Bladder Accumulators SB 330/SB 400/SB 550

Operating and Maintenance Instructions

INDEX 1. DESCRIPTION 2. DELIVERY INSPECTION 3. INSTALLATION AND MOUNTING 4. CONNECTION 5. COMMISSIONING AND SAFETY PRECAUTIONS 6. INSPECTION AND MAINTENANCE 7. STORAGE AND PRESERVATION 8. DISASSEMBLY, INSPECTION AND ASSEMBLY 9. SPECIAL TOOLS AND SPARE PARTS 10. CUSTOMER SERVICE

6.2. CHARGING PROCEDURE WITH THE CHARGING AND TESTING UNIT Using the charging and testing unit FPU1, hydraulic accumulators can be charged with nitrogen to the precharge pressure p0, or tested. Firstly, isolate the bladder accumulator from the hydraulic system by closing the shutoff valve A and discharge it on the fluid side. Then remove the valve protection cap, the cap nut and the Oring. The charging and testing unit FPU1 and the nitrogen bottle can now be connected in accordance with the operating instructions (with adaptor A3). Ensure that the pressure release valve of the FPU1 is closed. Then slowly open the valve of the nitrogen bottle so that the nitrogen is released into the accumulator. Wait until approximately 1 bar has been reached before opening the shutoff valve of the nitrogen bottle further to enable faster charging. Interrupt the charging procedure from time to time and check the precharge pressure reached. When the required precharge pressure has been reached, close the shutoff valve of the nitrogen bottle. Wait for approx. five minutes whilst temperature equalisation takes place (a longer period must be allowed for larger charging quantities), then recheck the precharge pressure and adjust if necessary. If the pressure is too high, it can be lowered via the pressure release valve of the FPU1. Turn the spindle clockwise to close the valve. Then discharge the charging and testing unit via the pressure release valve and remove it by loosening the cap nuts. Then check for leakages on the accumulator gas valve using a leak detector spray. Screw on cap nuts and valve protection cap (for torque ratings see Table 1, Point 8.5). Further details can be found in the HYDAC brochure HYDAC Charging and Testing Unit and in the operating instructions for the FPU1.

6.3. PRESSURE TESTING For bladder accumulators with a permissible operating pressure p greater than 1 bar and a pressure capacity p*V > 1000, for noncorrosive fluids, a pressure test must be carried out by an approval authority every 10 years, otherwise every 5 years. An internal inspection must be carried out every five years and an external inspection every two years. For further information, refer to the (German) Pressure Vessels Regulations (DruckbehV).

7. STORAGE AND PRESERVATION

If the period of storage up until commissioning is no longer than three months, it is sufficient for the precharged accumulator, which is moistened on the inside with hydraulic fluid, to be stored in a cool, dry place, protected from direct sunlight. The accumulator can be stored in any position. To prevent contamination from entering the accumulator, ensure that the hydraulic connection is plugged. If the accumulator is to be stored for longer than three months, discharge the precharge pressure down to 2 bar to prevent the bladder from becoming deformed. When commissioning the accumulator allow the hydraulic fluid to flow in slowly in order to protect the bladder. If the accumulator is intended to be stored for longer than one year it is advisable to disassemble it and store the accumulator and bladder separately. When storing accumulator bladders, the DIN Standard 7716 Rubber Products, Guidelines for Storage, Maintenance and Cleaning must be followed.

6. INSPECTION AND MAINTENANCE

On the whole, nitrogen losses on bladder accumulators are very low. However, to prevent the bladder from becoming too deformed if there is a drop in the precharge pressure p0, a regular check of the precharge pressure is recommended. The precharge pressure shown on the adhesive label or type code label must be readjusted after every new installation or repair and then checked at least once during the first week. If no nitrogen loss is detected, a further check should be carried out after approximately four months. If after this period no pressure change is detected, an annual check of the nitrogen pressure will be sufficient.

6.1. CHECKING THE NITROGEN PRESSURE WITHOUT A CHARGING AND TESTING UNIT In this case, as shown in the following drawing, a pressure gauge is connected to a line which is directly connected to the accumulator.

