Diaphragm accumulator type AC

Transcription

1 Diaphragm accumulator type AC Product documentation Operating pressure pmax: 350 bar Capacity V0 max: 2.8 dm 3 D

2 by HAWE Hydraulik SE. The reproduction and distribution of this document as well as the use and communication of its contents to others without explicit authorisation is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of patent or utility model applications. Brand names, product names and trademarks are not specifically indicated. In particular with regard to registered and protected names and trademarks, usage is subject to legal provisions. HAWE Hydraulik respects these legal provisions in all cases. Printing date / document generated on: /26 D AC HAWE Hydraulik SE

3 Contents 1 Overview diaphragm accumulator type AC Available versions, main data Available versions Parameters General Dimensions Diaphragm accumulator Assembly, operation and maintenance recommendations General notes Safety instructions Legal provisions Transport and storage Intended application Assembly information Installation and commissioning Operating instructions Maintenance information Replacing USIT ring (20) Checking gas lling pressure Other information Notes regarding the lay-out Accessories, spare parts and separate components Testing device DFM Mounting brackets Fittings HAWE Hydraulik SE D AC /26

4 1 Overview diaphragm accumulator type AC Diaphragm accumulators are a type of hydraulic accumulator. A diaphragm separates the compressible gas cushion from the hydraulic uid. The diaphragm accumulator type AC is used as a source of pressurized oil. It supports or increases the pump delivery ow or stores pressure energy, e.g. for an accumulator charge circuit. With the aid of different ttings the hydraulic accumulator type AC can be integrated into a hydraulic system. Different installation orientations and installation positions are possible. Features and bene ts: Compact design Option of integration into the HAWE modular system Operating pressures up to 350 bar Intended applications: Clamping systems Jigs Accumulator charging systems Diaphragm accumulator type AC These accumulators are used to: store pressure energy support the pump delivery improve system efficiency pulsation dampening in hydraulic systems compensation of pressure variations due to temperature changes compensate internal leakage (when apparent) 4/26 D AC HAWE Hydraulik SE

5 2 Available versions, main data 2.1 Available versions Symbol: Examples: AC 2001 AC 1002 /90 /140 /3A /22 Connection thread (hydraulic side) Table 3 Connection thread Gas lling pressure Table 2 Gas pre-load pressure p 0 (bar) Basic type Table 1 Basic type Table 1 Basic type Basic type Nom. volume V 0 (dm 3 ) Max. perm. operating pressure p max (bar) Max. perm. pressure ratio p 2/p 0 Max. perm. pressure dyn. difference p 2 - p 1 AC / AC / AC / AC / AC / AC / AC /1 120 o AC /1 65 o AC /1 140 o AC /1 140 o CE - stamping plus letter of conformity HAWE Hydraulik SE D AC /26

6 Table 2 Gas pre-load pressure Basic type AC AC AC AC AC AC AC AC AC AC Max. gas pre-load pressure p 0 (bar) For information on the gas pre-load pressure p 0 see also Chapter 6.1, "Notes regarding the lay-out" For information on accessories, spare parts and individual parts see also Chapter 6.2, "Accessories, spare parts and separate components" 6/26 D AC HAWE Hydraulik SE

7 Table 3 Connecting thread Basic type Connecting thread Marking Description AC 0725 /1A - G 1/4A * AC 202 /3 /1A /2A /2AW /3A AC 322 /3 /1A /2A /2AW AC 603 /3 /1A /2A /2AW /3A AC 1002 /22 /2A /2AW /3A AC 1414 /22 /2A /2AW /3A AC 1035 /3 /1A /2A /2AW /3A AC 2001 /3A - G1/2A * AC 2002 /4 /3A AC 2825 /3 /1A /2A /2AW /3A * Basic version - G 1/2 (internal thread) * - G 1/4A - G 1/2A - G 1/2 (internal thread) * - G 1/4A - G 1/2 (internal thread) * - G 1/4A - G 1/2A - M22x1.5 (internal thread) * - M33x1.5 (external thread) * - G 1/2A (external thread) * - M22x1.5 (internal thread) * - M33x1.5 (external thread) * - G 1/2A - G 1/2 (internal thread) * - G 1/4A - G 1/2A - G 3/4 (internal thread) * - G 1/2A - G 1/2 (internal thread) * - G 1/4A - G 1/2A HAWE Hydraulik SE D AC /26

