HYDAC SB 600 User Manual

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Page 1

Accumulators

SB 210 / 600

Bladder Accumulators

Service and Parts

Index

1. General

Bottom Repairable Bladder Accumulators

2. Spare Parts List

2.1 Torque Requirements

3. Maintenance Instructions

3.1 Disassembly

3.2 Inspection Of Components

3.3 Assembly

Top Repairable Bladder Accumulators

4 Spare Parts List

4.1 Torque Requirements

5 Maintenance Instructions

5.1 Disassembly

5.2 Inspection Of Components

5.3 Assembly

To safeguard against a potential source of danger which can occur in bladder and diaphragm accumulators, we would like to draw your attention to the following information.

Please note that this should be taken into account when carrying out any work on systems with hydraulic accumulators.

After discharging and/or completely draining the accumulator (e.g. to depressurize the hydraulic system before work is carried out), the accumulator can build-up an amount of pressure again when

CAUTION!

the lines are later shut off on the ﬂuid side.

This problem must be taken into account generally and in particular before carrying out work on hydraulic systems which include connected hydraulic accumulators.

All the ﬂuid-side lines connected to the accumulator must therefore be depressurized and after that the lines remain open. Only then may the appropriate work (e.g. disassembly of the accumulator) be carried out.

WARNING!

Hydraulic accumulators are pressurized vessels and only qualiﬁed technicians should perform repairs. Never weld, braze or perform any type of mechanical work on the accumulator shell. Always drain the ﬂuid completely from the accumulator before performing any work, such as recommended repairs or connecting pressure gauges.

Special Tools Required:

1. HYDAC Charging and Gauging Unit:

• For bottom repairable bladder accumulators:

FPS or FPK with adapter FPK/SB may be used.

• For top repairable bladder accumulators only the FPK

with adapter FPK/SB may be used.

2. Gas Valve Core Tool

3. Spanner Wrench(es)

4. Bladder Pull Rod

5. Sockets 27mm / 32mm (top repairable only) / 36 mm

6. Blunt Flathead Screwdriver (with rounded edges)

NOTE: Additional standard tools are required including but not

limited to: Soft Faced Hammer / Sockets / Torque Wrenches / anti seize compound for stainless steel assemblies.

Refer to additional information contained in the “Operating and Installation Instructions for HYDAC Accumulators”.

The instructions included in this brochure cover Bottom Repairable and Top Repairable Bladder Accumulators.

Before servicing a bladder accumulator obtain the appropriate HYDAC repair kit. Use only original HYDAC replacement parts.

Read all instructions thoroughly before beginning any type of service or repair work.

PRESSURIZED VESSEL USE DRY

NITROGEN GAS ONLY

Please refer to HYDAC Operating

and Installation Instructions

CAUTION!

PN# 02073469 / 07.14 / ACU1102-1326

NOTE: All details subject to technical modification

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Page 2

Maintenance

15 16

2. Replacement Parts Drawing: SB210, SB330, SB330H, SB330N, SB400, SB500, SB550 SB600, SB600N

Detail Z

Detail Z (SB...S11...similar)

Item Description:

1 Shell

2 Bladder

3 Gas Valve Core

4 Bladder Stem Lock Nut

5 Valve Seal Cap

6 Valve Protection Cap

5 3

7 O-ring

8 Name Plate

9 Fluid Port

14 Anti-extrusion Ring

15 Flat Ring

16 O- ring

17 Spacer Ring

18 Fluid Port Lock Nut

19 Fluid Port Vent Screw

20 Seal Ring

23 Back-up Ring

Detail X

SB 210 SB 330: size 1 to 54 SB 600: size 1 to 4 SB 330N: size 1 to 54 SB330/400 (european mfg )0.5 to 6L

SB 600: size 10 to 54 SB 600N: size 10 to 54 SB330/400/500/550 (european mfg)10 to 50L

15 16

Repair Kit Consists Of:

2 Bladder

3 Gas Valve Core

4 Bladder Stem Lock Nut (SB 600 only)

5 Valve Seal Cap

7 O-Ring

15 Flat Ring

16 O-Ring

23 Back-up Ring

(where applicable)

All SB 50L assemblies use the M50

(2” ) diameter gas valve, not the M22 (7/8”) diameter gas valve.

