Danfoss iSave 40 Energy Recovery Device Owner's manual

Brand: Danfoss

Model: iSave 40 Energy Recovery Device

Type: Owner's manual

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ENGINEERING TOMORROW

Instruction

iSave Energy Recovery Device

iSave 40

Recommended service intervals

Danfoss iSave 40 Energy Recovery Device Owner’s Manual

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Contents

1 General information

2 Design/features

3 Service intervals

3.1 iSave 40 (Serial no. 01 to 03)

3.2 iSave 40 (Serial no. 04 and

newer)

4 Appendix 1 (serial no. 01 to 03)

5 Appendix 2 (serial no. 04 and newer)

6 Documents / Resources

7 Related Posts

General information

This guideline provides information on the recommended service intervals. The recommendation is based upon

good engineering practice and on experience gained from operation even under extreme conditions.

The recommendation is for guidance only.

To ensure the correct selection of spare parts the version number of the iSave have to be identiﬁed. The version is

shown on the product label as illustrated on the picture.

ERD

Type iSave 40 ERD

Code no. 180FXXX

Serial no. XXXXXX04-XXX

MADE IN DENMARK

Danfoss A/S, 6430 Nordborg, Denmark

The serial number is referring to the Serial no. on the product label. The digits shown (04) indicate the version

number of the iSave.

Design/features

Danfoss iSave ERD is designed for long operation and low maintenance and life cycle costs.

Provided that the ERD has been running according to the Danfoss speciﬁcations, Danfoss guarantees one year

service-free operation, however, max. 18 months from date of production. After one year of operation it is

recommended to inspect the iSave and replace worn parts, if any.

If the Danfoss recommendations concerning system-design (see our data sheet) are not followed, the service life

of the iSave ERD might be aﬀected.

The recommended service intervals on the diﬀerent parts in the iSave ERD appears from the table below:

Service intervals

iSave 40 (Serial no. 01 to 03)

Description 1) Service interval Service interval (2nd, 3rd)

Tool kit)

Valve plate kit (2 pcs), Pressure exchanger 32,000 hours 26,000 hours

Port plate, Brine (1 pc), Pressure exchanger 32,000 hours 26,000 hours

Port plate, Sea water (1 pc), Pressure exchanger 32,000 hours 26,000 hours

Sealing kit, Pressure exchanger 32,000 hours

Sealing kit, Vane pump 32,000 hours 26,000 hours

Vane kit (8 pcs) 56,000 hours 56,000 hours

Port plate kit out Vane pump

Port plate kit in, Vane pump

Sealing plate out, Vane pump 32,000 hours 26,000 hours

Sealing plate in, Vane pump 32,000 hours 26,000 hours

Coupling kit, internal

1. For detailed information on parts, see Service guide AX290231141118en-000101 Parts list

iSave 40 (Serial no. 04 and newer)

Description 1) Service interval Service interval (2nd, 3rd)

Tool kit)

Screw and seal kit 32,000 hours 26,000 hours

Shaft seal kit 32,000 hours 26,000 hours

Coupling kit 56,000 hours 56,000 hours

Port plate, Brine (1 pc), Pressure exchanger 32,000 hours 26,000 hours

Port plate, Sea water (1 pc), Pressure exchanger 32,000 hours 26,000 hours

Vane kit (8 pcs) 56,000 hours 56,000 hours

Valve plate kit, Pressure exchanger 32,000 hours 26,000 hours

Sealing plate kit 32,000 hours 56,000 hours

Rotor stop 32,000 hours 32,000 hours

1) For detailed information on parts, see Service guide AX290231141118en-000101 Parts list

Appendix 1 (serial no. 01 to 03)

Stator

The stator does not have to be replaced even If there are grooves on the surface.

Burrs on the surface should be sanded down.

Rotor

Measure the height diﬀerence between the points indicated in Fig. 2 and Fig. 3.

Point where there normally is no wear..

Point where the rotor normally is most worn. This is the side of the rotor where the shaft is. The rotor is worn if the

height diﬀerence is above 0.15 mm.

Side plates

Measure the height (thickness) diﬀerence between the points indicated in Fig. 4 and Fig. 5

This is where there normally is little wear.

This is where there normally is most wear.

The side plate is worn if the height diﬀerence is aboe 0.15 mm.

Side plates

(continued) It is possible to restore the surface in contact with the rotor by lapping it with extra ﬁne sandpaper with

water (ISO P800, CAMI grit 320) placed on a ﬂat surface.

Thoroughly clean the side plate after lapping.

The minimum allowed thickness of the side plates is 10,40 mm. However, the combined thickness of the two side

plates in a unit should not be less than 20,85 mm.