8 3 Parameters 3.1 General Design Surface protection Installed position Mounting Diaphragm type accumulator conforming Pressure Equipment Directive PED 97/23/EC All types welded design Enameled (2k paint) Preferable vertical position (with the uid connection at the bottom), horizontal Directly via pipe ttings. Note Ensure the pipe screw connection is correctly assembled. In the event of strong vibrations, secure the accumulator to prevent it from coming loose. Gas lling Temperature Only N 2 (nitrogen)! } uid: -10 C C } Oil: -35 C C for type AC 0725, AC 202, AC 603, AC 1035, AC 2825 Hydraulic uid Hydraulic oil: according to Part 1 to 3; ISO VG 10 to 68 according to DIN Viscosity range: min. approx. 10, max. approx. 300 mm 2 /s Optimal operating range: approx. 10 to 35 mm 2 /s Also suitable for biologically degradable pressure uids type HEES (synthetic ester) at operating temperatures up to approx. +70 C. Diaphragm material Lifetime NBR ECO (compound) for type AC 0725, AC 202, AC 603, AC 1035, AC x 10 9 cycles For all other operating conditions the lifetime in accordance with PD 5500 Annex C must be observed (Pressure Equipment Directive) Weight Type AC 0725 Type AC 202 Type AC 322 Type AC 603 Type AC 1002 Type AC 1414 Type AC 1035 Type AC 2001 Type AC 2002 Type AC 2825 = 0.75 kg = 1.0 kg = 1.3 kg = 3.0 kg = 3.5 kg = 6.0 kg = 7.5 kg = 4.0 kg = 7.5 kg = 8.6 kg 8/26 D AC HAWE Hydraulik SE

9 4 Dimensions All dimensions in mm, subject to change. 4.1 Diaphragm accumulator Type AC 0725 /1A Type AC 202 /1A Type AC 202 /2A Type AC 202 /2AW Type AC 202 /3 Type AC 202 /3A See also Chapter 6.2, "Accessories, spare parts and separate components" HAWE Hydraulik SE D AC /26

10 Type AC 322 /3 Type AC 322 /1A Type AC 322 /2A Type AC 322 /2AW Type AC 322 /3A See also Chapter 6.2, "Accessories, spare parts and separate components" 10/26 D AC HAWE Hydraulik SE

11 Type AC 603 /3 Type AC 603 /1A Type AC 603 /2A Type AC 603 /2AW Type AC 603 /3A See also Chapter 6.2, "Accessories, spare parts and separate components" HAWE Hydraulik SE D AC /26

12 Type AC 1002 /22 Type AC 1414 /22 Type AC 1002 /2AW Type AC 1414 /2AW Type AC 1002 /2A Type AC 1414 /2A Type AC 1414 /3A Type AC 1002 /3A Type D H AC AC See also Chapter 6.2, "Accessories, spare parts and separate components" 12/26 D AC HAWE Hydraulik SE

13 Type AC 1035 /3 Type AC 1035 /1A Type AC 1035 /2A Type AC 1035 /2AW Type AC 1035 /3A See also Chapter 6.2, "Accessories, spare parts and separate components" HAWE Hydraulik SE D AC /26

14 Type AC 2001 /3A Type AC 2002 /4 Type AC 2002 /3A See also Chapter 6.2, "Accessories, spare parts and separate components" 14/26 D AC HAWE Hydraulik SE

15 Type AC 2825 /1A Type AC 2825 /2A Type AC 2825 /2AW Type AC 2825 /3 Type AC 2825 /3A See also Chapter 6.2, "Accessories, spare parts and separate components" HAWE Hydraulik SE D AC /26

16 5 Assembly, operation and maintenance recommendations 5.1 General notes The hydraulic accumulators are subject to the Pressure Equipment Directive 2014/68/EU. According to Article 3 of the Pressure Equipment Directive 2014/68/EU the following hydraulic accumulators require a declaration of conformity as well as a CE mark: Hydraulic accumulators with a volume > 1 litre and p V > 50 bar litre (section 1.1 a, uids in group 2) Hydraulic accumulators with p V > 10,000 bar litre (section 1.1 b, uids in group 2) Operation is only allowed within the permissible values. The accumulator must only be installed, maintained and repaired by authorised and appropriately trained staff; these tasks are governed by national regulations in Germany, through the Betriebssicherheitsverordnung (BetrSichV) Industrial Safety Regulation, and in the EU through EU Directive 2009/104/EG. The gas pre- lling must be checked regularly. Note The complete hydraulic system has to be discharged prior to any kind of repair. A respective plate (HAWE order No ( )) has to be applied at an easily visible spot on or near-by the accumulator. No modification (welding, soldering, nor mechanical) must be carried out on the accumulator. Only original spare parts are allowed to be used Safety instructions Further information on the technical design of accumulator systems is provided by DIN EN ISO In a nutshell, there must be a facility to release the accumulator pressure on the uid side when servicing is carried out (drain valve and pressure gauge for monitoring purposes). The accumulator must have its own safety valve (valve with TÜV certi ed unit approval). This must limit any momentary overpressure to 10% of the highest permissible pressure. In addition, a warning stating Caution pressure to be released from accumulator before removal must be af xed Legal provisions Hydraulic accumulators are classi ed as pressure vessels under the European Pressure Equipment Directive 2014/68/EU. For hydraulic accumulators, the regulations that apply at the installation location must be adhered to before commissioning and during operation. The operator holds sole responsibility for compliance with the existing regulations. The supplied documents must be kept in a safe place; they will be needed for recurring inspections. 16/26 D AC HAWE Hydraulik SE