W E A

Isolate the fullycharged bladder accumulator from the hydraulic system by closing the shutoff valve A. Very slowly discharge the accumulator on the fluid side via drain valve E. The pressure gauge must be constantly monitored during this process. A slow, steady pressure drop is displayed. The pressure only drops abruptly when the accumulator has been completely discharged. The pressure displayed before the drop corresponds to the precharge pressure of the bladder accumulator. If this pressure lies below the permissible value, the charging procedure must be carried out, as described in the following section.

1. DESCRIPTION
These Operating and Maintenance Instructions apply to HYDAC bladder accumulators of the series SB330 / SB400 / SB550 having the following specifications: permiss. operating pressure: 330 / 400 / 550 bar permiss. operating temperature: 10 / +80 C (standard, with NBR seal) max. precharge pressure p0: p0,tmax 0.9 p1 permiss. pressure ratio 4:1 p2 : p0 Design, Approval: TRB/AD Regulations, TV where: p0 = precharge pressure, p1 = minimum operating pressure, p2 = maximum operating pressure For volumes, dimensions and weights (when empty), see drawing or brochure. Manufacturer: HYDAC Technology GmbH Geschftsbereich Speichertechnik Postfach 1251 66273 Sulzbach/Saar Industriegebiet 66280 Sulzbach/Saar Germany Tel: 06897 / 50901 Fax: 06897 / 509464

3. INSTALLATION AND

MOUNTING
3.1. MOUNTING POSITION The accumulators can be mounted both vertically and horizontally. However, the vertical mounting position with the gas valve at the top is generally preferred. Irrespective of the mounting position, the type code label or vessel label must be accessible and legible. Sufficient clearance must be left to mount and disconnect the bladder accumulator. In particular, an area of at least 150 x 150 x 150 mm must be left above the gas valve for fitting and operating the charging and testing unit FPU1. 3.2. MOUNTING In accordance with the recommendations of the HYDAC brochure Supports for Hydraulic Accumulators, HYDAC bladder accumulators must be mounted vibrationfree using clamps and consoles. NOTE Mounting elements must never be welded to the bladder accumulator. On request we can build fully assembled and connected accumulator stands as standard and special models.

intended function of the accumulator. 5.1. COMMISSIONING The following precharge pressures are recommended: for energy storage: p0,tmax = 0.9 p1 for shock absorption p0,tmax = 0.6 ... 0.9 pm pm = average operating pressure for pulsation damping: p0,tmax = 0.6 ... 0.8 pm Examples: p0,tmax = 0.6 pm with 1 piston pump p0,tmax = 0.7 pm with three or more piston pumps p0,tmax = 0.8 pm with operating pressure range Critical value of the gas precharge pressure: p0 0.9 p1 permiss. pressure ratio of p2 : p0 4 : 1 Further information on the gas precharge pressures can be found in the HYDAC accumulator brochure Bladder Accumulators or Hydraulic Dampers. Charging and testing of the precharge pressure is described in Point 6 Inspection and Maintenance. 5.2. VENTING Prior to commissioning, the accumulator must be vented via the vent screw (Item 19). As soon as oil seeps past the vent screw, tighten it again. Then apply the maximum operating pressure to the complete hydraulic system and check for leakages. After commissioning, tighten the gas and oil valve lock nut (for torque ratings, see Point 8, Table 1). 5.3. SAFETY PRECAUTIONS NOTE! Only use nitrogen to charge the accumulator bladder, never oxygen or compressed air (risk of explosion). If the pressure of the nitrogen bottle is higher than the permissible operating pressure of the accumulator, a pressure release valve or gas pressure valve must be fitted.

4. CONNECTION
The hydraulic connection on HYDAC bladder accumulators is threaded as standard. The connection of the accumulator to the pipe must be stressfree and torquefree. It must be possible to isolate the accumulator from the pressurised hydraulic system. This means that it must be possible to discharge the vessel on the fluid side. In this regard the (German) Pressure Vessel Regulations (DruckbehV) and other relevant regulations must be observed.