Pressure measurement

It is possible to indirectly measure the leak and thereby the wear of the rotor and side plates by measuring the

pressure in one of the LP bleed ports in the vane pump. If the pressure in the bleed port is 2 barg (29 psig) above

the pressure in LPin port the vane poump needs to be examined. The side plates and possibly the rotor need to

be replaced. The thread in the bleed port is G ¼” (BSP).

Port plate

Measure the height (thickness) diﬀerence between the points indicated in Fig. 6 and Fig. 7.

The measruing point is where the outside land is worn the most. It might not be the indicated position. The port

plate is worn if the height diﬀerence is above 0.05 mm.

It is possible to restore the surface by lapping it with extra ﬁne sand paper with water (ISO P800, CAMI grit 320)

placed on a ﬂat surface. See Fig. 8. Thoroughly clean the port plate after lapping.

Lapping is permissible until the throttling groove indicated is a minimum of 0.1 mm deep.

Valve plate

The valve plate will wear where they are in contact with the land of the port plate. The valve plates are worn when

these grooves are 0.03 mm deep.

Appendix 2 (serial no. 04 and newer)

Vanepump basic inspection

1. Inspect the vanes. Note the position of the scratches and be extra observant at these areas when inspecting

the stator.

2. Inspect the stator for scratches on the wear surface. Use sandpaper grid 800 to polish any rough areas. Only

polish in rotation direction.

3. Inspect the side plate for cracks. You don’t have to remove the side plate if no visible cracks are found.

4. If the rotor bearing surfaces has wear grooves with a visible edge it should be changed. Call Danfoss for further

support.

5. Inspect the shaft seal. The rubber should not have any wear marks. If there are cracks or scratches on the

surface of the ceramic ring, replacement is needed

6. The ceramic rings should not have any cracks or scratches.

Vanepump general inspection

1. The side plate in the adapterﬂange and rotor ﬂange should only be inspected if there is reason to believe they

are broken or if the seals behind them needs to be changed. Carefully pull the side plate out, do not use pliers

ore metal tools as the ceramics may break.

2. Once the side plate is removed the two O-rings – one in the side groove and one in the bottom groove can be

replaced..

3. Check the side plate thickness using a micrometer. Replace if below 11.5mm. Always replace the side plate

and the rotor element at the same time.

4. The rotor stop has a hole in the middle that can be used for removing it. If the rotor stop is hard to remove,

compressed air can be used by carefully blowing air into the hole which will push the stop upwards.

5. Check the rotorstop thickness using a micrometer. Replace if below 10.3 mm

6. Carefully use a small screwdriver to remove the rotor element. Once loose the O-ring can be changed. The

rotor element should only be changed if the side plate is changed.

Exchanger portplate inspection

Port plate

Measure the height (thickness) diﬀerence between the points indicated in Fig. 6 and Fig. 7.

The measruing point is where the outside land is worn the most. It might not be the indicated position. The port

plate is worn if the height diﬀerence is above 0.05 mm.

It is possible to restore the surface by lapping it with extra ﬁne sand paper with water (ISO P800, CAMI grit 320)

placed on a ﬂat surface. See Fig. 8. Thoroughly clean the port plate after lapping.

Lapping is permissible until the throttling groove indicated is a minimum of 0.1 mm deep.

Valve plate

The valve plate will wear where they are in contact with the land of the port plate. The valve plates are worn when

these grooves are 0.03 mm deep.

Danfoss A/S

High Pressure Pumps » danfoss.com « +45 7488 2222 « highpressurepumps@danfoss.com

Any information, including, but not limited to information on selection of product, its application or use, product

design, weight, dimensions, capacity or any other technical data in product manuals, catalogues descriptions,

advertisements, etc. and whether made available in writing, orally, electronically, online or via download, shall be

considered informative, and is only binding if and to the extent, explicit reference is made in a quotation or order

conﬁrmation. Danfoss cannot accept any responsibility for possible errors in catalogues, brochures, videos and

other material.

Danfoss reserves the right to alter its products without notice. This also applies to products ordered but not

delivered provided that such alterations can be made without changes to form, ﬁt or function of the product.

All trademarks in this material are property of Danfoss A/S or Danfoss group companies. Danfoss and the

AX290136382992en-000501

Documents / Resources

Danfoss iSave 40 Energy Recovery Device [pdf] Owner's Manual

iSave 40 Energy Recovery Device, iSave 40, Energy Recovery Device, Recovery Device, Devic

Manuals+,

Danfoss iSave 40 Energy Recovery Device Owner's manual

Danfoss iSave 40 Energy Recovery Device Owner's manual

Danfoss iSave 40 Energy Recovery Device Owner's manual

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