Hydraulic accumulator general operating instructions

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(1)Schwerll Diaphragm Accumulators General Operating Instructions Hydraulic accumulator general operating instructions Correct design and calculation, installation & mounting, use, maintenance and with related safety accessories are the premise of the safe use of this pressure vessel, otherwise serious casualties and accidents will be caused! The pressure vessel is as a stationary pressure vessel, must only be commissioned in conjunction with a machine or hydraulic system! The pressure equipment must only be operated within the permitted operating parameters. And the operating parameters can not be changed arbitrarily after putting into operation! Schwerll just delivers the pressure equipment (accumulator or accumulator unit) according to customer’s requirements and Schwerll shall not take any responsibility for the suitability of the pressure equipment to be installed in a related machine or system, or for its correct installation. The pressure equipment is only allowed to be filled with qualified nitrogen and it’s under gas pressure.The pressure equipment can become hot, Risk of burns! Commissioning and maintenance can only be carried out by trained / instructed professionals in accordance with the manufacturer's operation manual and local regulations. Repair and disassembly of accumulator can only be carried out by the accumulator manufacturer or by a qualified representative authorized by the accumulator manufacturer! Do not open pressure equipment (accumulator) unless pressure has been released from everywhere of the equipment, the equipment contains nitrogen, Danger of asphyxiation. No changes are allowed to the pressure equipment including welding, drilling and forced opening... Schwerll hydraulic accumulator has a limited service life. The user can calculate the service life according to the data in the delivery documents provided by the Manufacturer according to the actual working conditions, and use it within the specified working conditions and service life. The user shall be fully responsible for the preservation of the accumulator during the accumulator changes its use address. After the replacement, the complete set of pressure vessel documents, including the accumulator operation manual, shall be transferred and kept properly at the same time. The pressure equipment shall be received, checked before acceptance and inspected regularly according to the local laws and regulations, and shall be disposed in time after the service life of the operating condition or the design life (whichever comes first). If the pre-charged nitrogen pressure P0 is set unreasonably or the pre-charged nitrogen pressure value during operation deviates, it will cause abnormal working conditions such as diaphragm damage, resulting in failure of the pressure equipment. Schwerll will not take any responsibility for this. The end user is responsible for meeting the requirements of local laws and regulations when the pressure equipment is put into operation and during the operation.. Further information can be obtained from: [email protected] Further documentation please visit: www.schwerll.com www.schwerll.com.cn The version belongs to our company, and can not be copied or excerpted without permission.. 濦濖濢濄濇濁濃濃濆激濘濃濃.

(2) Schwerll Diaphragm Accumulators Operating Instructions. Accumulator used in the hydraulic system For hydraulic system with accumulator, if the hydraulic medium in the accumulator is drained and/or completely drained (for example, before the hydraulic system completes its work, the hydraulic medium in the hydraulic system is drained), the accumulator will build up a certain amount of pressure again if the pipeline on the fluid side are later shut off. This is the general situation of the hydraulic system with accumulator, which must be considered before operating the hydraulic system. Therefore, all pipelines connected to the hydraulic accumulator must be depressurised and remain open afterwards.. 1. General information Hydraulic diaphragm accumulator is pre-charged with nitrogen, which is separated the hydraulic medium and nitrogen through the diaphragm. Diaphragm accumulator is installed in the hydraulic system to store the hydraulic energy and release the stored hydraulic medium when necessary. According to the definition of PED or other specifications, hydraulic diaphragm accumulator belongs to pressure vessel. Volume calculation, design, manufacturing and sales shall be implemented based on corresponding national standards or accepted international standards.The requirements of national regulations shall be observed during initial installation and operation. The owner shall be responsible for the compliance with the relevant specifications and regulations during use, the integrity of the inspection documents, and the proper preservation of the relevant documents of the accumulator to guide the installation, inspection and regular inspection requirements. According to the current catalogue of special equipment in China, accumulators with a volume of not more than 4L do not belong to the scope of special equipment management. However, as a pressure vessel, the user should strictly implement correct operation and carry out regular inspection during using. Use in accordance with regulations also includes compliance with the manufacturer's manual for operation, maintenance and repair.. Notice of safety operation All SCHWERLL diaphram accumulators must be carried out by trained and qualified professionals in accordance with the manufacturer's operating manual, improper operation can cause serious injury. Professionals: According to the definition of EN60204-1, a professional is a person who can judge his work and correctly estimate the potential danger according to his professional training, knowledge and experience and the understanding of relevant specifications.. P1 SCO1411MD-E02. Only then can remove the accumulator from the hydraulic system. Before operating the accumulator removed from the system, ensure that the gas side of the hydraulic accumulator must be also depressurised and remain open. Only then may the appropriate work can be carried out with strictly reference to the operating or repair manual provided by the manufacturer (maintenance or repair is limited to threaded diaphragm accumulators only) . It is not allowed to carry out any welding, brazing, machining and other mechanical work on the diaphragm accumulator. It is necessary for professional personnel to carry out accumulator maintenance and repair work.. Risk of explosion! The hydraulic accumulator must only be filled with qualified nitrogen, and oxygen or air and other gases can never be used漊 Danger of bursting and loss its operating permission if machining or welding/ brazing operation are carried out!. Warning of burns! The accumulator shell can become hot, Risk of burns.. Danger of nitrogen suffocation! There is a danger of suffocation when discharging the accumulator in a narrow and closed space.. Notice In case of any ambiguity in the description in the manual, please contact the manufacturer for confirmation..

