Danfoss iSave 40 Energy Recovery Device Owner’s Manual

ENGINEERING TOMORROW
Instruction
iSave Energy Recovery Device
iSave 40
Recommended service intervals

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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)

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

iSave 40 (Serial no. 04 and newer)

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

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© Danfoss | DCS-SGDPT/SI | 2022.09
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, Device
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References

• Sustainable Desalination with SWRO Technology | Danfoss

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