17 5.1.3 Transport and storage Caution Comply with the relevant regulations on transportation and safety. Wear protective equipment. Note Accumulators must be stored in a cool, dry place and protected from direct sunlight. Dirt must be prevented from entering the accumulator. If the accumulator is stored over a longer period, it is advisable to reduce the gas pre-load pressure to approx. 10 bar to prevent deformation of the sealing element or separator. 5.2 Intended application This productis exclusively intended for hydraulic applications ( uid engineering). The product demands high technical safety standards and regulations for uid engineering and electrical engineering. The user must observe the safety measures and warnings in this documentation. Essential requirements for the product to function correctly and safely: All information in this documentation must be observed. This applies in particular to all safety measures and warnings. The product must only be assembled and put into operation by quali ed personnel. The product must only be operated within the speci ed technical parameters. The technical parameters are described in detail in this documentation. The operating and maintenance manual of the speci c complete system must also always be observed. If the product can no longer be operated safely: Remove the product from operation and mark it accordingly. It is then not permitted to continue using or operating the product. HAWE Hydraulik SE D AC /26

18 5.3 Assembly information The must only be installed in the complete system with standard and compliant connection components (screw ttings, hoses, pipes, etc.). The hydraulic power pack must be shut down correctly prior to dismounting; this applies in particular to power packs with hydraulic accumulators. Danger Risk to life caused by sudden movement of the hydraulic drives when dismantled incorrectly! Risk of serious injury or death. Depressurise the hydraulic system. Perform safety measures in preparation for maintenance Installation and commissioning Installation Warning Risk of injury due to stored pressure escaping in an uncontrolled manner! Risk of serious injury or death. Prior to all maintenance work, release the pressure in the hydraulic system. 1. Fit the accumulator to the bracket intended for this purpose, if possible route the gas side directing upwards. 2. Fit the required shut-off, drain and safety valves between the accumulator and the hydraulic system. The easiest way to do this is probably using a 'safety block' that contains all the above cap. Initial lling Danger Risk to life due to hydraulic accumulators potentially exploding if they are not lled correctly! Risk of serious injury or death. The maximum operating pressure, lling pressure and temperature range of the hydraulic accumulator must be suitable for the operating conditions. Fill hydraulic accumulators only with N 2 (nitrogen). Only use suitable lling and testing devices. Ensure that the accumulator is suitable for the operating conditions with regard to max. operating pressure, lling pressure and temperature range. Filling with gas: M16x2 mm gas valve with protective cap. 18/26 D AC HAWE Hydraulik SE

19 Filling device for diaphragm accumulators type DFM The pressure of the gas lling of diaphragm accumulators can be checked and altered with the lling device DFM. It is suited for accumulators with thread M28x1.5 and a lling socket screw M8x10. The lling device comes in a box 210x230x80 mm which also contains a pressure gauge As diaphragm accumulators are pressure vessels where the European pressure Vessel Directive applies (for exceptions see there), it has to be made sure that the safety especially against excessive pressure is guaranteed. Usually the accumulators are lled from nitrogen bottles (pressure 200 or 300 bar). It is therefore mandatory to use a pressure reducing valve to make sure that the permissible Permissible operating gauge pressure of the diaphragm accumulator Permissible gas lling pressure of the diaphragm accumulator Permissible display range of the related pressure gauge are not exceeded. Therefore these accumulators must not be lled via adaptors directly from the nitrogen bottle! Testing and lling have to be performed only by trained staff utilizing a pressure reducing valve, pressure gauge and hoses with ttings G 1/4 and G 1/2 DIN 560 (BSPP). Note For order numbers for the lling and testing device, see Chapter 6, "Other information" HAWE Hydraulik SE D AC /26