2.1 Torque Requirements: Bottom Repairable Bladder Accumulators in Nm (lb-ft)

Part Name SB 210/ SB 330 / SB330N SB 330 H / SB 400 / SB500 SB 550 SB 600 / SB 600N

1 4 to 6 10 to 54 10 to 20 1 to 5 1 to 4 10 to 54

Gas Valve Core 0.5 (0.4) 0.5 (0.4) 0.5 (0.4) 0.5 (0.4) 0.5 (0.4) 0.5 (0.4) 0.5 (0.4) Bladder Stem Lock Nut 80 (59) 80 (59 ) 80 ( 59) 80 (59 ) 80 (59) 80 (59) 15 0 (111 ) Valve Seal Cap 30 (22) 30 (22) 30 (22) 30 (22) 30 (22) 30 (22) 30 (22) Fluid Port Lock Nut 90 (66) 200 (148) 440 (325) 600 (443) 15 0 (110 ) 200 (148) 440 (325) Vent Screw

1) For SAE threads only. For other thread types, consult HYDAC.

4 (3) 22 (16) 30 (22) 30 (22) 4 (3) 22 (16 ) 30 (22)

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PN# 02073469 / 07.14 / ACU1102-1326

Page 3

Maintenance

3. Bottom Repairable Bladder Accumulators

3.1 Disassembly

A After removal from the system, place the accumulator in a vice or secure it to a workbench.

Remove valve protection cap (item 6) and unscrew valve seal cap (item 5). Attach the proper HYDAC Charging and Gauging Unit and completely relieve the gas precharge

(refer to HYDAC Charging and Gauging brochure #02068202).

Remove gas valve core (ite m 3) by using the gas valve core tool.

B Unscrew vent screw

Unscrew lock nut ( item 18) by using spanner wrench. Remove spacer ring (i te m 17) .

If necessary, tap spacer ring with a plastic hammer to loosen.

C Loosen ﬂuid port (item 9 ) and push it into the shell. Remove back-up ring, (item 23)

where applicable, O-ring (it em 16 ) and ﬂat ring (it em 15 ) from ﬂuid port.

D Pull anti-extrusion ring ( it em 14 ) off ﬂuid port and remove it through ﬂuid side opening

by folding it in half.

E Remove ﬂuid port

F Remove bladder stem lock nut (item 4 ) and name plate (item 8 ) from the gas side.

Remove bladder (item 2) from ﬂuid side. It may be necessary to fold the bladder lengthwise to remove it.

3.2 Inspection of Components

Shell:

• inside to ensure it is free of debris, rough spots, or chafe marks.

• ﬂuid side bore for damage which could hamper proper sealing.

• exterior for any sign of damage.

If any interior or exterior damage is found, contact HYDAC for proper repair or replacement instructions.

Bladder:

The bladder must be checked for leakage. Reinstall gas valve core (item 3 ) and charge the bladder with nitrogen or compressed air to its natural shape and inspect for leakage.

If leakage occurs, ﬁrst check the gas valve core ( item 3) and replace it if necessary. If leakage still occurs, then the bladder must be replaced. The bladder must be visually inspected for lateral grooves and deep chafe marks. If any are found, the bladder should be replaced. Shallow chafe marks are insigniﬁcant and will not hamper performance.

Note: Bladders can not be repaired or revulcanized !

Fluid Port:

Depress poppet and rotate 90° to ensure free movement. Visually inspect poppet, threads, and sealing surfaces for any damage. If any damage is found, the ﬂuid port should be replaced.