2. DELIVERY INSPECTION
Prior to delivery, HYDAC accumulators undergo a careful inspection. Upon receipt of the accumulator, check that: no damage has been sustained during transport. In particular, carry out a visual check of the gas valve and the hydraulic connection for damage, the details shown on the type code label correspond to the order details the test certificates (if required) are present and correspond to the factory number of the accumulator, the protective cap of the gas valve is tightly closed, the hydraulic connection has been closed off with a protective plug.

5. COMMISSIONING AND SAFETY PRECAUTIONS

Prior to connecting the accumulator to the pressurised system, the precharge pressure should be rechecked. If the accumulator was precharged at HYDAC the pressure level can be found on the adhesive label or stamped on the type code label. The level of the precharge pressure generally depends on the following criteria: type of system, expected changes in operating temperature,

8. DISASSEMBLY, INSPECTION AND ASSEMBLY

See Point 9.2 for item numbers 8.1. DISCONNECTION Carefully clean the area around the connections on the gas and fluid side. On backup type bladder accumulators the nitrogen feed line must be isolated by means of the shutoff valve. Completely release the pressure on the fluid side of the accumulator. Remove all nonpressurised lines on the fluid side and remove the complete bladder accumulator from the system.

8.2. DISASSEMBLY Secure the accumulator to a horizontal base and disassemble as follows: The gas precharge pressure must always be released first. NOTE! When releasing nitrogen, ventilate area well, danger of suffocation! Unscrew valve protection cap (item 6) and cap nut (item 5). Release the nitrogen pressure using the charging and testing unit FPU1. Remove gas valve insert (item 3) using a gas valve wrench. Clamp small accumulators in a vice and secure large ones on an assembly bench (clamps, chains etc.). Remove vent screw (item 19). Loosen and unscrew lock nut (item 18) with a Cspanner. Remove spacer (item 17). If not easily removable it can be knocked loose using a plastic hammer. Loosen valve and slide it into the body. Reach into the opening and remove the Oring (item 16) and the washer (item 15) from the oil valve (if fitted, the support ring (item 23) should also be removed). Strip antiextrusion ring (item 14) from the oil valve, fold and remove it. Remove oil valve. Loosen lock nut (item 4) on the gas valve and remove bladder. NOTE! Collect hydraulic fluid draining from the gas and fluid side in a suitable container!

8.3. INSPECTION OF COMPONENTS a) Pressure vessel Carefully clean the inside of the pressure vessel with a nonaggressive, nonabrasive cleaning agent, then dry with a lintfree cloth. Check that the bore on the fluid side is undamaged to ensure that the Oring provides a tight seal. If any external or internal damage is found, the pressure vessel must be submitted immediately to the manufacturer and, if applicable, the appropriate inspection authority for assessment. b) Bladder Charge the bladder fully with nitrogen, or possibly compressed air, and check for damage. The bladder must be replaced if there is evidence of even the slightest leak. Revulcanisation or repair is neither possible nor permissible. Possible chafe marks should be examined for depth. If such chafe marks exist, it is advisable to check the pressure vessel again for rough spots. Small grooves in the elastomer are not significant and do not impair the function of the bladder. If the gas valve insert is leaking, it must be replaced with a new one. The seat can be slightly abraded beforehand using a special tool. Even bladders under more operating pressure (in the pressure vessel) must be absolutely leakfree at the gas valve. If this is not the case, the bladder must be replaced. c) Oil valve Push down valve plate and turn through approximately ninety degrees a few times to ensure that it moves freely. The valve plate shaft must be free of grooves and the selflocking nut must be tight. The valve plate, fitting surfaces and threads must be undamaged. If a new selflocking nut is to be fitted, it must be secured with adhesive. There must be no damage due to the effect of force. d) Antiextrusion ring The ring must be replaced if the elastomer is badly cracked or shows signs of embrittlement or ageing. (There must be no grooves or rough areas on the seat surfaces). e) Seal kit The seals should always be replaced. f) Other parts These should also be checked for damage and replaced where necessary.

