Danfoss iSave 21 Original operating manual

isave.danfoss.com
Service instruction
Disassembling and assembling
iSave 21
MAKING MODERN LIVING POSSIBLE
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Service instruction Disassembling and assembling iSave 21
2
180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013
1. General introduction....................................................................2
2. Disassembling the iSave.................................................................3
3. Disassembling the pressure exchanger ..................................................4
4. Assembling the pressure exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5. Disassambling the vane pump..........................................................12
6. Assembling the vane pump ............................................................13
7. Assembling the iSave ..................................................................17
8. Exploded view vane pump ...................................................... 18
9. Exploded view pressure exchanger............................................... 19
10. Exploded view iSave ...................................................................20
Table of Contents
This document covers the instructions for
disassembling and assembling the iSave 21.
Important: It is essential that the iSave is
serviced in conditions of absolute cleanliness.
For a better understanding of the iSave, please
see the exploded view in item 8, 9 and 10.
The weight of the iSave is 65 kg / 143 lb
and it must be lifted with suitable lifting
equipment.
The weight of the pressure exchanger alone is
28 kg / 62 lb.
It is essential that the iSave is serviced in
conditions of absolute cleanliness
To prevent cold welding, lubricate threads of
screws with grease screw them into the compo-
nent and tighten them by the hand. Use PTFE
lubrication type.
Tools needed for disassembling the iSave:
- 6 mm and 8 mm allen key
- 2 screwdrivers
- 2 M8 bolts
- Plastic tube
- Plastic tool for shaft seal assembly
- Loctite 270
Torque wrench with special socket
Code no. 180Z0610
1. General Introduction

Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013
2. Disassembling
the iSave
1. Place the iSave on a clean table.
3. Remove the vane pump.
2. Unscrew the bolts in the ange.

Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013
3. Disassembling the
pressure exchanger
1. Unscrew the bolts in the ange.
3. Gently push out the ange.
2. Screw in the two M8 bolts.
4. Wet the shaft and shaft seal with clean
ltered water. Gently lever the shaft
assembly free using 2 screwdrivers.
5. Unscrew the bolts in the ange. 6. Gently remove the ange.
Note: Loose parts on the inside of the ange.

Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013
7. Gently remove the cylinder barrel.
9. Gently remove the housing.
Note: Loose parts on the inside of the ange.
8. Unscrew the bolts in the ange.
10. Remove port plate and pin.
Pin
11. Unscrew high-pressure bearing using a
special socket.

Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013
13. Remove the high-pressure bearing. 14. Gently lift the valve plate assembly free
with the aid of the screwdrivers.
15. Gently remove both valve plates. 16. Replace the O-rings and the back-up rings
on the valve plate.
4. Assembling the
pressure exchanger
2. Lubricate all the bores in the cylinder barrel
with grease and clean ltered water.
1. Mount the new back-up rings on the valve
plate rst and then the new O-rings.

Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013
18. Adjust the distance between the cylinder
drum and the second valve plate.
The distance must be about 4-6 mm.
This is not critical.
3. Gently press, by hand, the rst valve plate
onto the cylinder barrel.
Note: don’t scratch the valve plate when
placing it on the plastic tube.
4. Gently press, by hand, the second valve
plate onto the cylinder barrel by placing it
on the plastic tube.
Note: don’t scratch the valve plate when
placing it on the plastic tube.
The distance must be about 4-6 mm.
This is not critical.
5. Adjust the distance between the cylinder barrel
and the second valve plate (short shaft end).

Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013
7. Tighten the high-pressure bearing using
special socket and torque wrench with
70Nm±7
6. Mount the high-pressure bearing
8. Remove old O-ring with a new one 9. Position the housing over the guide pin
10. Mount all bolts in the ange and tighten
them all with 30Nm±3
11

Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013
11. Fit the guide pin in the ange.
13. Position the port plate over the guide pin.
Note: Make sure that the guide pin is located
in the locating hole in the port plate.
There are two dierent port plates in the iSave. One of them can be mounted on both anges in
the pressure exchanger. Make sure that they are assembled on the right ange.
12. Location hole in port plate.
14. Gently guide the cylinder barrel into the
bearing in the ange.
16. Wrong! large center hole.15. Check the next port plate is correct.
Correct small
center hole
Wrong! large
center hole

Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013
21. Mount all bolts in the ange and tighten
them to a torque of 30 Nm ± 3 Nm.
20. Position the port ange over the guide pin.
22. Wet the shaft seal with clean ltered water.
Do not use silicone grease.
Fit the shaft seal with the carbon surface upward.
17. Position the port plate over the guide pin.
19. Change the O-ring in the ange and
position the guide pin.
O-ring Guide pin
18 Check that the port plate ts the center
bearing and the guide pin.