Vulcanized Anti-extrusion Ring:

Visually check vulcanized area between steel and rubber to make sure it is undamaged and that adhesion is still good (no gaps between rubber and meta l). If the adhesion is poor or the rubber is cracked or shows signs of embrittlement or aging, replace anti-extrusion ring. Also check the seat area on the steel parts for grooves or any other damage. If any are found replace anti-extrusion ring.

Non-Vulcanized Anti-extrusion Ring:

Visually inspect area between the steel and rubber to make sure that the steel ring is properly seated. If the rubber is cracked or shows signs of embrittlement or aging, replace anti-extrusion ring. Also check the seat area on the steel parts for grooves or any other damage. If any are found replace anti-extrusion ring.

Seals:

New seals should always be used whenever reassembling any bladder accumulator.

Other Parts:

Inspect for damage and replace if necessary.

(i tem 19) and remove seal ring (item 20).

(item 9).

PN# 02073469 / 07.14 / ACU1102-1326

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Maintenance

3.3 Assembly:

The interior of the shell must be absolutely free of any contamination or debris prior to assembly.

Prepare bladder for installation by removing valve seal cap (item 5), and

gas valve core (item 3) . Press all residual air out of bladder.

G Lubricate interior of shell and exterior of bladder with appropriate ﬁltered ﬂuid, using a

ﬂuid volume of approximately 10% of total accumulator volume.

(Do not use water, it is not a lubricant).

Different bladder compounds require different lubricants.

H Place bladder stem lock nut

the pull rod handle. Insert bladder pull rod through shell

(threaded connection toward ﬂuid side opening) .

Thread pull rod onto gas valve. Fold bladder in half lengthwise, then again if necessary.

Pull the pull rod until gas valve emerges through gas port opening. Make sure bladder is stretched and not twisted when being inserted. Once gas valve is through opening, loosely attach bladder stem lock nut (item 4 ) to prevent bladder from slipping back into shell. Remove pull rod from gas valve.

Insert gas valve core ( item 3) and torque to 0.5 Nm ( 0.4 lb-ft).

I To prevent damage to the threads and O-ring, tape ﬂuid port threads before assembly.

Insert ﬂuid port into shell. Make sure bladder is fully extended within the shell.

J Fold anti-extrusion ring

side opening. To do this, push ﬂuid port further into shell and then pull it back through the middle of the anti-extrusion ring.

K Slightly pull on the ﬂuid port to position it. Do not allow ﬂuid port to fall back into shell.

This can be accomplished by either pulling on the ﬂuid port while inserting seals or precharging the bladder with 10 to 15 psi of dry nitrogen to keep ﬂuid port in position

(refer to HYDAC Charging and Gauging brochure #02068202).

L Order of Assembly:

ﬂat ring item 15 O-Ring item 16 back-up ring spacer ring item 17 ﬂuid port lock nut item 18

(where applicable) item 23

(item 4) over the pull rod with the male threads facing

(item 14) in half and insert into shell with steel seat facing ﬂuid

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PN# 02073469 / 07.14 / ACU1102-1326

Page 5

Maintenance

M Insert ﬂat ring (item 15 ) into space between ﬂuid port and shell. If it does not slide on

properly, recenter ﬂuid port in opening. Next, insert O-ring by pressing with a blunt ﬂathead screwdriver (with rounded edges) at 90° intervals. Carefully, level O-ring onto seat.

Where applicable insert back-up ring (item 23) over O-ring with grooved surface

toward O-ring.

N Remove protective tape from ﬂuid port threads. Insert spacer ring

placed in the shell. Thread on ﬂuid port lock nut ( item 18 ) and torque with spanner wrench*. Place seal ring (item 20) on vent screw (it em 19 ) install in ﬂuid port and torque*.

O On gas side, remove loosely attached bladder stem lock nut

plate (item 8 ). Reapply bladder stem lock nut ( item 4) and torque*.