(3) Schwerll Diaphragm Accumulators Operating Instructions 2. Transport and storage of accumulator Transport The transport of gas-charged accumulators must be carried out with the utmost care and meet the requirements of relevant national transportation regulations in the region where the accumulator is transported (usually the local dangerous goods transportat regulations). Any damaged diaphragm accumulators during hoisting and transport must not be put into operation. If the user has to return the accumulator to the manufacturer for repair or other reasons, the precharged pressure must be drained before transportation. Storage The standard delivery of Schwerll diaphram accumulator is pre-charged with 2 bar of N2, which can adapt to short-term storage, such as 3 months if stored in a dry, cool environment and avoid direct sunlight and mechanical press and without other radiation sources. In case of long-term storage, please pay attention to the allowable storage period of diaphragm material. The accumulator can be stored in any position, When leaving the factory, all external interfaces are well sealed. After the user disassembles, if it still needs to be saved, the liquid side connection needs to be sealed again to prevent dirt, especially external hard pollution from mixing.. 3. Equipment and safety element According to the different requirements of national specifications, the equipment and safety device necessary for the installation and operation of the hydraulic accumulator, and the user needs to configure according to the corresponding specifications. For example, according _` _{5#$X| < } configured for accumulator use at least: -Shut-off device漓 -Device which protects against excessive pressure (must be type-tested, either using a prototype or through individual expert assessment), -Pressure release device between the hydraulic accumulator and the shut-off device, -Pressure measurement device marked with the maximum permitted operating pressure, -The pressure test port for the pressure gauge. Users can also install the following devices漡 -Safety device for excess temperature漓 -Solenoid-operated pressure release valve. For more information, please refer to漡 -SCHWERLL products catalogue Q%#X Y Q%#ZZ [\ ][^5$QZ. Notice: If it is necessary to install permanent devices on the gas side, such as valve block etc., it is necessary to remove the screws of accumulator charging valve (refer to the anatomy diagram).. 4. Commissioning of diaphragm accumulator Inspection before putting into operation - Mounted the accumulator in the hydraulic system and confirm the accumulator is pre-charged to the specified nitrogen pressure before commissioning, then check again whether the connections of each part are tightened, without any twisted attachments. -According to the delivery documents and working condition parameters, determine the operation and maintenance plan of the accumulator, and determine the service life of the accumulator. -The temporary closing elements(protection caps/plugs etc) on the end cap must be removed, check the min/max operating data on the accumulator nameplate, and keep the nameplate clear and legible during operation. -Check for corrosion and evaluated for its effect on service life if use corrosion medium. Before the accumulator is put into use, it is necessary to check the pre-charged nitrogen pressure value. 4.1 Pre-charge pressure - During and after pre-charge of the accumulator, the foam should be used to check the gas tightness on threaded connections, joints, shut-off valves and other connection points. -Pre-charge pressure P0 漡The accumulator nitrogen precharge pressure value P0 is calculated according to the hydraulic unit operating data. The accumulator must be charged by the operator to the required pre-charge pressure before commissioning. When the pressure value specified by the user is precharged by the supplier, the precharged pressure will be indicated on the accumulator label. Relationship between the pre-charged nitrogen pressure value and the ambient temperature at the operating site漡 Ppre-charge pressure=P0@Tmax*漏Tpre-charge temperature+273) /漏Tmax+273漐 P0@tmax=pre-charge pressure at max.operating temperature The pre charged nitrogen pressure of diaphragm accumulator is limited by compression ratio (P2:P0):

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(12) %&58 4.2 Pre-charged nitrogen specifications Hydraulic accumulators must only be charged with nitrogen class 4.0 minimum or equivalent standards with a purity of not less than 99.99%

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(14) Schwerll Diaphragm Accumulators Operating Instructions 4.3 Charging the diaphragm accumulator SCHWERLL PCM charging and testing unit must be used to charge the piston accumulator, Operation manual please check No. SCOP14.005V*. The accumulator must be securely mounted before charging. 4.4 Permitted operating pressure and temperature Based on certified regulation, the permitted operating pressure depends on the material of accumulator shell, and permitted temperature depends on the shell material and sealing material. They are indicated on the name plate, and also indicated on the certificate documents. 4.5 Hydraulic fluids specifications Hydraulic accumulators must only use non-corrosive hydraulic fluid , with a minimum cleanliness calss of漡 -NAS 1638 Class 6 or 8 -ISO 4406 Class 17/15/12 or corresponding grade by equivalent replacement standard. 4.6 Installation The best installation method of diaphragm accumulator is vertical installation with gas side up. Other installation methods will affect the performance of accumulator. Installation considerations漡 - The nameplate or shell must be legible, - Reliability of installation, - Allowed area for gas filling (for SCHWERLL PCM tool, approx.LxWxH=240*240*200mm), - Operability of installation and removal, 4.7 Mounting The diaphragm accumulator must be installed firmly, and the user must fully consider the vibration of the installed accumulator during operation or any breaks in the connecting pipeline. In addition, the mounting element must not stress the accumulator in any way. The diaphragm accumulator with volume of 2L and below is allowed to be screwed on the hydraulic pipeline. Please check the catalogue for support accessories of diaphragm accumulator. 4.8 More information More information please check SCHWERLL product catalogue V10.04.03.****.. 5. Maintenance 5.1 Basic maintenance during operation In order to ensure long-term trouble free operation of the diaphragm accumulator, the below inspections must be carried out regularly. - Test the pre-charge pressure P0漢 - Check connections for tightness and leak-free漢 - Check that valves and safety devices are in correct operation漢 - Check fastening condition of mounting elements漢. Notice User must be observe the current regulations for inspection before commissioning and repeat testing in the Country of use. 5.2 When to test the pre-charge pressure Testing frequency It is recommmended that the following testing time/frenquency: - after each installation, - one week or within 10 days after each installation, - two months after each installation, - every year after each installation. If it is based on special application and lack of experience data, it is recommended to select pressure charging valve (such as mini M16 * 1.5), and it is also recommended to increase the number of times to detect the pre charged nitrogen pressure. -after each installation; -one week after installation; -the 10th week after installation; -every year; -for continuous work in high temperature environment, it is suggested to increase the inspection times. Based on the experience data of operation conditions, the user decides the cycle of checking the pre charged nitrogen pressure. How to test the pre-charge pressure - Use SCHWERLL PCM filling and testing kit to test pre-charge pressure.漏refer to the PCM operation manual No.SCOP14.005V*漐 - The fluid-side of the accumulator must be released of pressure and must remain open. - Check if the max.working pressure of PCM filling and testing kit is suitable for the testing and without any damage. - Check if the target test pressure value P0 is half of the range of the pressure gauge, which is the best. Remark: For small size piston accumulator, it is not recommended to use PCM kit, to avoid nitrogen loss during the detection process. It is recommended to select pressure charging valve when the precharge nitrogen pressure needs to be tested frequently.. P3 SCO1411MD-E02.