20 Filling instructions Danger Risk to life due to hydraulic accumulators potentially exploding if they are not lled correctly! Risk of serious injury or death. The maximum operating pressure, lling pressure and temperature range of the hydraulic accumulator must be suitable for the operating conditions. Fill hydraulic accumulators only with N 2 (nitrogen). Only use suitable lling and testing devices. Gas lling: Gas lling valve M28x1.5 mm with protective cover 1. Check that the diaphragm accumulator (1) is completely depressurized on the hydraulic side. Undo and remove the protective cap (2) from the lling port (3) (M28x1.5). Carefully slacken the gas lling screw by a 1/4-turn via an Allan head ( (4) / 6 mm) 2. Close the drain screw (5) at the lling device 6 to its stop. 3. Mount the lling device (6) incl. hose (7) onto the gas port (3) of the diaphragm accumulator (take care that sealing ring (8) is apparent and properly positioned in the groove). Connect hose tting (13) to the outlet port of the pressure reducing valve (15) (bottle valve (16) and shut-off valve (17) have to be still closed) 4. Open the bottle valve (16) and slowly turn the knob (18) until the desired pressure is visible on the pressure gauge (19). Open shut-off valve (17). 5. Twist the toggle (11) until the Allan key (10) engages in the socket head of the lling screw (4). Turn it slowly counter clockwise until pressure balance is audible. Leave shut-off (17) open i.e. let the nitrogen ow, until pressure gauge (12) shows the desired pressure. Close shut-off valve (17) and bottle valve (16) wait until the diaphragm accumulator, cooled down by the lling process, has achieved ambient temperature again. Repeat lling procedure when the gas pressure in the accumulator has dropped. As soon as the desired gas lling pressure is achieved: 6. Make sure that the Allan key (10) is still engaged and rotate toggle (11) clockwise until the lling screw (4) is shut. Open drain screw (5) that the trapped gas can escape from the lling device. 7. Remove lling device 6 from the diaphragm accumulator (1). Tighten the lling screw (4) with 20+5 Nm and reinstall the protective cap (2) on gas port 3 (M28x1.5) 20/26 D AC HAWE Hydraulik SE

21 5.4 Operating instructions Purity and ltering of the hydraulic uid Fine contamination can significantly impair the function of the hydraulic component. Contamination can cause irreparable damage. Examples of ne contamination include: Metal chips Rubber particles from hoses and seals Dirt due to assembly and maintenance Mechanical debris Chemical ageing of the hydraulic uid Note Fresh hydraulic uid from the drum does not always have the highest degree of purity. Under some circumstances the fresh hydraulic uid must be ltered before use. Adhere to the cleanliness level of the hydraulic uid in order to maintain faultless operation. (Also see cleanliness level in Chapter 3, "Parameters"). 5.5 Maintenance information This product is largely maintenance-free. Conduct a visual inspection at regular intervals, but at least once per year, to check if the hydraulic connections are damaged. If external leakages are found, shut down and repair the system. Clean the device surface of dust deposits and dirt at regular intervals, but at least once per year Replacing USIT ring (20) If there is a suspicion of damage or a leak is found, the USIT ring (20) must be replaced; for this purpose the gas lling pressure must be fully relieved (mostly after a very long period of use and/or if there are large pressure differences in the ow of lling gas). To relieve the pressure undertake the rst 3 steps for the gas pressure lling check and then open the drain screw (5) until the pressure gauge (12) indicates the value zero. Once the lling device (6) has been unscrewed, the gas lling screw M8x12 (4) (part number ) can be fully unscrewed and the USIT ring (20) (part number ) can be replaced with a new ring. During this process, ensure that the sealing surface is clean and undamaged. After screwing back in the gas lling screw (4) the lling process as per Chapter 5.3, "Assembly information" for a gas lling pressure change from zero to the required value can be started. HAWE Hydraulik SE D AC /26