P Attach appropriate HYDAC Charging and Gauging Unit and apply proper gas precharge

(refer to HYDAC Charging and Gauging brochure #02068202). Check bladder stem lock nut (item 4) torque*.

Q Screw on valve seal cap

*refer to torque table in section 2.1

(item 5) and torque*. Replace valve protection cap ( item 6).

WARNING!

HYDAC offers either a 7/8” - 14UNF gas valve body or M50x1.5 gas valve body depending on accumulator size and pressure.

Never under any circumstances should a 7/8” gas valve body be used in an accumulator assembly with a shell having a ~ ø 2” opening in the shell. Do not add spacers of any kind!

(it em 17) with “lip”

(item 4) and position name

Figure 1: 7/8” (22.3mm) gas valve body

in ~ø2” (~ø50.8mm) shell opening

Never under any circumstances should a 2” gas valve body be used in an accumulator assembly with a shell having a ~ø 7/8” opening in the shell. Do not add spacers of any kind !

Figure 3: 2” ( 50.8mm) gas valve body

in ~ø2” (~ø22.3mm) shell opening

Figure 2: 7/8” (22.3mm) gas valve body

in ~ø7/8” (~ø22.23mm) shell opening

Figure 4: 7/8” (50.8mm) gas valve body

in ~ø7/8” (~ø50.8mm) shell opening

PN# 02073469 / 07.14 / ACU1102-1326

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Page 6

Maintenance

15 16

4. Replacement Parts Drawing: SB330T, SB330HT, SB330TR, SB330NTR, SB 600T, SB600TR, SB600NTR

Detail Z

Detail Y

SB330T: size 10 to 54 SB330HT: size 20 to 54 SB330TR: size 10 to 54 SB330NTR: size 10 to 54 SB600T: size 20 to 54 SB600TR: size 10 to 54 SB600NTR: size 10 to 54

Detail X

SB330T: size 10 to 54 SB330TR: size 10 to 54

SB330NTR: size 10 to 54 SB330HT: size 20 to 54 SB600T: size 20 to 54 SB600TR: size 10 to 54 SB600NTR: size 10 to 54

SB 330 TR

10 to 54

SB 600 T

20 to 54

5 3

15 16

SB 600 TR

10 to 54

Detail Z

Detail Y

Detail X

4.1 Torque Requirements: Top Repairable Bladder Accumulators in Nm (lb-ft)

Part Name

Gas Valve Core 0.5 (0.4) 0.5 (0.4) 0.5 ( 0.4) 0.5 (0.4) 0.5 (0.4) Bladder Stem

Lock Nut Valve Seal Cap 30 (22) 30 ( 22) 30 (22) 30 (22) 30 (22) Fluid Port Lock Nut 600 (443) 440 ( 325) 440 ( 325) 440 (325) 440 (325) Vent Screw Gas Port Lock Nut 600 (443) 600 (443) 440 (325) 440 (325) 30 (22)

3) For SAE threads only. For other thread types, consult HYDAC.

SB 330 H

20 to 54

80 (59 ) 80 ( 59) 80 (59) 80 (59) 80 (59)

30 (22) 30 ( 22) 30 (22) 30 (22) 30 (22)

SB 330 T

10 to 54

Item Description:

1 Shell

2 Bladder

3 Gas Valve Core

4 Bladder Stem Lock Nut

5 Valve Seal Cap

6 Valve Protection Cap

7 O-ring

Fluid Side

9 Fluid Port

14 Anti-extrusion Ring

15 Flat Ring

16 O-ring

17 Spacer Ring

18 Fluid Port Lock Nut

19 Vent Screw

20 Seal Ring

23 Back-up Ring

Gas Side

22 Gas Port Adapter

24 Anti-extrusion Ring

28 Flat Ring

29 O-ring

30 Back-up Ring

31 Gas Port Lock Nut

SB330T, SB330TR, SB330NTR, SB600T, SB600TR, SB600NTR Repair Kit consists of:

