A.
Prior to installation
1. Make sure that both end caps of the accumulator
are securely tightened.
2. Make sure that the maximum working pressure stamped on the
accumulator cylinder is equal to, or greater than, the maximum
pressure used in the system line.
3. Make sure that the accumulator is properly pre charged. Only
dry nitrogen (N2) should be used. Use of air and oxygen involve
risk of explosion!
B.
Pre charging piston accumulator using Universal Charging Kit 105CK-xx:
1. Ensure that the accumulator is isolated from
system pressure and flow. Any stored system fluid left in the
Accumulator under pressure should be drained back to tank. Otherwise
ensure system pressure is Zero.
2. Remove the protective cap exposing the gas valve assembly.
Remove gas valve cap from the gas valve.
3. Screw adaptor 10712 on to gas valve.
4. Attach the swivel connection on the Charging Head from the
Universal Charging Kit to the gas valve adaptor and tighten whilst
holding adaptor.
5. Ensure that the Charging Head Bleed Valve is shut. Open up
the gas valve by unscrewing (counter clockwise) the top hex (19mm)
on the gas valve, 2-3 laps until stop. Insure that the gas valve
does not come loose ! The pressure reading on the charging head
gauge will display the current nitrogen pre charge pressure.
6. If Pre charging is required. Open valve on nitrogen back-up
bottle/regulator slowly until the piston bottoms in the accumulator.
Pre charge to required pressure, plus 5 to 10%, then shut off
Gas Bottles. Allow gas pressure to normalise (It is advantageous
to allow pressure to rise slightly above required pre charge pressure
before shutting off Gas Bottles since normalisation will see a
slight drop in nitrogen pressure). Continue to add nitrogen and
normalise until required pressure is obtained. Shut of gas bottles.
7. Once pre charge is set, close the gas valve by screwing the
top hex, on the gas valve, clockwise. No gas will now flow in
or out of the accumulator. Slowly loosen the Charging Head Bleed
Valve. The gas that remains in the line between the accumulator
and gas bottles will then be release to atmosphere. Once pressure
gauge reads zero, the charging head and adaptor may be removed.
8. Place a small amount of water in the top
of the accumulator and gas valve to test for any leakage (bubbles).
With no flow of bubbles then disperse remaining water and reinstall
gas valve cap and protective cap.
C.
Installation in system
1. When possible the accumulator should be mounted
in a vertical position, fluid port connection downwards.
2. Mount the accumulator rigidly to avoid tensions in piping.
Never weld support brackets etc. to the accumulator cylinder or
end caps!
3. A combined shut-off valve, drain valve and relief valve should
be installed between the accumulator and the pressure main line.
D.
Removing accumulator from service
1. Close shut-off valve fitted between the accumulator
and the main pressure line. Exhaust all hydraulic pressure from
the accumulator. Ensure system pressure is at zero.
2. Remove the accumulator carefully from the system.
E.
Dismantling of piston accumulator provided with end caps locked
with wires
1. Clamp the accumulator to a steady clean work
bench. Avoid contaminant atmosphere.
2. Remove valve guard and gas protective cap from the accumulator.
3. Turn upper hexagon nut on gas valve counter clockwise until
all gas is expelled. Insure that the gas valve does not come loose
!
4. Remove the locking screws from the end cap.
5. Press or knock the end cap into the cylinder until the two
semicircular locking wires are visible
6. Remove locking wires.
7. Pull out the end cap.
8. Remove piston carefully (by means of a draw bar or a smooth
wooden baton).
F.
Dismantling of piston accumulator equipped with threaded end cap
1. Clamp the accumulator to a steady clean
work bench. Avoid contaminant atmosphere.
2. Remove valve guard and gas protective cap from the accumulator.
Turn upper hexagon nut on gas valve counter clockwise until all
gas is expelled. Insure that the gas valve does not come loose
!
3. Remove gas valve.
4. Unscrew the end cap using two M12 bolts and e.g. some kind
of bar.
5. Remove piston carefully by means of a draw bar or a smooth
wooden baton.
G.
Inspection and replacement of piston and seals in piston accumulator
provided with end caps locked with wires
1. Clean all parts of the accumulator carefully.
2. All seals should be examined for wear and signs of abrasion.
3. Clean and check gas valve as well as the end cap seats. The
cylinder, piston and end caps surface must be completely free
from damage, scratches and foreign particles.
4. Change to new piston seals.
5. Lubricate the piston seals carefully with system fluid before
pushing the piston into the cylinder. To avoid damages on seals
upon entry into the cylinder, use piston mounting tools.
6. Install O-ring seal on end cap. The back-up ring should be
closest to the outer end of the end cap and the locking wires.
7. Press or knock the end cap on to the cylinder until the groove
of the locking wires is visible.
8. Install the locking wires.
9. Pull up the cap.
10. Install locking screws with washers onto the cap.
11. Install the gas valve with the O-ring lubricated.
12. Pre-charge according to procedure explained at B.
H.
Inspection of piston and seals in piston accumulator equipped
with threaded end cap
1. Clean all parts of the accumulator carefully
2. All seals should be examined for wear and signs of abrasion.
Replace all damaged or worn parts.
3. Clean and check gas valve as well as the end cap seats. The
cylinder, piston and end cap surface must be completely free from
damages, scratches and foreign particles.
4. Change to new piston seals.
5. Lubricate the piston seals carefully with system fluid before
pushing the piston into the cylinder. To avoid damages on seals
upon entry into the cylinder, use piston mounting tools.
6. Install O-ring seal on end cap. The back-up ring should be
closest to the thread.
7. Screw end cap on to the cylinder.
8. Install the gas valve with the O-ring lubricated.
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