Danfoss iSave 21 User manual

Service guide
Energy Recovery Device
iSave 21
Disassembling and assembling
hpp.danfoss.com

Service guide Disassembling and assembling iSave 21
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180R9219 | 521B1171 | DKCFN.PI.003.K5.02 / 03.2016
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 views in the sections 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.
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:
- iSave 21 tool kit (180F4126)
- 2 screwdrivers
- Loctite 270
1. General Introduction
Contents
1. General Introduction........................................................................2
2. Disassembling the iSave ................................................................3
3. Disassembling the pressure exchanger ..................................................4
4. Assembling the pressure exchanger .....................................................7
5. Disassembling the vane pump .........................................................12
6. Assembling the vane pump ............................................................14
7. Assembling the iSave...................................................................17

Service guide Disassembling and assembling iSave 21
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1. Place the iSave on a clean table.
3. Remove the vane pump.
2. Unscrew the bolts in the flange.
2. Disassembling the
iSave
3. Use internal coupling tool to remove
coupling part from exchanger shaft.

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180R9219 | 521B1171 | DKCFN.PI.003.K5.02 / 03.2016
3. Disassembling the
pressure exchanger
1. Unscrew the bolts in the flange.
3. Gently push out the flange.
2. Screw in the two M8 bolts.
4. Wet the shaft and shaft seal with clean
filtered water. Gently lever the shaft
assembly free using 2 screwdrivers.
5. Unscrew the bolts in the flange. 6. Gently remove the flange.
Note: Loose parts on the inside of the flange.

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180R9219 | 521B1171 | DKCFN.PI.003.K4.02 | 03.2016
7. If bearing in flange need to be changed
gently press the bearing out from the
back side with a tube or a drift.
Place the new bearing in the hole in the
flange.
8. Lubricate the new bearing with clean
filtered water. With use of a hand press
gently press the new bearing in place
until it is in line with the flange surface.
Do not use a hammer!
9. Gently remove the cylinder barrel. 10. Unscrew the bolts in the flange.
11. Gently remove the housing.
Note: Loose parts on the inside of the flange.
12. Remove port plate and pin.
Pin

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180R9219 | 521B1171 | DKCFN.PI.003.K5.02 / 03.2016
13. Unscrew high-pressure bearing using a
special socket.
14. Remove the high-pressure bearing.
15. Gently lift the valve plate assembly free
with the aid of the screwdrivers.
17. Replace the O-rings and the back-up rings
on the valve plate.
16. Gently remove both valve plates.

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180R9219 | 521B1171 | DKCFN.PI.003.K4.02 | 03.2016
4. Assembling the
pressure exchanger
3. Lubricate all the O-rings and back up
rings with clean filtered water and gently
by help of the 3 compression tools in
every fourth hole mount both valve plate
on the cylinder barrel.
4. Adjust the distance between the cylinder
barrel and valve plate at the short
shaft end. Distance 4-6 mm.
2. Lubricate all the bores in the cylinder
barrel with clean filtered water.
1. Mount the new back-up rings on the
valve plate first and then the new O-rings.
IMPORTANT:
It is essential that the iSave is serviced in
conditions of absolute cleanliness.
All Parts must be absolute clean before
mounting.
WARNING:
Do not use silicone when assembling the
iSave. Do not reuse dismantled O-rings: they
might be damaged. Always use new O-rings.
Lubrication
- To prevent seizing-up, lubricate threads on
screws.
- O-rings inside iSave may be lubricated only
with clean filtered water.
- O-rings for port flange, mounting flange may
be lubricated with a small amount of grease.
- It is important to lubricate ALL parts to be
assembled with clean filtered water (Especially
all PEEK parts).

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180R9219 | 521B1171 | DKCFN.PI.003.K5.02 / 03.2016
5. Mount the high-pressure bearing 6. Tighten the high-pressure bearing using
special socket and torque wrench with
90Nm±9
7. Replace old O-ring with a new one 8. Position the housing over the guide pin
10
9. Mount all bolts in the flange and tighten
them all with 30Nm±3
10. Fit the guide pin in the flange.