22 5.5.2 Checking gas lling pressure 1. Release diaphragm accumulator (1) on the uid side and check the unpressurised state. Unscrew protective cover (2) from gas connection (3) M28x1.5. Carefully loosen gas lling screw (4) by approx. 1/4 rotation using 6 mm hex key (Allen key in accordance with DIN 911). 2. Close the drain screw (5) at the lling device (6) to its stop. 3. Mount the lling device (6) without hose (7) onto the gas port (3) of the diaphragm accumulator (take care that sealing ring (8) is apparent and properly positioned in the groove). Note The check valve (9) installed at the hose side will only work when no hose is connected. 4. Twist the toggle (11) until the Allan key (10) engages in the socket head of the lling screw (4). Turn it slowly counter clockwise until pressure audible enters the lling device. (Note: The gas lling screw (4) can t be completely screwed out while the lling device (6) is mounted. It can be screwed out only as far until a slot apparent on the side can act as passage. The passing gas generates a hissing noise also acting as a warning when the gas lling screw gets opened unintended) The gas lling pressure apparent (conditions: ambient temperature) will be shown at the pressure gauge (12). Close shut-off valve (17) and bottle valve (16) wait until the diaphragm accumulator, cooled down by the lling process, has achieved ambient temperature again. Repeat lling procedure in case the gas pressure in the accumulator has dropped. As soon as the desired gas lling pressure is achieved: 5. Make sure that the Allan key (10) is still engaged and rotate toggle (11) clockwise until the lling screw (4) is shut. Open drain screw (5) that the trapped gas can escape from the lling device. 6. Remove lling device (6) from the diaphragm accumulator (1). Tighten the lling screw (4) with 20+5 Nm and reinstall the protective cap (2) on gas port 3 (M28x1.5) Note Each test sequence causes a small loss of gas lling pressure due to the internal volume of the lling device. It is possible to carry out a gas lling pressure check on the uid side. 22/26 D AC HAWE Hydraulik SE

23 6 Other information 6.1 Notes regarding the lay-out Max. perm. operating pressure Parameters p 0 : Gas lling pressure p 1 : min. working pressure p 2 : max. working pressure The max. perm. operating pressure (p max ) is the pressure to which the accumulator may be maximally exposed. V 0 : Effective volume of the accumulator V 1 : Gas lling volume of the accumulator at p 1 V 2 : Gas lling volume of the accumulator at p 2 SV: Removed/absorbed effective volume between p 1 and p 2 1 Accumulator discharged The diaphragm is forced to the walls of the accumulator by the gas lling. A valve plate at the hydraulic connection prevents any damage of the diaphragm. 2 Accumulator, lower working pressure A residual uid quantity should remain in the accumulator always to prevent any damage to the diaphragm (p 0 < p 1). 3 Accumulator, upper working pressure The volumetric change ΔV apparent between lower and upper working pressure, corresponds to the effective volume to be used: ΔV = V 1 - V 2 Gas pre- lling pressure p 0 (guideline) Pressure storage: approx. 90% of the lower working pressure Pulsation dampening: approx. 60% of the upper working pressure Compensation of temperature in uences Change of state The compression and decompression in a diaphragm type accumulator follow the law of polytrophic change of state for gases. The following has to be distinguished: isotherm changes during slow operations ( (polytrophic exponent n = 1), e.g. when leakage has to be compensated ) Adiabatic changes during quick operations ( (polytrophic exponent n = 1.4, applies to Nitrogen), e.g. when used for dampening circuits ) Calculation V 0 (guideline: V 0 = x ΔV) HAWE Hydraulik SE D AC /26

24 6.2 Accessories, spare parts and separate components Testing device DFM Basic type Display range of the pressure gauge (bar) Upper limit for perm. operating gauge pressure (bar) DFM DFM DFM Mounting brackets HAWE-order No. for the lling and testing device Type D min. - D max. A B C min. - C max. E M x L G H I J K CE M8 x CE M8 x CE M8 x CE M8 x CE M10 x CE M10 x /26 D AC HAWE Hydraulik SE

25 6.2.3 Fittings Coding Description Material number Suitable for /1A Straight tting, /2A Straight tting, /2AW ERMETO GE 16-SR-3/8 EW 16-PS EGE 16-SR-ED /3A Straight tting, /2A Straight tting, /2AW ERMETO GE 16-SM-ED EW 16-PS GE 16-PS/R /3A Straight tting, AC 0725 AC 202 AC 322 AC 603 AC 1035 AC 2825 AC 1002 AC 1414 /3A Straight tting, AC 2002 HAWE Hydraulik SE D AC /26

26 Further information Additional versions Valve bank (nominal size 6) type BA: D 7788 Miniature hydraulic accumulators, type AC: D 7571 Piston type accumulators, type HPS: D 7969 HPS D AC HAWE Hydraulik SE Streitfeldstraße München Postfach München Germany Tel Fax info@hawe.de