2 Bladder

3 Gas Valve Core

5 Valve Seal Cap

7 O-ring

15 Flat Ring

16 O-ring

23 Back-up Ring (where applicable)

28 Flat Ring

29 O-ring

30 Back-up Ring

SB330HT Repair Kit consists of:

2 Bladder

3 Gas Valve Core

5 Valve Seal Cap

7 O-ring

23 Back-up Ring (where applicable)

28 Flat Ring

29 O-ring

30 Back-up Ring

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PN# 02073469 / 07.14 / ACU1102-1326

Page 7

Maintenance

5. Top Repairable Bladder Accumulators

Top repairable accumulators may also be repaired from the bottom (ﬂuid) side. For this procedure please see section 3.

5.1 Disassembly

A Relieve system ﬂuid pressure and drain all ﬂuid from accumulator.

Remove valve protection cap

Attach proper HYDAC Charging and Gauging Unit (FPK with adapter FPK/SB) and completely relieve the gas precharge pressure (refer to HYDAC Charging and Gauging brochure # 02068202).

B Remove gas valve core (item 3) by using the gas valve core tool. Thread pull rod onto gas

valve and hold to keep gas port from falling into shell.

C Unscrew gas port lock nut ( item 31) using spanner wrench. Remove spacer ring (i te m 17 ) .

If necessary, tap spacer ring with a plastic hammer to loosen. Push gas port adapter into shell.

D Remove back-up ring (item 30), O-ring (ite m 29), and ﬂat ring (item 28) before removing

anti-extrusion ring. Remove anti-extrusion ring (item 24) from gas port adapter, then fold it in half to pull it through the gas side opening.

E Pull gas port adapter through gas side opening and grasp the gas port adapter with one

hand, while removing the pull rod with the other.

Remove the gas port/bladder assembly

to fold the bladder lengthwise to remove it.

F Remove bladder stem lock nut

(item 22) from bladder (item 2).

(item 6) (if applicable) and unscrew valve seal cap (item 5).

(item 22 and 2) from the shell. It may be necessary

(item 4) from gas valve and separate gas port adapter

5.2 Inspection of Components

Shell:

• inside to ensure it is free of debris, rough spots, or chafe marks.

• ﬂuid side and gas side bores for damage which could hamper proper sealing.

• exterior for any sign of damage.

If any interior or exterior damage is found, contact HYDAC for proper repair or replacement instructions.

Bladder:

The bladder must be checked for leakage. Reinstall gas valve core (item 3 ) and charge the bladder with nitrogen or compressed air to its natural shape and inspect for leakage.

If leakage occurs, ﬁrst check the gas valve core still occurs, then the bladder must be replaced. The bladder must be visually inspected for lateral grooves and deep chafe marks. If any are found, the bladder should be replaced. Shallow chafe marks are insigniﬁcant and will not hamper performance.

Note: Bladders can not be repaired or revulcanized.

Fluid Port:

Depress poppet and rotate 90° to ensure free movement. Visually inspect poppet, threads, and sealing surfaces for any damage. If any damage is found, the ﬂuid port should be replaced.

Vulcanized Anti-extrusion Ring:

Non-Vulcanized Anti-extrusion Ring:

Visually inspect area between the steel and rubber to make sure that the steel ring is properly seated. If the rubber is cracked or shows signs of embrittlement or aging, replace antiextrusion ring. Also check the seat area on the steel parts for grooves or any other damage. If any are found replace anti-extrusion ring.

Gas Porter Adapter:

Visually inspect the threads and sealing surfaces of the gas port adapter for signs of damage. If any damage is found, the gas port adapter should be repaced.

Seals:

New seals should always be used whenever reassembling any bladder accumulator.

Other Parts:

Inspect for damage and replace if necessary.

