Hydac FPU-1 Operating Manual

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1. DESCRIPTION

1.1. FUNCTION

The HYDAC charging and testing unit FPU-1 is used to charge accumulators with nitrogen or to check or to change the existing pre-charge pressure in accumulators. For this purpose the charging and testing unit is screwed onto the gas valve of the hydraulic accumulator and connected via a hose to a commercial nitrogen bottle. If the nitrogen pressure is only to be checked or reduced, the charging hose does not need to be connected. The unit

has a screw-type tting with a built-in

gauge, check valve and a spindle for opening the accumulator gas valve to control the pressure.

HYDAC piston and diaphragm accumulators can be charged and checked without the need for adapters. Bladder accumulators, however, require an A3 adapter.

Please read the Operating Manual! No. 3.501.CE

Universal Charging and Testing Unit FPU-1

for Bladder, Piston and Diaphragm Accumulators

1.3. SPECIAL MODELS1.2. DESIGN

The HYDAC charging and testing unit for bladder, piston and diaphragm accumulators consists of:

z Valve body z Spindle z Check valve z Release valve z Pressure gauge z Charging hose z A3 adapter for bladder accumulators

Release valve

Spindle

Check valve

Pressure gauge

For higher pressures, the following special models are available:

z FPS 600

for bladder accumulators up to 600 bar max. pre-charge pressure (see technical information 293715).

z FPK 600

for piston, diaphragm and SB800-1.5 accumulators up to 600 bar max. pre-charge pressure (see technical information 297248).

z FPH 800

for high pressure bladder accumulators up to 800 bar max. pre-charge pressure (see technical information 242948).

The photo top left shows a possible order option, including accessories.

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2. TECHNICAL SPECIFICATIONS

2.1. MODEL CODE

(also order example)

FPU-1 - 250 F 2,5 G2 A1 K

Universal charging and testing unit

max

= 350 bar

Gauge indication range

0 - 10 bar 0 - 145 psi 10 0 - 25 bar 0 - 363 psi 25 0 - 100 bar 0 - 1450 psi 100 0 - 250 bar 0 - 3625 psi 250 0 - 400 bar 0 - 5800 psi 400

Charging hose

F = for 200 bar nitrogen bottle with connection W24.32x1/14 (DIN 477, Part 1) FM = for 300 bar nitrogen bottle with connection M30x1.5 (DIN 477, Part 5 up to April 2002) FW = for 300 bar nitrogen bottle with connection W30x2 (DIN 477, Part 5 from April 2002)

Length of charging hose

2.5 = 2.5 m

4.0 = 4 m Special lengths on request

Adapter G for nitrogen bottles

See table, Point 3.6.

Adapter A

A1 = M16x1.5 A2 = 5/8 - 18 UNF A3 = 7/8 - 14 UNF A4 = 7/8 - 14 UNF A5 = M8x1 A6 = G 3/4 A A7 = G 1/4 A8 = G 3/4 A9 = Vg 8 A10 = 7/8 - 14 UNF A11 = M16x2 A12 = M16x2 D4 = 5/8 - 18 UNF (Part no. 366374) other adapters on request

Protective case

Accessories - please give full details when ordering (see Point 4.)

(A3 is supplied as standard)

1.4. TESTING INTERVALS

In general, nitrogen losses on HYDAC hydraulic accumulators are

very low. However, a regular check of the gas lling pressure is

recommended to prevent the piston from hitting the end cap, or the bladder or diaphragm from becoming too deformed if there is a drop in the pressure p

The pre-charge pressure p0 as shown on the label or the accumulator body, must be re-set after every new installation or repair and then checked at least once during the following week. If no nitrogen loss is detected, a further check should be made after approx. 4 months. If after this period no change in the pressure is

found, a yearly check should be sufcient.

