1. 14 DESCRIPTION FUNCTION Fluids are practically incampressiole and cannot therefore store pressure eneray. The compressibity ofa gas is utised n hycro-pneumatic accumulators for storing Mids. HYDAC bladéer accumulators are based on this principle, using itrogen es the compressible medium. ‘The bladder accumulator consists ofa fluid secton and a gas section wih the bladder acting as 0 995- proof screen. The fu around {he bladder Is connected with the hyeraulie crcut, so thatthe bladder accumulator draws in Nui when pressure increases and the gas is Eompressed. When the pressure Grops, the compressed gas expands and forces the stored fuid into the eeu HYDAC bladder accumulators an be used ina wide valety of ‘ppicatons, some of which are fisted below energy storage ‘emergency operation force equilibrium ‘leakage compensation ‘volume compensation ' shock absorption ‘ vehicle suspension ‘ pulsation damping (see brochure on “Hydraulic Dampers no. 3.701) Bladder Accumulators Standard1.2. CONSTRUCTION Ias-onrsion 4.2.1, Construction ‘# Standard bladder accumulators '33301400/500/550 HYDAC standard bladder Becumlatos consist of tho pressure vessel, the Nexble blader Uinth gas valve and the hye oanocton nih check valve. ‘The pressure vessel is seamless and manufactures rom high tensile Stoel ‘Bladder accumulator SB330N The fow optimised design ofthe standard a valve enables the ‘animum possible operating Nid fow rate t increase fo 25 08 on this Becumulator ype ‘High Flow bladder accumulator SB330H HYDAC high fow bladder accumulators, ype SB330H, are Figh performance accumulators with 8 flow rate of up 1030 1s. ‘The fue connestion i onarged to allow higher Now rates. Bladdor materials ‘The folowing elastomers are avaiable 28 standard ‘© NBR (acrylonitile butadiene rubber Perbunan), {IR (buy ubben, ‘© FKM (loro rubber, Viton ‘ECO (etnyene oxide epichlorohyarin rubber). The material used depends on the partculer operating mem and temperature. When selecting the elastomer, allowances must b@ made forthe fact that the gas can cool down to below the prmissbo elastomer temperature if there are adverse ischarge conditions (igh pressure fato py, apid discharge speed). ‘This 6an Gauso col cracking inthe elastomer. The gas temperature tan be calculates using tho HYDAG ‘Resumalator Simulation Program ASP 122 Cra 1.23 Corrosion protection For use with chemically aggressive media the accumulator shell ean be ‘Supplied wih corrosion protection, Such as plastic coating on the Inside or chemical nickel plating, Ithis is insufficient, then stainless steal accumulators must be used. 1.3. MOUNTING POSITION HYDAC bladder accumulators can be installed vertically, horizontally and ata start. ‘When instaling vertically or at a slant, the oil valve must be at the bottom, On certain applications listed below, particular postions are preferable: ‘energy storage vertical ' pulsation damping: ‘ny position from horizontal to vertical ‘© maintaining constant pressure: ‘any position from horizontal 0 vertical ‘© volume compensation: vertical Ifthe mounting positon is horizontal for ata slant the effective volume {and the maximum permissible fluid flow rate are reduced, 1.4. TYPE OF MOUNTING ‘© By using an appropriate adaptor, HYDAC accumulators, up to size 1 can be mounted directly inline ‘© For strong vibrations and volumes ‘above 1 |, we recommend the use ‘of HYDAC accumulator supports or the HYDAC accumulator mounting set (Brochure “Supports for Hydraulic ‘Accumulators" no, 3.502, and "ACCUSET SB", no. 3.503.) TECHNICAL ‘SPECIFICATIONS EXPLANATORY NOTES Working pressure see tables {Ii some countries this can differ from the nominal pressure) Nominal volume seo ables, Effective gas volume see tables, ‘based on nominal dimensions; this differs slightly from the nominal Yolume and must be used when Calculating the effective volume. Effective volume ‘The fluid volume ‘vallable between the working pressures p, and p, ‘Max. pressure fluid flow rate Inorder to achieve the max. flow rate given in the tables, the ‘acoumulator must be mounied Vertically Ithas to be taken into ‘account that residual fuid volume of approx. 