(item 3) and replace it if necessary. If leakage

PN# 02073469 / 07.14 / ACU1102-1326

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Page 8

Maintenance

5.3 Assembly

The interior of the shell must be absolutely free of any contamination or debris prior to assembly.

Prepare bladder for installation by removing valve seal cap (item 5 ), and gas valve core (item 3 ). Purge all residual air.

Lubricate interior of shell and exterior of bladder with appropriate ﬁltered ﬂuid, using a ﬂuid volume of approximately 10% of total accumulator volume.

(Do not use water, it is not a lubricant).

Different bladder compounds require different lubricants.

G Attach gas port adapter

valve protruding through adapter opening. Loosely screw bladder stem lock nut (item 4) onto gas valve to keep gas port and bladder connected.

H Fold bladder (item 2) in half lengthwise and inser t

through gas side opening. Make sure bladder is stretched and not twisted when being inserted. Thread pull rod onto gas valve to position gas port adapter.

I Place the anti-extrusion ring (item 24) over the pull rod

with the steel parts facing upward. Fold anti-extrusion ring (ite m 24) in half and insert into shell. To do this, push gas port adapter further into shell and then pull it back through anti-extrusion ring. Slide gas port lock nut (item

over and pull rod with beveled surface facing away

31)

from shell; loosely thread the gas port lock nut onto the gas port adapter. Remove pull rod from gas valve.

J Insert gas valve core ( item 3) and torque to 0.5 Nm

(0.4 lb-ft). Precharge bladder with 10 to 15 psi of dry nitrogen to hold gas port adapter (item 22 ) in place while completing assembly.

K Remove gas port lock nut ( item 31) . Insert ﬂat ring (item

into space between gas port and shell. If it does

28)

not slide on properly, re-center gas port in opening. Next, insert O-ring (item 29 ) by pressing with a blunt ﬂathead screwdriver (with rounded edges) at 90° intervals. Carefully, level O-ring onto seat. Insert back-up ring

(item 30) over O-ring with grooved surface toward O-ring.

L Install spacer ring (i te m 17) . Thread on gas por t lock

nut (it em 31) with beveled surface facing away from shell and torque with spanner wrench*. Torque* bladder stem lock nut (item 4 ).

M Attach HYDAC Charging and Gauging Unit (FPK

with adapter FPK/SB)

pressure (refer to HYDAC Charging and Gauging brochure

#02068202)

torque2).

N Screw on valve seal cap (item 5) and torque*. Replace

valve protection cap ( item 6) (if applicable).

*refer to torque table in section 4.1.

. Check bladder stem lock nut ( item 4)

(item 22) to bladder with gas

and apply proper gas precharge

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PN# 02073469 / 07.14 / ACU1102-1326

Page 9

Maintenance

WARNING!

HYDAC offers either a 7/8” - 14UNF gas valve body or M50x1.5 gas valve body depending on accumulator size and pressure.

Never under any circumstances should a 7/8” gas valve body be used in an accumulator assembly with a shell having a ~ ø 2” opening in the shell. Do not add spacers of any kind !

Figure 1: 7/8” (22.3mm) gas valve body

in ~ø2” (~ø50.8mm) shell opening

Never under any circumstances should a 2” gas valve body be used in an accumulator assembly with a shell having a ~ø 7/8” opening in the shell. Do not add spacers of any kind!

Figure 3: 2” ( 50.8mm) gas valve body

in ~ø2” (~ø22.3mm) shell opening

Figure 2: 7/8” (22.3mm) gas valve body

in ~ø7/8” (~ø22.23mm) shell opening

Figure 4: 7/8” (50.8mm) gas valve body

in ~ø7/8” (~ø50.8mm) shell opening

HYDAC CORPORATION Accumulator Division

90 Southland Drive • Bethlehem, PA 18017 Tel 610.266.0100 Fax 610.231.0445