Danfoss 180F7024 User guide

Service guide

Energy Recovery Device

iSave 21 Plus

Disassembling and assembling

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Service guide | Disassembling and assembling iSave 21 Plus

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Table of Contents

This document covers the instructions for

disassembling and assembling the iSave 21 Plus.

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 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.

Tools needed for disassembling the iSave:

- iSave 21 Plus tool kit (180F4160)

- 2 screwdrivers

- Lock ring plier

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

8. Exploded view vane pump.............................................................18

9. Exploded view pressure exchanger ...............................................19

10. Exploded view iSave ...................................................................20

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1. Place the iSave on a clean table.

3. Remove the vane pump.

2. Unscrew the bolts on the frontange.

(See above - bolts marked in red)

2. Disassembling the

iSave

4. Use special tool to x the coupling in

place while loosing the coupling.

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3. Disassembling the

pressure exchanger

1. Unscrew the bolts in the ange.

3. Gently push out the ange.

2. Screw in the two M8 bolts.

4. Wet the shaft and shaft seal with clean

ltered water. Gently lever the shaft

assembly free using 2 screwdrivers/allen

keys..

5. Unscrew the bolts in the ange. 6. Gently remove the ange.

Note: Loose parts on the inside of the ange.

Service guide | Disassembling and assembling iSave 21 Plus

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7. If bearing in ange 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

ange.

8. Lubricate the new bearing with clean

ltered water. With use of a hand press

gently press the new bearing in place

until it is in line with the ange surface.

Do not use a hammer!

9. Gently remove the cylinder barrel.

10. Unscrew the bolts in the ange.

11. Gently remove the housing.

Note: Loose parts on the inside of the

ange.

12. Remove port plate and pin.

Service guide | Disassembling and assembling iSave 21 Plus

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13. Remove the high-pressure bearing using

a lock ring plier.

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 Plus

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4. Assembling the

pressure exchanger

3. Lubricate all the O-rings and back up

rings with clean ltered 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 ltered water.

1. Mount the new back-up rings on the

valve plate rst 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 ltered water.

- O-rings for port ange, mounting ange may

be lubricated with a small amount of grease.

- It is important to lubricate ALL parts to be

assembled with clean ltered water (Especially

all PEEK parts).

Service guide | Disassembling and assembling iSave 21 Plus

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5. Mount the high-pressure bearing

6. Lock the high-pressure bearing in place

with the lock ring.

7. Replace old O-ring with a new one

8. Position the housing over the guide pin

9. Mount all bolts in the ange and tighten

them all with 30Nm±3

10. Fit the guide pin in the ange.

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11. Location hole in port plate.

There are two dierent port plates in the iSave. One of them can be mounted on both anges in

the pressure exchanger. Make sure that they are assembled on the right ange.

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 ange.

14. Change the O-ring in the ange and

position the port plate over the guide

pin.

15. Check that the port plate ts the center

bearing and the guide pin.

Service guide | Disassembling and assembling iSave 21 Plus

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17. Position the port ange over the guide

pin and shaft. Make sure the guide pin is in

lign wih the ange..

18. Wet the shaft seal with clean ltered

water.

Do not use silicone grease.

Fit the shaft seal with the carbon surface

upward.

19. Shaft seal NOT mounted correct.

The rubber seal face must turn into the ange.

17. Mount all bolts in the ange and tighten

them to a torque according to exploded

view.

20. Using the plastic assembly tool provided,

large diameter rst, press the seal home

against the shoulder, by hand.

Be careful not to damage the carbon seal face

on the shaft seal.

21. Shaft seal in right position:

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22. Remove the old ceramic ring from the

ange. Position the new O-ring on the seal

ange.

23. Push the new ceramic ring into the ange

using plastic tool provided (small diameter).

Make sure the face with the rubber seal is

positioned against the shoulder in the

ange.

Before assembly wet the parts with clean

ltered water.

24. Position the seal ange and the bolts.

Tighten the 4 bolts with a torque according

to exploded view.

Service guide | Disassembling and assembling iSave 21 Plus

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1. Install the special tool for locking the

shaft.

3. Remove all bolts in the int. ange.

2. Unscrew the bolt in the middle of the

coupling and remove the coupling.

4. Gently remove the ange, the side plate

may stick to the ange. - make sure that it

do not drop.

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. Rotate the housing to access the

connection ange.

10. Remove the screws in connection

ange.

11. Remove connection ange and port

ange.

12. Remove side plate and remove pin in

side plate.

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1. Place the connection ange with the

nozzle downward.

2. Place the side plate on the port plate.

Note the pin.

6. Assembling the

vane pump

3. Place the port ange on top of the

connection ange. Note the pin.

4. Side plate mounted correct.

6. Turn the anges and stator while

pushing the parts together.

5. Note the pin. Place the new stator rin

on the port ange.

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7. Fasten screws with a torque according

to exploded view.

8. Place the 4 pins in the rotor.

9. Lubricate with water and gently place the

rotor in the bearing.

10 Position the 8 vanes in the rotor. The

pins may be moved by using a

screwdriver.

11. Lubricate and check that all vanes are

positioned correctly.

12. Replace the O-ring on the int. ange and

wet the ange properly with clean

ltered water.

Service guide | Disassembling and assembling iSave 21 Plus

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15. Lift the shaft while carefully pushing the

int. ange incl. side plate on to the stator.

16. Rotate the assembly and install the six

screws. Tighten according to exploded

view.

18. Install O-rings on ange.

17. Install coupling. Lock the shaft with speciall

tool, tighten the screws to a torque

according to exploded view.

13. Position the side plate over the guide pin. 14. Fit the int. ange into both the bearing in

the ange and the location pin in the

stator.

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3. Ensure O-rings are in place.

7. Assembling the

iSave

1. Place the exchanger vertical on the HP

connector, and install the coupling spider.

2. Fit the polymer coupling insert on the

steel coupling. Note correct position of

the hole in the insert. Install pin on

exchanger.

4. Orient the steel coupling and place the

vane pump on the pressure exchanger.

5. Install the remaining bolts and tighten

them according to a torque speciec on

the exploded view.

6. When assembled it should be possible to

rotate the shaft at a torque between 10 and

15 Nm.

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8. Exploded view

vane pump

Service guide | Disassembling and assembling iSave 21 Plus

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9. Exploded view

pressure exchanger

Danfoss A/S

High Pressure Pump

Nordborgvej 81

DK-6430 Nordborg

Denmark

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10. Exploded view iSave

Danfoss 180F7024 User guide

Danfoss 180F7024 User guide

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