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016
1. Assemble the O-ring on the LP in port
ange.
2. Position the guide pin into the casing.
6. Assembling the
pressure exchanger 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).
Assembling cylinder barrel in pressure
exchanger, see page 19.
Follow step 1-3 if LP in ange has been dis-
assembled from casing.
3. Position the LP in ange on the guide pin
and assemble all the bolts into the casing.
Tighten the bolts to a torque of 30 ±3 Nm.
4. Turn the assembly and position the two
guide pins in the ange inside the casing.

Service guide Disassembling and assembling iSave 40
16 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016
7. Carefully guide the cylinder barrel into the
ange bearing.
8. Assemble the O-ring on the HP/LP ange
and position the two guide pins into the
ange.
5. Position the port plate on the ange using
the two guide pins as guide. Only one port
plate ts.
6. Mount the provided M6 threaded rod into
the shaft of the cylinder barrel.

Service guide Disassembling and assembling iSave 40
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180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016
9. Position the port plate on the HP/LP ange
using the two guide pins as guide. Only
one port plate ts.
10. Position the guide pin into the casing.
11. Carefully position the ange assembly onto
the guide pin in the casing.
12. Carefully assemble a bolt into the casing to
ensure that ange assembly stays in place.
13. Assemble all the bolts and tighten them to
a torque of 30 ±3 Nm.
14. Mount the 3 pins in shaft and place the
coupling part.

Service guide Disassembling and assembling iSave 40
18 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016
15. Tighten the bolts to a torque of 30 ±3 Nm. 16. Assemble booster pump and pressure
exchanger. Mount the two guide pins and
coupling spacer.
17. Tighten bolts to a torque of 60 ±6 Nm.

Service guide Disassembling and assembling iSave 40
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180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016
The shaft is normally not a wear part and can
only be changed by Danfoss.
1. Assemble back-up rings and O-rings on the
valve plates. Back-up rings rst.
2. Lubricate the O-rings and back-up rings
with clean ltered water and position the
two valve plates into the rotor ends.
7. Assembling the
cylinder barrol in
pressure exchanger
3. Using the tools provided gently screw in
the valve plates.
4. Check the distance between the two valve
plates and the cylinder barrel. Adjust the
distance if necessary.
O-ring
Back-up ring
Small shaft diameter: No distance. Large shaft diameter: Distance 4-5 mm.

Service guide Disassembling and assembling iSave 40
20 180R9242 | 521B1213 | DKCFN.PI.003.R3.02 | 04.2016
1. Replace springs in the rotor.
2. Assemble the retainer over the springs.
8. Changing springs in
the pressure exchange
rotor.
3. Assemble the O-ring over the retainer.
4. Using the tool provided, press down the
retainer by tightening the nut until the
O-ring is placed in the recess.
5. Carefully lever the bolt and tool assembly
and check the O-ring assembly.
It is basically not necessary to change the
springs in the rotor. If needed, follow the
guidelines below:
8.1 Disassembling
Using the tool provided, press down the
retainer and remove/cut the O-ring, and
remove retainer.