Danfoss iSave 40, Service Manual

Page 1: ...ro solutions com Instruction Disassembling and assembling iSave 40 Service guide Energy recovery device iSave 40 Disassembling and assembling hpp danfoss com...

Page 2: ...y 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 screwdri...

Page 3: ...nscrew 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 m...

Page 4: ...ble 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 first In this case please follow step 1 5...

Page 5: ...t with clean filtered 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 bo...

Page 6: ...FN PI 003 R3 02 04 2016 6 Loosen all the bolts in the adapter flange 7 Carefully disassemble adapter flange and port plate from the stator ring 9 Remove the 8 vanes 8 Remove the sealing plate 10 Caref...

Page 7: ...mbling 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 flange 14 Remove the HP outlet flange 15 Re...

Page 8: ...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 Lubric...

Page 9: ...ng an allen key 6 Tilt the flange and stator assemble and screw in the rest of the bolts in the flange Tighten bolts to a torque of 60 6 Nm 7 Assemble and position the two pins in the pin holes 9 Moun...

Page 10: ...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...

Page 11: ...rt flange in on the adapter flange and position the two guide pins 19 Position the guide pin in the adapter flange 18 Assemble the new O ring on the correct sealing plate It is important to lubricate...

Page 12: ...lean filtered 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 fla...

Page 13: ...16 29 Mount the four bolts and tighten them to a torque of 30 3 Nm 3 Unscrew all the bolts 4 Carefully lever the flange and port plate from the casing 5 Disassembling the pressure exchanger 1 Unscrew...

Page 14: ...ng 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 screwdriv...

Page 15: ...nditions 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...

Page 16: ...uide the cylinder barrel into the flange bearing 8 Assemble the O ring on the HP LP flange and position the two guide pins into the flange 5 Position the port plate on the flange using the two guide p...

Page 17: ...ns as guide Only one port plate fits 10 Position the guide pin into the casing 11 Carefully position the flange assembly onto the guide pin in the casing 12 Carefully assemble a bolt into the casing t...

Page 18: ...ling 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 1...

Page 19: ...s first 2 Lubricate the O rings and back up rings with clean filtered water and position the two valve plates into the rotor ends 7 Assembling the cylinder barrol in pressure exchanger 3 Using the too...

Page 20: ...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 th...

Page 21: ...Service guide Disassembling and assembling iSave 40 21 180R9242 521B1213 DKCFN PI 003 R3 02 04 2016 9 Exploded view vane pump...

Page 22: ...Service guide Disassembling and assembling iSave 40 22 180R9242 521B1213 DKCFN PI 003 R3 02 04 2016 10 Exploded view pressure exchanger...

Page 23: ...Service guide Disassembling and assembling iSave 40 23 180R9242 521B1213 DKCFN PI 003 R3 02 04 2016 11 Exploded view iSave...

Page 24: ...Service guide Disassembling and assembling iSave 40 24 180R9242 521B1213 DKCFN PI 003 R3 02 04 2016 12 Exploded view iSave on base plate horizontal...

Page 25: ...Service guide Disassembling and assembling iSave 40 25 180R9242 521B1213 DKCFN PI 003 R3 02 04 2016 13 Exploded view iSave on foot vertical...

Page 26: ...Danfoss DCS im 2016 04 180R9242 521B1213 DKCFN PI 003 R3 02 26 Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark...