MAKING MODERN LIVING POSSIBLE

Service instruction

Assembly and disassembly

iSave 21

isave.danfoss.com
Service instruction iSave 21

This document illustrates instructions for changing internal parts in iSave21.

To understand the design of the iSave, see exploded in page 14-16.

The weight of the iSave is 41 kg and must be lifted with suitable lifting equipment.
The weight of the pressure exchanger alone is 28 kg.

It is essential that the iSave is serviced in conditions of absolute cleanliness

Tools needed for disassembly the iSave:

- 6mm and 8 mm alien key
- 2 screwdrivers
- 2 M8 bolts
- Plastic tube
- Plastic tool for shaft seal assembly
- Loctite 270

To prevent cold welding, lubricate threads screws with grease and screw them into the component
and tighten by hand. Use PTFE lubrication type.

iSave disassembly 1. Place the iSave on a clean table 2. Unscrew the bolts in the flange

3. Remove the Vane pump

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Pressure Exchanger 4. Unscrew the bolts in the flange 5. Screw in the two M8 bolts
assembly

6. Gently pull out the flange 7. Wet the shaft and shaft seal with clean (fil-
tered) soap-water. Gently lever the shaft seal
assembly free using 2 screwdrivers

8. Unscrew the bolts in the flange 9. Gently remove the flange

NB! Loose parts on the inside of the flange

10. Gently remove the cylinder barrel 11. Gently lever the valve plate assembly free
with the aid of the screw-drivers

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12. Gently remove the valve plates 13. Replace the O-rings and the back-up rings on
the valve plate

14. Mount the new back-up rings on the valve 15. Lubricate all the bores in the cylinder barrel
plate first and then the new O-rings with grease or soap

16. Gently press, by hand, the first valve plate 17. Gently press, by hand, the second valve plate
onto the cylinder barrel onto the cylinder barrel by placing it on the ??
NB don’t scratch the valve plate by placing it NB don’t scratch the valve plate by placing it
on the plastic tube. on the plastic tube.

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18. Adjust the distance between the cylinder The distance must be about 4-6 mm.
drum and the second valve plate This is not critical

19. Fit the guide pin in the flange 20. 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.

21. Position the port plate over the guide pin. 22. Gently guide the cylinder drum into the
NB: Make sure that the guide pin is located in bearing in the flange
the locating hole in the port plate. See #20

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23. Check that the next port plate is correct 24. Not correct port plate

25. Position the port plate over the guide pin 26. Check that the port plate fits the guide pin

27. Change the o-ring in the flange and position 28. Position the port flange over the guide pin
the guide pin

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29. Mount all bolts in the flange and tighten 30. Wet the shaft seal with soap.
them all with 30 Nm Do not use silicone grease.
Fit the shaft seal with the carbon surface upward

31. Shaft seal NOT mounted correct. 32. Using the plastic assembly tool provided,
The rubber seal face must turn into the flange 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

33. Shaft seal in right position 34. Remove the old ceramic ring from the flange.
Position the O-ring on the seal flange

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35. Push the new ceramic ring into the flange 36. Position the flange and the bolts.
using plastic tool provided. Make sure the face Tighten the 4 bolts with 12 Nm
with the rubber seal is positioned against the
shoulder in the flange.
Wet the parts with clean (filtered) soap-water
Before assembly.

Vane Pump assembly 37. Gently adjust the spanner wrench around the 38. Unscrew the bolt in the middle of the
Coupling and use it as back stop coupling and remove the coupling

39. In the table where the service is made place 40. Fix the vane pump with the 2 bolts
one of the two bolts in a hole

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41. Remove all the bolts in the flange 42. Remove the flange

43. Remove side plate 44. Side plate removed

45. Gently remove the rotor. 46. Remove vanes

NB! Loose parts inside the rotor

47. Gently remove side plate. 48. Check that the guide pin is OK and located
correct.

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49. Location hole in the side plate 50. Position the side plate over the guide pin.
NB: Make sure that the guide pin is located
in the locating hole in the port plate. See #49

51. Place the 4 pins in the rotor 52. Gently place the rotor in the bearing

53. Position the 8 vanes in the rotor. 54. Check that all vanes are positioned correct.
The pins my be moved by use of a screwdriver Below is OK

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55. One vane is NOT positioned correct 56. Replace the o-ring on the flange and wet the
flange properly with filtered water

57. Position the side plate over the guide pin 58. Make sure that the guide pin is located in the
locating hole in the side plate. See #57

59. Fit the flange into both the bearing in the 60. Make sure that the guide pin is located in the
flange and the location pin in the stator location hole

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61. Change the o-ring in the flange 62. Bolt the flange onto the vane pump.
Tighten the bolt with 30 Nm

63. Fit the coupling into the pump.

Glue the threat on the bolt with “loctite 270”
and tighten the bolt with 10 Nm.
Change the two o-rings in the flange.

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iSave assembly 64. Fit the seal coupling onto the shaft of the 65. Fit the polymer coupling on the steel
pressure exchanger coupling

66. Orient both the seal coupling and the 2 guide 67. Mount the bolts into the flange and tighten
holes on the vane pump to fit into the pressure them with 30 Nm
exchanger

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Exploded view
Vane pump

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Exploded view
Pressure Exchanger

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Exploded view iSave

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