1.5. SCHEMATIC DRAWING

Fluid connection

Nitrogen bottle

Hydraulic accumulator

Adapter A

MG1

Charging

hose

Adaptor G Pressure reducer Charging and testing unit FPU-1

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3. DIMENSIONS

3.1. CHARGING AND TESTING UNIT FPU-1 WITH ADAPTER FOR HYDAC ACCUMULATORS

Bladder accumulators 330-0.5 / 400-0.5

Bladder accumulators ≥ 1l

Gas valve to ISO 10945

Piston and diaphragm accumulators

D4 Adapter

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3.2. CHARGING HOSE F

(200 bar nitrogen bottle - connection to DIN 477, Part 1)

Length Part no.

2.5 m 236514

4.0 m 236515

10.0 m 373405

15.0 m 2115552

20.0 m 2109765

28.0 m 2109574

3.3. CHARGING HOSE FM

(300 bar nitrogen bottle - connection to DIN 477, Part 5 up to April 2002)

Length Part no.

2.5 m 3019417

4.0 m 3019418

3.4. CHARGING HOSE FW

(300 bar nitrogen bottle - connection to DIN 477, Part 5 after April 2002)

Length Part no.

2.5 m 3019419

4.0 m 3019420

Charging hoses are suitable for the particular maximum permitted operating pressure marked on them and 10,000 charging processes. (HYDAC charging hoses comply with the EC Machinery Directive and with DIN EN 982 and DIN EN 853 to 857)

knurl

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A1 (Part no. 361619)

A2 (Part no. 361605)

A3 (Part no. 291533)

A4 (Part no. 291536)

A5 (Part no. 291531)

A6 (Part no. 2108819)

A7 (Part no. 2110629)

A8 (Part no. 2124524)

A9 (Part no. 2128638)

A10 (Part no. 2128849)

A11 (Part no. 3018210)

A12 (Part no. 3203185)

3.3. ADAPTERS A1 TO A12

The universality of the FPU-1 is

guaranteed because as well as HYDAC

piston and diaphragm accumulators,

bladder accumulators can also be charged

and tested using the A3 adapter.

By using additional adapters other makes

of accumulator can also be charged and

tested.

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G 10 (Part no. 2103427)

G 11 (Part no. 3018678)

G 12 (Part no. 3195556)

G 6 (Part no. 2103423)

G 7 (Part no. 236377)

G 8 (Part no. 2103425)

G 9 (Part no. 241168)

G 2 (Part no. 236376)

G 3 (Part no. 2103421)

G 4 (Part no. 236374)

G 5 (Part no. 236373)

3.4. ADAPTERS G2 TO G12

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3.4.1 Schedule of countries

G adapters for nitrogen bottles from different countries.

Country Type / Part no.

G2 G3 G4 G5 G6 G7 G8 G9 G10 G11 G12 236376 2103421 236374 236373 2103423 236377 2103425 241168 2103427 3018678 3195556

Albania

Algeria

Argentina

Australia

Austria

Bahamas

Bahrain

Bangladesh

Barbados

Belgium

Bolivia

Botswana

Brazil

Bulgaria

Burma

Canada

Chile

China

Columbia

Costa Rica

Cyprus

Czech Republic

Denmark

Djibouti

Dominican Republic

Ecuador

Egypt

Ethiopia

Fiji

Finland

France

Gabon

Gambia

Germany

Ghana

Great Britain

Greece

Guatemala

Guinea

Guyana

Honduras

Hong Kong

Hungary

India

Indonesia

Iran

Iraq

Ireland

Israel

Italy

Ivory Coast

Jamaica

Japan

Jordan

Kenya

Korea

Kuwait

Lebanon

Libya

Malawi

Malaysia

Malta

Mauritius

Mexico

Morocco

Mozambique

Netherlands

New Zealand

Nigeria

Norway

Oman

Pakistan

Paraguay

Peru

Philippines

Poland

Portugal

Puerto Rico

Qatar

Romania

Russia

Saudi Arabia

Singapore

South Africa

Spain

z z

Sri Lanka

Sudan

Surinam

Swaziland

Sweden

Switzerland

Syria

Taiwan

Tanzania

Thailand

Trinidad/Tobago

Tunisia

Turkey

United Arab Emirates

Uruguay

USA

Venezuela

Vietnam

Yugoslavia

Zambia

z = suggestion

= already tted to hose

= Bosnia, Herzegovina, Croatia, Macedonia, Slovenia

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4. ACCESSORIES

4.1. PROTECTIVE CASE

For storing the charging and testing unit and adapters.