(15) Schwerll Diaphragm Accumulators Operating Instructions E. Ř PCM filling and test kit B A C. D. -After recording the pressure value displayed on the pressure gauge, use a 14mm wrench to turn the spindle(A) Clockwise about 1 / 2 turn to close the screw charging valve, open release valve B to release the gas pressure in the PCM kit, then loosen the lock nut D anti-clockwise, and take away the PCM kit. -Tighten the M8 inflation screw of the charging valve with SW6 hexagon torque wrench (25Nm) (Note: this step is very important, otherwise air leakage may occur after working for a period of time). -Check the air tightness of the charging valve with foaming agent, and tighten the protective metal cap (Torque 150Nm).. A=spindle B=release valve C=non-return valve D=lock nut Diagram with pressure reducing valve E=gas bottle adaptor. E. B. A. C. D. 1=PCM kit 2=filling hose assembly 3=outlet valve of raw N2 gas bottle 4=adaptor 5=pressure reducer 6=raw gas bottle 7=diaphragm accumulator 8=MNC N2 charging unit. 5.3 Pressure testing for diaphragm accumulator with standard 2C Screw charging valve Testing pre-charge pressure with Schwerll PCM kit -Unscrew (SW24) the metal protective cap on the gas charing connection, slowly turn around 1/2 a rotation anti-clockwise to observe if there is gas discharge, and then screw off the metal protective cap. -Screw lock nut D (M28*1.5) of PCM kit to the gas charging connection by hand, then close the release valve(B), Please follow below steps only if when the accumulator MUST also be charged further, you have to connect one side of the filling hose with non-return valve C of PCM kit, the other side connected with raw nitrogen bottles, depending on target charging pressure, take following steps: Option a) Connect directly to the outlet valve on the raw nitrogen bottle through the gas bottle adaptor E, Option b) Connected to the MNC charging unit discharge port, take another filling hose to connect with the outlet valve on the raw nitrogen bottle through the gas bottle adaptor E. Option c) Connect to the pressure reducer (it is a must when the pressure of raw gas bottle is higher than 200bar). Then take another filling hose to connect with the outlet valve on the raw nitrogen bottle through the gas bottle adaptor E. 5.3.1 Testing -Use a wrench 14mm to slowly rotate spindle(A) about 1/2 a rotation Anti-clockwise to observe if there is a display value on the pressure gauge of PCM kit. When the inflation screw is opened, the pressure value displayed on the pressure gauge is the pre charged nitrogen pressure value inside the accumulator (Please note the target measurement value is half range of the pressure gauge, which is the best) (if the test pressure value is lower than the precharge pressure value and more nitrogen filling is required, turn to step 5.3.2). 5.3.2 Charging (when need) If take a pressure reducer (option c), the pressure setting of the pressure reducer must not exceed the operating pressure of the accumulator. -Slowly open the nitrogen bottle, nitrogen can flow into the accumulator, -Constantly interrupt the charging process and check the pre-charge pressure value displayed on the pressure gauge, -Once the temperature has equalised, re-check the precharge pressure value and adjust if necessary. -If the pressure is too high, it can be reduced via the release valve B, -Once the required pre-charge pressure has been reached, close the shut-off valve at the outlet of raw nitrogen bottle漢 -Turn the spindle A clockwise (about 1/2 rotation) to close the screw charging valve, then open the release valve B to depressurise the nitrogen in the PCM kit, -Turn the locking nut D anti-clockwise to remove the PCM kit, -Tighten the M8 inflation screw of the charging valve with SW6 hexagon torque wrench (25Nm) (Note: this step is very important, otherwise air leakage may occur after working for a period of time). -Check the air tightness of the charging valve with foaming agent, and tighten the protective metal cap (Torque 150Nm). 5.3.3 When the diaphragm accumulator is mounted other type of filling valves漣 Such as漡 Minimess filling valve M16*1.5, corresponding adaptors must be used.. Danger of injury Due to external-type filling valve , when removing the adaptor, please also use a fixed wrench to fix the filling valve, to avoid connection between filling valve and the accumulator cap loosen. Operation for other kind of filling valve, please refer to SCHWERLL PCM operation manual No.SCOP14.005V* 5.3.4 Testing pre-charge pressure without PCM kit If there is no further charging request and also if the accumulator is equiped with safety and shut-off block SA/SAF or similar type safety block, pre-charge pressure can be also tested via the accumulator fluid side: 1. Disconnect the fluid-filled piston accumulator from the hydraulic system by operating the main shut-off valve (2) of the SA safety and shut-off block漢 2. Slowly discharge the piston accu. on the fluid side with releasse valve(3); 3. At the same time observe the pressure gauge range installed on the SA/SAF valve block漢 4. The pressure will start to fall slowly and it will drop suddenly only after the accumulator has been discharged completely. The pressure now is the same as the pre-charge pressure in the piston accumulator.. SCO1411MD-E02 P4.