10% ofthe effective gas. ‘volume remains in the accumulator, Fluids ‘The various seal and bladder ‘materials are compaiible with the following fluids: Water iid NBR Mineral os (aL, ALP, HEA, HEB, HFG), water EO Mineral oi IR Phosphate ester FRM Chlonnated hydrocarbons, petrol 2.,7 Permissible operating temperature “The permissible operating temperatures are dependent on the application limits of the metalic ‘materials and the bladders, ‘The standard valve bodies, gas valves and accumulator shells are suitable for temperatures -10 °C 0 +80°C. Outside these temperatures, special material combinations ‘must be used. The folowing table shows the correlation between bladder material and application 24 244 242 245 temperature, “Miateral [Temperature ranges NBRZ0, + 80°C NBR21 + 80°C NBRZZ + 80 ECO sat 120°C IR + 80°C FM 10°C. + 150°C. 24.8 Gas charging ‘Always charge with 99.995% ritrogen only fitered fo < 3 pm, other gases are to be used, please contact HYDAC for advice. NEVER USE OXYGEN OR COMPRESSED AIR. RISK OF EXPLOSION,2.1.9 Critical values for 7 Ag EU member sates WP Japan P ‘Switzedand u Usa s {gas pre-charge pressure p.209-p! with a permissible pressure rato of pp, $41 ‘max, operating pressure (gas pre-charge pressure others on request (On no account must any welding, soldering or mechanical work be: tarred out on the accumulator shell After the hydraulic line has Been connected it must be completely vented. Work on systoms with accumulators (repair, connecting pressure gauges etc) must only be carried out once the pressure and fuid have been released, Please observe operating instructions! Note: ‘Application examples, accumulator sizing and extracts from approvals regulations on hydraulic ‘accumulators can be found in the “Accumulators” overview brochure ro 3.000. 2.2. MODEL CODE {also order example) SB330H-32A4/ 112 -330A.050 High Flow increased flow, standard ol valve dimensions shock absorber pulsation damper Suction flow stabiliser blader top-repairable Combinations possible: og High Flow with a top-repairable bladder or pulsation damper with high flow rat. No details = standara Nominal volume in | Fuld connection slancard connection, tvead with internal seal face flange connection valve mounting with serews on underside Sealing surfaces on the front interface (2, on thread MEOx1.5) male thread special connection according o customer specification as side ‘standard model 4) = back-up model = gas valve 7/8-14UNF with M8 female thread 5/8" gas valve {988 valve MSOx1.5 in accumulators smaller than 60 | “18-14UNF gas valve = M28x1 5 gas valve = M16x1'§ gas valve 9 = special gas valve according to customer specification Material code" 112 =standard for mineral of depending on operating medium thers on request Fluid connection 4 carbon steel 2 = high-strength steel 3 = stainiess staat (Niro) 6 = low temperature steel ‘Accumulator shell @Y9020N=—9 oomo (= plastic coated (internally) 1 = Carbon steel 2 = chemically nickel plated (internally) 4 = stainless steal (Niro) > 6 = low temperature steel ‘Accumulator bladder 2] NBR20 Eco. = IR (Buty) NBR21 (low temperature) FKM others 9 = NBR22 Certificate code $$$] U's PED eTi2sIeC Permissible operating pressure (bar) Connection Thread, codes for fuid connections: A, C, E, G ‘A™= thread to ISO 228 (BSP) B = thread to DIN 13 of ISO 965/1 (metle) thvead to ANS! B11 (UN.-2B seal fo SAE J 514) 1D = thread to ANSI B1.20.1 (NPT) 'S = special thread according to customer specification Flange, codes for fu connection: F ‘A= DIN flange B= flange ANSI 16.5 (C= SAE flange 3000 psi = SAE flange 6000 psi 'S = special flange according to customer specification Gas pre-charge pressure p, at 20 °C must be stated separately if required —! CaS3. DIMENSIONS AND SPARE PARTS 3.1. DIMENSIONS Dimensions a Je Joo p —oESw la ¢ mx. Imax. [thread ie g 22 |e 2 |, BS le |e = |g aie |e 28 (ii & 's0 Lives bar [tires ao [mm frm fmm [mm [226 [mmm us 05 140005 [a8 [270], |a3.s|oss 1 390 |, [45 [302 7 rig [O84 | [92 |y 550 ese | fare] (s - e024 10 sates] [te form) [ooo tender (550 [25 [135 [sso loo] frie | fas la 30 ts se [17], 4 sty [HS are fos [9 [loaner |s0 [10 3 sees oor os] fat jer Se § 00 |s.7_ [15 [sat ote 10 390 [93 [25 [728 |°° "73 lore po 10 andere 75 Rone [P29 fo [om | lng fo? fro fs 10 fi ia [oas [eos [rae e2% [125|80_ [30 1a00_ [odors [sr2 [roa | [ase stancere [500 [ee [37.5 [585 [77 [ea lear |? |'0|7 "5 andara 5 fo om |i fi | ne fez flo Fe 7 a6 ans 88 (52% [125 [60 [30 sandara [a00| [a Jose ros] [sa Joa [100/705 standard 75 no [18+ [05 foe fio | Lng fez flo fe oon 20 |W 75 [535 [eat [138 62% [125|80 [30 seca wooed oa Ja06 [ra | [ase 70070 standard [500 17 [755 [901 |77 |68 lae1 |? [110|75_|'° andard 75 va Pert yyy [238 [900 fr062 103 |e, [any [62 |roofro HS H [24 [721097 [138 G2% (125/90 [30 | 3.2. ADAPTORS * [standard 15_ | Series ronal pK Sw ono fe fiom |e | Lng oz foo ria we |e 55 [oo [reas [a8 (62% [195|00_ [90 ives {83 |. low hm Vmonsoa [00 [309-|roas|v4is [os | fae] [100/70], eee s00 [30.5 [rar [144 [rr [68 [ast ‘10|75 seamuool os ole iex [a Lae andard 75 To" 60 [oz e136 [os i he IN 330 Jaz 5 7-5 [1991 [103 laza |S? [10/7 as ‘$8550 1-5 |e1 [ox [31 | 46 so |e rans |rass ae ee | [eax as |a0 foo | Seooo—[o0 20016271 -. Yon Low "00 a2 fiestas] fase 70 sesoon [10-40 [62% standard [500_|4a.3 [169 [1951 [77 at |O? [1075 1" | esr sepa @ joo 182 [156 EE ented woes [a 400 fossa se | land |ss0 [OS TEE L688 aa5 fon | [oz |125|00 loo 160 170 [306 [2008 Loe | 200 201 [485 [2306 | = ma operating fd ow ato Cra3.3. SPARE PARTS '38330/400/440/500/550 '3B330H / SB330N Detail "x" SB330/400 0.5 61 f 15 16 AT '$B330/400/500 - 10 to 200 | and SB330H ~ 10 to 2001 SB550- 1105! Description stom Anitextrusion #7 74 valve complet, consisting of Oil valve body 3 Valve 70 Damping sleeve 1 Safety nut 12 Valve spring 13 ‘Anti-extrusion ring 14 Protection ring 15 (O-ring (see above) 16 Spacer a7 Lock nut 18 Ventscrew 19 Seal ing 20 Back-up ring Ey Seal kit” consisting ‘O-ring (see above) 7 Protection ring 6 (O-ring (see abe 16 Seal ing 20 Back-up ring 23 (O-ring (see above) 2 Description item Gas valve inser” 3 Repair kit") consisting of: 2 3 4 Seal cap 5 Valve protection cap 6 (O-ring 7.52.0" 7 Protection ring 15 Oring. 16 Seal ing 20 Back-up ring 23 O-ring 20 Recommended " For code 069 and 605 ‘erent mensions 2 vnen ordering please state smallest adder connection por size hem 4 net avaable as spare part, Item 25 must be ordered separately (see paged) 3.4. REPAIR KITS NBR, carbon steel Nom: volume: 0.5 to 200 litres Standard gas valve Nom. volume tL ‘Stock no 05 02128169) 1 (02106261 25 (02106200 4 (02106204 5 (02106208. 6 02112100 70 osti7512 10) (02106212 13 (02106216. 20 (02106220, 28 2106224 32 (02106228 50 (02106252 60 os1i7513, 20 osti7st4 700 Os1i7515 120 OSTI7516 160 osti7517 200, 03117558, * slimline version for confined spaces others on request azo 200264, BLADDER ACCUMULATORS BACK-UP TYPE $B330-...A2 4.1. CONSTRUCTION Based on the bladder accumulators 20-50 |, the gas side ofthese ‘accumulators is designed especialy for connecting to nitrogen bots. A perforated anti-extrusion rod Prevents damage tothe bladder When the accumulator Is charged. This construction can also be used for the separation of fuids (taking Into account the volume ratios vals for bladder accumulators). 4.2. DIMENSIONS Non. Jefe ges Went 7A ives” _[lives"” ig |r 2017s S35 | 908 24 [a 72__[7070 2 aes 29 [1420 soars 7195 [1990 4.3. SPARE PARTS Description om Repair kit" ‘consisting of Bladder 2 Lock nut 4 O-ring 7.5x2.07 7 Protection ring 75 (O-ring 8055" 16 (O-ring 2252.57 31 Oring 12” 33 Rnicextrusion ring 14 od! 30) Recommended pares ° Fx code 69 an 5 erent hom ‘not avaiable a spare pat. lem 250 be ergered separately (208 page 4). Nom 32 ype + Standard ‘Other spare pars ~ se point 3 4.4. REPAIR KITS: Designation Stock 563301400220 NER ‘03119500, 5SB330/400A2-24 NBR (03119502, ‘SB330/400A2-32 NBR (03119496 53B330/80002. ‘thers on request NBR (03119499) Cra Type t orn hm 32, adaptor partno 240 5 ‘ ~ tom Sing 2x25Type 2 deport 32 manger O*PaTEX porto 20348 5. NOTE ‘The information in this brochure ‘lates tothe operating conditions and applications