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

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

180R9219 | 521B1171 | DKCFN.PI.003.K4.02 | 03.2016

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.

Service guide Disassembling and assembling iSave 21

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.

Service guide Disassembling and assembling iSave 21

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.

Service guide Disassembling and assembling iSave 21

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.

Service guide Disassembling and assembling iSave 21

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).

Service guide Disassembling and assembling iSave 21

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

9. Mount all bolts in the ﬂange and tighten

them all with 30Nm±3

10. Fit the guide pin in the ﬂange.

Service guide Disassembling and assembling iSave 21

180R9219 | 521B1171 | DKCFN.PI.003.K4.02 | 03.2016

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

Service guide Disassembling and assembling iSave 21

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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