Danfoss iSave 21 Plus Service guide

Service guide

Energy Recovery Device iSave 21 Plus

Disassembling and assembling

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Service guide | Disassembling and assembling iSave 21 Plus

Table of Contents

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
8.	Exploded view vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
9.	Exploded view pressure exchanger	. . . . . . . . . . . . . . .	. . . . . . .	.	19
10.	Exploded view iSave . . . . . . .	. . . . . . . . . . . . . . . . .	. . . . . . . .	.	20

1. General Introduction	This document covers the instructions for
	disassembling and assembling the iSave 21 Plus.
	Important: It is essential that the iSave is	Tools needed for disassembling the iSave:
		- iSave 21 Plus tool kit (180F4160)
	serviced in conditions of absolute cleanliness.	- 2 screwdrivers
		- Lock ring plier
	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 47 kg / 103 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.

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Service guide | Disassembling and assembling iSave 21 Plus

2.Disassembling the iSave

1.Place the iSave on a clean table.

2.Unscrew the bolts on the frontflange. (See above - bolts marked in red)

3.Remove the vane pump.

4.Use special tool to fix the coupling in place while loosing the coupling.

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Service guide | Disassembling and assembling iSave 21 Plus

3.Disassembling the pressure exchanger

1.Unscrew the bolts in the flange.

3. Gently push out the flange.

5.Unscrew the bolts in 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/allen keys..

6.Gently remove the flange.

Note: Loose parts on the inside of the flange.

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Service guide | Disassembling and assembling iSave 21 Plus

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.

9.Gently remove the cylinder barrel.

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!

10.Unscrew the bolts in the flange.

11.Gently remove the housing.

Note: Loose parts on the inside of the flange.

Pin

12.Remove port plate and pin.

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Service guide | Disassembling and assembling iSave 21 Plus

13.Remove the high-pressure bearing using a lock ring plier.

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.

14.Remove the high-pressure bearing.

16.Gently remove both valve plates.

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