8.4. ASSEMBLY Assembly is carried out as follows: Moisten the inside of the accumulator with the operating medium. Unscrew protective cap (item 6), cap nut (item 5) and lock nut (item 4). Remove gas valve insert (item 3) using gas valve wrench. Press the bladder to expel all the air. Larger bladders can be rolled up to the gas valve. Spray the bladder with oil or the intended operating medium. IMPORTANT! Do not use pure water as water alone does not constitute a permanent lubricant. Exception: accumulators that are specially designed for use with pure water. Large bladders should be screwed onto a pull rod at the external thread of the valve Vg 8 and inserted carefully. NOTE! Do not twist bladder when inserting it! Screw lock nut (item 4) loosely onto the gas valve. Inflate the bladder with air until it touches the side of the accumulator. Insert oil valve into the body. Make sure that the bladder has not folded over. 8.5. TORQUE RATINGS Designation Item

Fold antiextrusion ring (item 14) slightly and insert it into the body. Push antiextrusion ring onto the oil valve. Assembly order: Washer Item 15 Oring Item 16 Support ring Item 23 Spacer Item 17 Lock nut Item 18 Firstly, push the Oring into position at four different points. A blunt, rounded screwdriver can be used for this purpose. To protect the Oring, the oil valve thread can be covered with adhesive tape. Insert the spacer and screw on the lock nut; tighten up lock nut with a Cspanner. Screw in vent screw (item 19) with seal ring (item 20). Remove loosely screwedon lock nut (item 4), position type code label and tighten securely with lock nut. Screw in gas valve insert using a torque wrench. Apply precharge pressure, as described in Point 6.2.

Since the precharge pressure changes proportionally to the gas temperature, approximately 5 minutes waiting time must be allowed, or in the case of large quantities of nitrogen and high pressures, up to approximately 1 hour, after the required accumulator precharge pressure has been reached, to allow the temperature to equalise. Then check the precharge pressure again and adjust if necessary. Screw on the cap nut and the valve protection cap (use torque ratings given in Table 1, Point 8.5) Tighten retaining nut (item 4), (use torque ratings given in Table 1, Point 8.5)

SB 330/400 0.5 1 l 2.5 5 l 10 50 l [ Nm ]

SB 550 15l

SB 330/400 H 10 50 l

Lock nut Vent screw Safety nut Gas valve insert Lock nut with 7/8 14 UNF M 50 x 1.5 Cap nut Table 1: Torque ratings

18 19 12 3

90 3 4

200 3 12

440 30 25 0.3 0.5

150 3 12

600 30 45

80 150

30

9. Special tools and spare parts

9.1. SPECIAL TOOLS In addition to the commercially available screwdrivers and torque wrenches, the following tools, which can be purchased from Hydac, are required. 9.2. SPARE PARTS Tool Gas valve wrench Torque wrench Cspanner Table 2: Special tools Designation Gas valve insert Repair kit consisting of: Bladder Gas valve insert Lock nut Cap nut Valve protection cap Oring Washer Oring Seal ring Support ring Oring Antiextrusion ring Item 3 2 3 4 5 6 7 15 16 20 23 27 14 HYDAC Stock no. 616886 379354 Specialist suppliers

Detail X SB330/4000.56l

Oil valve, complete, consisting of: Oil valve body 9 Valve plate 10 Damping sleeve 11 Safety nut 12 Valve spring 13 Antiextrusion ring 14 Washer 15 Oring 16 Spacer 17 Lock nut 18 Vent screw 19 Seal ring 20 Support ring 23 Seal kit consisting of Oring 7 Washer 15 Oring 16 Seal ring 20 Support ring 23 Oring 27

10. CUSTOMER SERVICE

Detail X SB330/400 (H)10650l SB55015l SB6001050l Customer service, in particular repairs and pressure repeat tests, can be carried out at our head office: HYDAC Technology GmbH Geschftsbereich Zentraler Kundendienst Postfach 1251 66273 Sulzbach/Saar Industriegebiet 66280 Sulzbach/Saar Germany Tel: 06897 / 50901 Fax: 06897 / 509828 or at any national or international HYDAC Sales and Service branch.