Different types of case are available, depending on customer requirement.

FPU-1, standard model, without case: approx. 1.4 kg

FPU-1, standard model, with case: approx. 3.0 kg

4.2. GAS SAFETY VALVE

Provides protection by reducing the pressure in a controlled way if pressure exceeds the permitted level unexpectedly, see catalogue section:

z Safety Equipment for

Hydraulic Accumulators No. 3.552

4.3. ADAPTER D4

For screw connector D on bladder accumulators < 1 l (see Point 3.)

4.5. PRESSURE REDUCER

For adjusting the required pre-charge pressure between the nitrogen bottle and the accumulator.

4.5.1 Pressure reducer for 200 bar nitrogen bottles Inlet: connection W24.32x1/12-DIN 477, Part 1

Outlet: male thread W24.32x1/14-DIN 477, Part 1

Bottle pressure [bar] Pressure after reducer [bar] Part no.

200 20 635409

200 100 635411

200 200 635412

4.5.2 Pressure reducer for 300 bar nitrogen bottles Inlet: connection W30x2-DIN 477, Part 5

Outlet: male thread W24, 32x1/14-DIN 477, Part 5

Bottle pressure [bar] Pressure after reducer [bar] Part no.

300 20 6004020

300 100 6004021

300 200 6004022

300 270* 6004023

* if pressure after reducer > 200 bar, the outlet has a male thread W30x2-DIN 477, Part 5

Weight: 0.5 kg

4.4. INTERMEDIATE PIECE GSV6-10-CE

Intermediate piece for installing the gas safety valve GSV6 between the 200 bar nitrogen bottle and the charging and testing unit FPU-1.

Item Quantity Description Dimension Part no.

Intermediate piece GSV6-10-CE 242558

12 2 O-ring 20x2.5x2 601058

13 1 Seal ring 20x11.5x2 614706

14 1 Seal ring 14x8.5x2 612735

Seal kit for intermediate piece 2117287

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6. NOTE

The information in this brochure relates to the operating conditions and applications described. For applications and operating conditions not described, please contact the relevant technical department.

Subject to technical modications.

5. SPARE PARTS, ADAPTERS AND TOOLS

5.1. SPARE PARTS

CHARGING AND TESTING UNIT FPU-1 Item Quantity Description Part no. 1 1 O-ring 6x1 601032 2 1 Seal ring 612730 3 1 Pressure gauge 0 - 10 bar

0 - 25 bar 0 - 100 bar 0 - 250 bar 0 - 400 bar

635139 635140 635141 635142

635143 5 1 O-ring 15x2 601049 6 1 Seal ring 601456 7 1 O-ring 11x2 601043 8 1 O-ring 9x2 601040 9 1 O-ring 11x2.5 603681 10 1 O-ring 5.7x1.9 6004009

Seal kit FPU-1 2117669

5.2. ADAPTERS

Description Part no. Seal kit for adapters A1-12 3269153

5.3. TOOLS

Description Part no. Wrench 14x15 1011065 Allen key SW6 1005164 Torque wrench 3136470 Valve tool for gas valve 616886

HYDAC Technology GmbH

Industriegebiet

66280 Sulzbach/Saar, Germany

Tel.: +49 (0) 68 97 / 509 - 01 Fax: +49 (0) 68 97 / 509 - 464 Internet: www.hydac.com E-Mail: [email protected]

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