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11. Location hole in port plate.
There are two different port plates in the iSave. One of them can be mounted on both flanges in
the pressure exchanger. Make sure that they are assembled on the right flange.
12. 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.
13. Gently guide the cylinder barrel into the
bearing in the flange.
14. Check the port
plate is correct -
small center hole.
15. Wrong! large
center hole.
New design
Old design
New design
Old design
Correct - small
center hole

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180R9219 | 521B1171 | DKCFN.PI.003.K5.02 / 03.2016
16. Position the port plate over the guide pin.
17. Check that the port plate fits the center
bearing and the guide pin.
20. Mount all bolts in the flange and tighten
them to a torque of 30 Nm ± 3 Nm.
19. Position the port flange over the guide
pin.
21. Wet the shaft seal with clean filtered
water.
Do not use silicone grease.
Fit the shaft seal with the carbon surface
upward.
18. Change the O-ring in the flange and
position the guide pin.
O-ring Guide pin

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22. Shaft seal NOT mounted correct.
The rubber seal face must turn into the flange.
23. Using the plastic assembly tool provided,
large diameter first, press the seal home
against the shoulder, by hand.
Be careful not to damage the carbon seal face
on the shaft seal.
24. Shaft seal in right position: 25. Remove the old ceramic ring from the
flange. Position the new O-ring on the seal
flange.
26. Push the new ceramic ring into the flange
using plastic tool provided (small diameter).
Make sure the face with the rubber seal is
positioned against the shoulder in the
flange.
Before assembly wet the parts with clean
filtered water.
27. Position the seal flange and the bolts.
Tighten the 4 bolts with 12 Nm ±1.2 Nm.

Service guide Disassembling and assembling iSave 21
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1. Gently adjust the spanner wrench around
the coupling and use it as back stop.
3. Remove all bolts in the HP out connection
flange.
2. Unscrew the bolt in the middle of the
coupling and remove the coupling.
4. Remove the flange.
5. Remove side plate and pin
5. Disassembling the
vane pump
6. Side plate removed.

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7. Gently remove the rotor.
Note: Loose parts inside the rotor.
8. Remove vanes.
9. Gently remove side plate and pin.

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1. Position the guide pin. 2. Location hole in the side plate:
6. Assembling the
vane pump
4. Place the 4 pins in the rotor.3. Position the side plate over the guide pin.
Note: Make sure that the guide pin is located
in the locating hole in the port plate. See #2
5. Gently place the rotor in the bearing. 6. Position the 8 vanes in the rotor.
The pins may be moved by using a
screwdriver.

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180R9219 | 521B1171 | DKCFN.PI.003.K4.02 | 03.2016
7. Check that all vanes are positioned
correctly.
8. One vane is NOT positioned correctly.
9. Replace the O-ring on the flange and wet
the flange properly with clean filtered
water.
10. Position the side plate over the guide pin.
11. Make sure that the guide pin is located in the
locating hole in the side plate. See #10. 12. Fit the flange into both the bearing in the
flange and the location pin in the stator.

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13. Make sure that the guide pin is located in
the location hole.
14. Change the O-ring in the HP out
connection flange.
16. Fit the coupling into the pump.
Glue the threat on the bolt with “Loctite
270” and tighten the bolt with 10 Nm±1 Nm.
17. Change the two O-rings in the flange.
15. Bolt the flange onto the vane pump.
Tighten the bolt with 30 Nm ±3 Nm.

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180R9219 | 521B1171 | DKCFN.PI.003.K4.02 | 03.2016
7. Assembling the
iSave
1. Fit the steel coupling onto the shaft of the
pressure exchanger.
Correct
positions
2. Fit the polymer coupling insert on the
steel coupling. Note correct position of
the hole in the insert.
3. Orient both the steel coupling and the
2 guide holes on the vane pump to fit into
the pressure exchanger.
4. Mount the bolts into the flange and tighten
them with 30 Nm ±3 Nm.

Danfoss A/S
High Pressure Pump
Nordborgvej 81
DK-6430 Nordborg
Denmark
© Danfoss | DCS (im) | 2016.03
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