described. For applications or operating ‘conditions nat described, please Contact the relevant technical department ‘Subject to technical modifications. azo 20028GYarXs Navod k provozu Membranové akumulatory Betriebsanleitung Membranspeicher Betjeningsvejledning membranakkumulator Instrucciones de servicio Acumuladores a membrana Notice d'utilisation Accumulateurs @ membrane Kayttéohje Kalvoakut Instruction Manual Diaphragm Accumulator OSnyles Xprions Tapteunipes HepBpavns Istruzioni per I'uso Accumulatore a membrana Bruksanvisning Membranakkumulator Gebruiksaanwijzing Membraanaccumulator Instrugées de Servico Acumuladores de membrana instrukeja eksploatacji Membranowy akumulator cisnieniowy Pyxosonetsono axcnayarayun Memopanneie. FMApOAKKYMYNsTOpbI Instruktion Membranackumulator INTERNATIONAL 0 6/6/0/6/6/6 6/6/66 16/8 6 6<= % LASCHE, SEITE 2Ye LASCHE, SEITE 3 FPU-1 Pinicim a kontrolnim zarizenim Fill-und Prifvorrichtung Forfyldningsudstyr Dispositivo de llenado y control Moyen du dispositif Tayttd- ja testauslaite Charging and testing unit Aucrragn eAéyxou Kat MAr}p@aNG Dispositivo di riempimento e controllo Opptyllings- og kontrollapparat Vuk en testapparaat Dispositivo de enchimento e de teste Pomoca urzadzenia do napetniania i kontroli Tlomoussio sapanHo-KoHTponsHoro ycTpolicTBa Férladdnings- och kontrollenheten ‘Schéma zapojeni Schattplan Hydraulikdiagram Esquema de flujo ‘Schéma hydraulique Hydraulikaavio Circuit diagram Yopaviiko Bsypapua ‘Schema di collegamento Hydraulikkskjema Hydraulisch schema Croquis do fluxo Plan instalagji Monraxnas oxema Hydraulschema a P _ot fis‘Standartni provedent svarovana konstrukce E1 pinitelny; E2nepinitelny! ‘StandardausfUhrung Schwei8konstruktion E1, nachfillbar; E2 nicht nachfallbar! ‘Standardversion svojsekonstruktion E1, eftertyldbar; E2 ikke eftertyldbar! Ejecucion estandar, construccién soldada, E1 con posbilidad de rellenado; E2 sin posibidad de relenado! Version standard a structure soudée E1 rechargeable; E2non-rechargeable! ‘Standardversion , svetsad konstruktion, E1 (patyliningsbar), E2 (ej pafyliningsbar)! Standard version, weld-type E1, rechargeable; E2non-rechargeable! Kayo} extéAeon (or6vrap) KaraoKeuh ‘hextpoouyroh nue Et, enavarnpoouewn, E2 un ‘enavor”npobevn! Versione standard in strutturaeletrosaldata E1, ‘icaricabile; E2 non rcaricabile! ‘Standardutgaven som sveiset konstruksjon E1, for ottefybar, E2 or kke etterfyibar! ‘Standaarduitvoering lasconstructie E1, navulbaer; ED nietnavubaar! Execugio padro construgao soldada E1 recarregavel; 2 nao recarregavel! \Wykonanie standardowe: konstrukcja spawana Et przewidziana do napelniania, E2~ nie przewidziana do napetniania. Cranaaprioe ucnonHeie CeapHan KoHCTpyKUMA E1 - posapanxa sosmoxna; E2 - gosapanKa HeBoaMoxHal ‘Standardversion , svetsad konstruktion, E1( patyilningsbar), E2 (ej patyliningsbar)! Standartn! provedent Sroubovana konstrukce A6, pinitelny ‘Standdardausfthrung Schraubkonstruktion A6, rachfallbar ‘Standardversion skruekonstruktion A6, eftertyidbar. Ejecucién estandar, construccién desrroscable AB, con postbilidad de rellenado, Version standard a structure vissée A6 rechargeable. ‘Standardversion, skruvad konstruktion, A6 (afyliningsbar) Standard version, screw-type AG, rechargeable Kavoux) exréheon (ovdvrap) BiGorh KaTGOKEUT AG ‘eniavartAnpooyevn Versione standard in strutura bullonata A6, ricaricabile Standardutgaven som skrudd konstruksjon A6, cr ettorfylbar. Standaarduitvoering schroefconstructie A6, navulbaar. Execugao padrao construcao rosqueada A6, Tecarregavel. \Wykonanie standardowe: konstrukcja skrecana A6 = przewidziana do napelniania, Cranaaptioe ucnoneHne PeatGoaan KOHCTPYKUMAR AB nosapazKa soawonia Standardversion, skruvad konstruktion, A6 (pafyliningsbar)..30 1. General Diaphragm accumulators are pressure vessels, as defined in the pressure equipment directive 97/28)EC. They are closed vessels which are designed and built to store fluids under pressure. They consist of a fluid and a gas component with a diaphragm acting as the gas- proof screen. Hydraulic accumulators are exclusively designed to store and