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Danfoss iSave 21 Service Manual
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Danfoss iSave 21 Service Manual

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

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Summary of Contents for Danfoss iSave 21

  • Page 1 Service guide Energy Recovery Device iSave 21 Disassembling and assembling hpp.danfoss.com...

  • Page 2: Table Of Contents

    Assembling the iSave..............17 General Introduction This document covers the instructions for disassembling and assembling the iSave 21. Tools needed for disassembling the iSave: Important: It is essential that the iSave is - iSave 21 tool kit (180F4126) serviced in conditions of absolute cleanliness.

  • Page 3: Disassembling The Isave

    Service guide Disassembling and assembling iSave 21 Disassembling the iSave Place the iSave on a clean table. Unscrew the bolts in the flange. Remove the vane pump. Use internal coupling tool to remove coupling part from exchanger shaft. 180R9219 | 521B1171 | DKCFN.PI.003.K4.02 | 03.2016...

  • Page 4: Disassembling The Pressure Exchanger

    Service guide Disassembling and assembling iSave 21 Disassembling the pressure exchanger Screw in the two M8 bolts. Unscrew the bolts in the flange. Gently push out the flange. Wet the shaft and shaft seal with clean filtered water. Gently lever the shaft assembly free using 2 screwdrivers.
  • Page 5 Service guide Disassembling and assembling iSave 21 Lubricate the new bearing with clean If bearing in flange need to be changed filtered water. With use of a hand press gently press the bearing out from the gently press the new bearing in place back side with a tube or a drift.
  • Page 6 Service guide Disassembling and assembling iSave 21 Unscrew high-pressure bearing using a Remove the high-pressure bearing. special socket. Gently remove both valve plates. Gently lift the valve plate assembly free with the aid of the screwdrivers. Replace the O-rings and the back-up rings on the valve plate.

  • Page 7: Assembling The Pressure Exchanger

    Service guide Disassembling and assembling iSave 21 Assembling the pressure exchanger IMPORTANT: WARNING: It is essential that the iSave is serviced in Do not use silicone when assembling the conditions of absolute cleanliness. iSave. Do not reuse dismantled O-rings: they All Parts must be absolute clean before might be damaged.
  • Page 8 Service guide Disassembling and assembling iSave 21 Mount the high-pressure bearing Tighten the high-pressure bearing using special socket and torque wrench with 90Nm±9 Replace old O-ring with a new one Position the housing over the guide pin Mount all bolts in the flange and tighten Fit the guide pin in the flange.
  • Page 9 Service guide Disassembling and assembling iSave 21 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.
  • Page 10 Service guide Disassembling and assembling iSave 21 Position the port plate over the guide pin. Check that the port plate fits the center bearing and the guide pin. O-ring Guide pin Position the port flange over the guide pin. Change the O-ring in the flange and position the guide pin.
  • Page 11 Service guide Disassembling and assembling iSave 21 Shaft seal NOT mounted correct. Using the plastic assembly tool provided, large diameter first, press the seal home against the shoulder, by hand. The rubber seal face must turn into the flange. Be careful not to damage the carbon seal face on the shaft seal.

  • Page 12: Disassembling The Vane Pump

    Service guide Disassembling and assembling iSave 21 Disassembling the vane pump Gently adjust the spanner wrench around Unscrew the bolt in the middle of the the coupling and use it as back stop. coupling and remove the coupling. Remove all bolts in the HP out connection Remove the flange.
  • Page 13 Service guide Disassembling and assembling iSave 21 Gently remove the rotor. Remove vanes. Note: Loose parts inside the rotor. Gently remove side plate and pin. 180R9219 | 521B1171 | DKCFN.PI.003.K4.02 | 03.2016...

  • Page 14: Assembling The Vane Pump

    Service guide Disassembling and assembling iSave 21 Assembling the vane pump Location hole in the side plate: Position the guide pin. Position the side plate over the guide pin. Place the 4 pins in the rotor. Note: Make sure that the guide pin is located in the locating hole in the port plate.
  • Page 15 Service guide Disassembling and assembling iSave 21 One vane is NOT positioned correctly. Check that all vanes are positioned correctly. Replace the O-ring on the flange and wet Position the side plate over the guide pin. the flange properly with clean filtered water.
  • Page 16 Service guide Disassembling and assembling iSave 21 Change the O-ring in the HP out Make sure that the guide pin is located in the location hole. connection flange. Bolt the flange onto the vane pump. Fit the coupling into the pump.

  • Page 17: Assembling The Isave

    Service guide Disassembling and assembling iSave 21 Assembling the iSave Correct positions Fit the steel coupling onto the shaft of the Fit the polymer coupling insert on the pressure exchanger. steel coupling. Note correct position of the hole in the insert.
  • Page 18 Danfoss A/S High Pressure Pump Nordborgvej 81 DK-6430 Nordborg Denmark © Danfoss | DCS (im) | 2016.03 180R9219 | 521B1171 | DKCFN.PI.003.K5.02 | 18...