(16) Schwerll Diaphragm Accumulators Operating Instructions 6. Spare parts How to order Please contact the manufacturer to obtain the spare parts and wearing parts that have been inspected and approved by the manufacturer, and replace it by a qualified professional person according to the operation manual provided by the manufacturer. Install the accessories and spare parts without manufacturer's permission, the manufacturer does not bear any responsibility. Pressure parts can only be replaced by the manufacturer or authorized by the manufacturer, the accumulator must be re-certified after replacement. For standard screw type charging valve of welded diaphragm accumulator, after 6 or more times normal repeated detection or inflation, it is necessary to replace the new pin sealing gasket of the charging valve (order code:2C-DS).. For accumulators that have reached the end of their service life, users need to do the disposal in time, after 5 years at the latest the pressure equipment must undergo an internal and external inspection with a following print sample, via manufacturer or authorized representative.. 9. Disposal In case of obvious mechanical damage in the accumulator shell or serious corrosion of components during operation, users must carry out the disposal, and aslo accumulators that have reached the end of their service life, users must carry out the disposal.. DANGER 7. Faults and causes Failure/ alarm. Possible diagnosis. Trouble shooting. Open the shut- off valve Testing pre- charge pressure Oil side relief valve closed or Oil side relief valve opens or damages changed heck the oil pump for normal Hydraulic pressure Oil pump does not supply oil operation and repair cannot reach required value Close the shut- off valve oil side shut- off valve closed Replace the accumulator Oil leaks from the gas side during pressure diaphragm damage test Air leakage causes the hydraulic oil to Replace the accumulator to find Diaphragm damage out the cause press the diaphragm to charging air side Cause valve port and to be torn Many times of sudden pressure loss Replace the accumulator to find on the oil side which causes the out the cause Diaphragm damage - protective device at the bottom of the fluid side Cause diaphragm to break away and squeeze the diaphragm into the oil side outlet, causing tearing Diaphragm damage - The compression ratio P2: P0 exceeds Working condition analysis and select matching type Compression ratio the allowable value Not installed correctly or not replace new sealing after too Filling valve leakage Valve seal damaged many times of pressure measuremen Accumulator or system does not properly drain hydraulic oil. Oil side shut- off valve closed Gas side pressure is too low. Notice: Troubleshooting needs to be performed by corresponding professionals in accordance with the operation and repair manual.. 8. Service life Like all pressure vessels, the service life of SCHWERLL diaphragm accumulators is limited, and the design life depends on the allowable cyclic test pressure and the number of load changes. The design, manufacture, and test and acceptance of SCHWERLL accumulators are based on Group II non-corrosive liquid media (such as petroleum-based hydraulic oil or emulsion) and gas side pre-charge with nitrogen. The allowable operating pressure range and the number of cyclic load changes are based on the conclusions given by the non-corrosive liquid medium.. With reference to the cyclic test pressure and the number of load changes allowed by the manufacturer's product design, authorized representatives can use this data to determine the service life of diaphragm accumulators (pressure shell etc.) according to the user's actual hydraulic system pressure change load and other operating conditions. The service life of the accumulator must also consider factors such as the corrosivity of the medium and the environment. If the hydraulic medium used by the user is corrosive, the user must consider the impact of the corrosion margin and factors on the service life.. P5. SCO1411MD-E02. Before any operation on the hydraulic accumulator, the relevant safety precautions must be taken! The disassembly tools and operation instructions provided by the manufacturer is required. Disposal of re-chargeable diaphragm accumulators漣 - Depressurise the fluid side and remain open, - Release pre-charge gas pressure and remain open, - Remove mounting accessories (valves, plugs, etc.) - Disassemble diaphragm accumulator according to instructions from manufacturer, -Destroy the accumulators and sort by materials漢 (Note: follow the manufacturer's service instruction manual!) Disposal of non-rechargeble diaphragm accumulators: - Depressurise the fluid side and remain open, - Secure the diaphragm accumulator, - Drill a 2mm hole in the fluid side that penetrates the diaphragm to release the pre-charge pressure, (Note: no person or object is allowed on the axial side during operation); - Remove the accessories on the gas side and oil side, use special tooling to disassemble the accumulator, destroy it and sort by materials.. 10.Customer service Service, pressure testing, repairs, operation/repairs manual instructions, order spare parts and special tools, Please contact SCHWERLL head office in china, Schwerll Accumulator Service Center Add. Plant B, Phase 3, Xianghe Robot Industrial Park, Langfang City, Hebei Province,065402 Email: [email protected] Tel漡 +86-(0)316-5181858 Schwerll Fluid Control INC. in USA Add. 1630 Oakland Rd. STE A106 San Jose, CA 95131 Email. [email protected] Tel. (408) 687-5180 Operating instructions/repairs manual.etc also can be downloaded from website.. www.schwerll.com.cn www.schwerll.com.

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