then discharge fluids under pressure. The diaphragm and the accumulator body must be suitable for the operating flu. ‘The regulations for commissioning and operating hydraulic accumulators which are in ‘force at the place of installation must be observed. ‘The plant operator is exclusively responsible for ensuring compliance with regulations. The certificate of conformity, it applicable, and any other documentation supplied with the diaphragm accumulator, depending on the conformity category, should be carefully stored at the place of installation for the on-site testing and for subsequent recurrent testing, Maintenance and repair instructions are available for work which may be carried out on the screw-type diaphragm accumulators after initial installation and commissioning, e.g. repair ‘work. These can be sent to customers on request. Avcauron ‘All work on the hydraulic and pneumatic connections of the diaphragm accumulator shal only be carried out by suitably trained staf. Improper installation or handling can lead to serious accidents, Before any work is carried out on hydraulic. equipment, the hydraulic system must be de- pressurized On no account must any welding, soldering, or mechanical work be carried out on the iaphragm accumulator. Danger of explosion if welding or soldering is carried out! Danger of bursting and loss of ‘operating permission if unauthorized mechanical work is carried out on the accumulator, Hydraulic accumulators must only be filed with nitrogen Nz (oxygen-free), and not with oxygen or air. Danger of Explosion! A CAUTION: ‘The accumulator shell can become hot. Risk of burns. 2. Installation and safety equipment The equipment, installation, and operation of hydraulic accumulators is subject to different regulations in different countries. In Germany the regulation is the "Technical Regulations - Pressure Vessels" (TRB) or EN 14359. This sets out the following minimum equipment: = Isolation valves — Equipment to prevent over-pressurization (this must be component-tested either by prototype checking or by individual inspection by expert) — Pressure release device between the accumulator and the isolation valves — Pressure measurement equipment and marking of the permissible operating pressure = Facility for a pressure test point. The following can also be fitted: — Excess temperature protection equipment, — Solenoid-operated pressure release valve. This equipment, in particular the safety equipment, is combined in compact form in a HYDAC Safety and Shut-off Block. 3. Transport and storage Transport The transport of gas-charged diaphragm accumulators must be carried out with the greatest care and in compliance with all relevant transport regulations. A\ caution: Do not put into operation any diaphragm accumulator which has been damaged during transportStorage ifthe storage period does not exceed 3 months, itwill be sufficient to store the pre-charged accumulators in a dry, cool place and protected from direct sunlight. The accumulator can be stored in any position. To avoid any contamination entering the accumulator it is essential to seal the hydraulic connection tightly If the storage period exceeds 3 months, the pre-charge prossure must be released down to 2 bar to prevent any deformation of the diaphragm, Inthe event that a screw-type diaphragm accumulator is to be stored for more than 1 year, itis advisable to disassemble it and to store the accumulator and the diaphragm Separately, When storing diaphragms the standard DIN 7716 "Rubber products: Quidelines for storage, maintenance and Cleaning" must be observed. 4. Commissio: AY CAUTION: Before commissioning a new diaphragm accumulator, it must be charged with nitrogen. The fluid side blanking plugs must be removed, The min/max. operating data are permanently marked on the accumulator. This marking must, always be visible, 4.1 Pre-charge pressure Diaphragm accumulators are normally supplied with a pre-charge pressure of approx. 2 bar. If required by the customer, the required pre- charge pressures can be set. The pre-charge pressure (p,) is indicated on a label on the accumulato? body, or stamped on the accumulator. The accumulator must be charged to the required pre-charge pressure by the operator before commissioning. The magnitude of the pre-charge pressure must be calculated from the operating data of the system, This can be calculated using the accumulator sizing program ASP, for example, which is available from HYDAC. Critical values of the gas pre-charge pressure Permissible pressure ratio p., paof the standard accumulatt te) Weld type: 28and3.5i 4:4 Other sizes: 8:1 ‘Screw-type: All sizes: 10:1 Torque setting of the gas charging screw: 20 Nm 4.2 Charging gas Hydraulic accumulators must only be charged with nitrogen to the minimum class of 4.5. 4.3 Charging the accumulator The HYDAG charging and testing unit FPU-1 must be used for charging the diaphragm accumulator, The charging and testing unit is supplied with a detailed instruction manual, See also section 5.3 of this manual. 4.4 Permissible operating temperature ‘The permissible operating temperature is determined by the type of accumulator body used and the elastomer mixture of the diaphragm and is indicated on the name plate and/or in the certificate of conformity. 4.5 Permissible operating pressure ‘The permissible operating pressure is determined by the type of accumulator body used and is indicated on the name plate and/or the certificate of conformity. 4.6 Installation position Diaphragm accumulators can be installed in any position. The vertical installation position is preferred. Other positions can affect the performance. If there is any risk of contamination, the hydraulic fluid connection should always be at the bottom. height of approximately 150 mm must be provided above the gas valve for fitting the charging unit 4.7 Mounting For sizes up to 2 | nominal volume and if ‘equipped with a standard connection, the accumulators can be screwed directly inline. The diaphragm accumulator must be mounted such that in the case of any vibration during operation or any possible failure of the connection pipework, the accumulator is securely fixed, The mounting elements must not exert stress in any form on the diaphragm accumulator. We recommend using HyRac clamps. Suitable clamps and consoles can be found in the brochure on mounting elements for hydraulic accumulators, Moreover, HYDAC offers a range of appropriate mounting suppor, including supports for extreme conditions. 4.7 General For further technical details like, for example, the selection of the pre-charge pressure, the max, permissible flow rate, weights etc. can be found in the brochure: Diaphragm accumulators. 3132 5. Maintenance of the accumulator 5.1 Basic maintenance advice HYDAC diaphragm accumulators are generally maintenance free, However in order to ensure long and trouble-free operation, the following maintenance procedures must be carried out regularly — Test the nitrogen pre-charge pressure — Check that connections are tight and leak free — Check valves and safety devices are working correctly — Check the mounting supports. 5.2 Testing frequency of the pre-charge pressure Itis recommended that the following testing frequencies be maintained: — after installation, — one week after installation, — eight weeks after installation, If no nitrogen loss is detected, the test frequency can be: = once per year. Li NOTE: Continuous operation at high operating temperatures requires more frequent testing. 5.3 Testing the pre-charge pressure ‘The gas pre-charge pressure can be checked with or without the charging and testing unit FPU- On small accumulators, and wherever possible, the pre-charge pressure should be tested without the charging and testing unit because this does not cause any nitrogen loss during the test Testing of rechargeable diaphragm accumulators using the charging and testing unit FPU-1 ‘The following steps should be followed for testing or charging with the FPU-1 device: — Release pressure from the fluid side of the diaphragm accumulator. ~ Unscrew the valve protection cap (2) from the diaphragm accumulator. — Slightly loosen the int. hex. screw (1) on the diaphragm accumulator using an Allen key SW6, DIN 911, (approx. 1/2 turn). ~ To prevent any leakage at the gas connection, the bonded seal (3) must be lubricated with a suitable fluid when first fitting. — Screw the FPU-1 onto the gas charging connection of the diaphragm accumulator (M28x1.5) by hand, = Close the release (8) on the FPU-1. The following steps are only necessary if the accumulator must also be charged. — Connect the nitrogen bottle (N2) with the pressure reducer (D) and adapter (G) (if any) with charging hose (F) to the FPU-1 at the non-return vaive (N). Testing — By tuming the spindle (H) clockwise, open the gas valve. Once the pressure gauge (M) indicator begins to move turn the spindle one more full rotation. — Read off the actual gas pre-charge pressure on the pressure gauge (M). illing = Slowly open the nitrogen bottle valve so that the nitrogen can flow into the accumulator. = From time to time interrupt the charging process and read the pressure reached on the pressure gauge (M) = After temperature equalisation has taken place, check the pre-charge pressure again and adjust if necessary. The standard values are generally based on 20°C charging temperature. — Ifthe pressure is too high, it can be reduced Via the pressure release (B). ~ Ifthe required gas pre-charge pressure is achieved, the int. hex. screw of the diaphragm accumulator must be closed by turing it clockwise. = Close the isolation valve on the nitrogen bottle, de-pressurize the FPU-1 via the release and remove the charging unit by unserewing the connector. Tighten the int hex. screw (1) (20 Nm). — Check the gas valve for leakage with an appropriate leakage spray. — Screw on the valve protection cap (2).Testing of (non-) rechargeable diaphragm accumulators without the charging and testing unit By seiting up the accumulator as per the drawing on the fold-out page or by using the Safety and Shut-off Block (SAF or SAB), the pre-charge pressure can also be checked via the fluid side. ~ Isolate the hydraulically charged diaphragm accumulator from the system by moans of the isolation valve (3), = Drain the diaphragm accumulator of fluid slowly via the drain valve (4) — Watch the pressure gauge (2). ~ The pressure will intially fall slowly. tt will drop suddenly only after complete drainage of the accumulator. This pressure is the same as the pre-charge pressure of the diaphragm accumulator. — Ifthe indicated pre-charge pressure is different from the required pressure, the diaphragm should be re-charged as described above, i itis rechargeable, LI note: Drawings referred to in the text are shown on the fold-out page. 6. Service life Like all pressure vessels, HYDAC diaphragm accumulators have a finite service life. The lifetime is dependant on the magnitude of the pressure cycle, and also on the number of cycles. Acyele table is supplied with the certificate of conformity. A suitably qualified person can use this table to determine the operational life of the diaphragm accumulator (body stability) as determined by the operating parameters of the hydraulic system, The transfer of gas across the diaphragm due to its physical properties, as well as a failure in the diaphragm, can resuit in a gas accumulation in the hydraulic system. In the event of a pressure drop this gas will expand significantly. Suitable measures must therefore be taken to relieve the gas. Instructions for the disposal of diaphragm accumulators. Rechargeable versions: Reliove the charging pressure via the gas charging connection, and remove the gas charging screw. Non-rechargeable version: Relieve the charging pressure by destroying the diaphragm, for example, by driling through it, ensuring suitable safety measures are taken’ 7. Customer service Service, repeat testing and repairs can be carried out at the HYDAC headquarters: HYDAC International GmbH Servicetechnik - Zentraler Kundendienst IndustriestraBe Postfach 1251 D-66273 Sulzbach Tel. +49 (0) 6897-509-01 Fax, +49 (0) 6897-509-828 Internet: www.hydac.com or at all national and international HYDAC sales and service centres. 33