REXROTH HAB Setup guide

1/12
Information on available service parts:
www.boschrexroth.com/spc
Assembly and repair instructions
Bladder-type accumulator, model HAB
RE 50140-R/05.05
Contents
Contents Page
Product list
2
Possible damage,
malfunctions and their causes
2
and 3
Initial startup
3
Assembly and disassembly
4
to 6
Cleaning and testing 7
Assembly of accumulator 7 to 10
Storage 10
List of service parts and exploded view 11 and 12
HAD 7254_04
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Type of damage:
Cause:
Repair:
External leakage: Gas valve
If the leakage is not rectified then the
bladder is destroyed immediately.
A fall in the inflation pressure causes
the permissible pressure ratio to be
exceeded
Gas valve with severe leakage.
Gas valve or valve cap damaged
Replace gas valve with valve cap.
Gas valve broken.
Nitrogen improperly discharged
(e. g. through unscrewing the gas valve)
Replace gas valve (The use of
automobile tire valves is not permitted
because of the high operating pressure)
External leakage: Oil valve
Leakages at O-ring sealing
O-ring damaged by assembly fault or
hardened because of excessively high oil
temperature
Replace O-ring, check oil temperature.
Internal leakage: Bladder
Premature failures of bladder
(0-20000 load cycles)
Bladder at vulcanizing seam leaks
Foreign-body inclusions in rubber.
Manufacturing or material fault. Poor
vulcanization.
After checking gas valve and if it is OK,
install new bladder.
Bladder is brittle, rigid, porous and
carbonized.
Operating ratio greater than 1:4, and
thus compression temperature too
high, nitrogen excessively heated. Oil
temperature too high.
Install new bladder, calculate new
inflation pressure and set. Set oil
temperature to permissible value.
Bladder porous and swollen.
Unsuitable medium, e.g. fire-inhibiting
liquids and buna bladder.
Check whether the medium specified
in the operating instructions has been
used. If so, consult system manufacturer.
Bladder carbonized at gas valve side.
Inflow speed and operating pressure
ratio too large, contingent on pressure
peaks on system or through too low
inflation pressure.
Heat accumulation on gas valve side
insufficiently dissipated.
Install new bladder.
Reduce inflow speed using flap or
increase inflation pressure.
Bladder has areas of abrasion.
Inflation pressure too low. Particularly
with synthetic heavy fluids the bladder
rubs up against the container wall due to
the greater buoyancy.
Check inflation pressure.
As from a 10l accumulator a horizontal
installation position is advisable.
Bladder base has a crack, hole etc.
Faulty oil valve
Replace oil valve and bladder.
Bladder has crack, hole etc.
Foreign bodies; chippings, sand and
suchlike in container.
Clean container, filter and system.
Replace bladder.
Greater oil valve impression on bladder
base.
Inflation pressure too high. Bladder base
hammers against fluid valve. Discharge
speed too high.
Replace bladder.
Reset preload pressure.
Bladder has folds in it.
30l and 50l accumulators with assembly
fault.
Replace bladder.
Volumes [l]
1
4
10
20
35
50
0 531 012 730
0 531 013 730
0 531 014 730
0 531 015 770
0 531 015 771
0 531 016 730
0 531 013 731
0 531 014 731
0 531 015 772
0 531 015 773
0 531 016 731
0 531 014 735
0 531 015 776
0 531 015 777
0 531 016 733
0 531 015 779
2
/12
Bosch Rexroth AG
Bosch Rexroth AG
Assembly and repair instructions
RE 50140-R/05.05
Product list
Possible damage, malfunctions and their causes
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Type of damage:
Cause:
Repair
Internal leakage: Retaining ring
Retaining ring, with divided steel ring
damaged.
Normal degree of wear
Mount new retaining ring, sealings for oil
valve and slotted nut.
Lack of maintenance:
Inflation pressure too low:
Inflation pressure too high:
Consequence:
Consequence:
Note:
High deformation and flexing energy.
Areas of abrasion through bladder folds
Bladder base hammers against oil valve.
Bladder base turns scaly.
Minor gas inclusions in accumulators
that have already been in operation are
insignificant in terms of additional use
Bosch Rexroth AG
Bosch Rexroth AG
RE 50140-R/05.05
Assembly and repair instructions
3
/12
Initial startup
Delivery condition
The accumulator is generally supplied with a 10 bar inflation
pressure.
Preload with nitrogen
To charge the bladder-type accumulator with nitrogen and to check
the accumulator inflation pressure use the BOSCH REXROTH
inflation and testing device, order no. 0 538 103 011.
Bladder-type accumulators must always be inflated to the
specified preload pressure before initial startup. The inflation
pressure must be lower than the calculated pressure, which is
rolled into the housing.
Measures before initial startup and prescribed test
periods
- Check tightness of gas valve (soapy water)
- Tighten sealing cap
- Periodically monitor preload pressure
Use BOSCH REXROTH inflation and testing device to check
inflation pressure at initial startup. Repeat this test during first
week of operation, and thereafter every 6 months under normal
operation or monthly if operation is intensive.
Important:
It is absolutely necessary to use dry nitrogen
(Class 4.0) from a cylinder with a pressure-reducing fitting. The
use of an air compressor of charging with nitrogen is strictly
forbidden.
Installation
To achieve ideal efficiency the hydropneumatic accumulator
should be installed as closely as possible to the consumer. It
is important to have a clearance area of 200 mm, to be able to
install the testing device.
The hydropneumatic accumulator can be installed vertically
(valve upwards) up to a horizontal position. It is important that
the type label is legible at all times, and that access to the
bleeder screw is given.
Connection is done by means of an internal thread or a flange.
It may be fitted with a reduction connection flange or a counter
flange.
Fastening
Note instructions in terms of each accumulator.
Initial startup pressure when pressurized. Bleed lines, to do so
carefully open bleeder screw until fluid escapes and then close
screw.
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4
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Bosch Rexroth AG
Bosch Rexroth AG
Assembly and repair instructions
RE 50140-R/05.05
Fig. 2
Unscrew cap nut first and then the valve cap of the gas valve
Fig. 1
Detach accumulator from system and de-pressurize with aid
of accumulator safety block (drain tap) or hydraulic circuit.
Dismantle accumulator and locate horizontally in vise or a
suitable fastening system. Protect housing against damage.
Disassembly and assembly
Fig. 3
Allow gas to escape from the bladder with the aid of the check
valve until a pressure of 0 is displayed. Check whether the
bladder is now de-pressurized through an open valve.
Fig. 4
Remove gas valve
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Bosch Rexroth AG
Bosch Rexroth AG
RE 50140-R/05.05
Assembly and repair instructions
5
/12
Disassembly and assembly
Fig. 5
Undo fastening nut on gas valve and remove type label
Fig. 6
Undo slotted round nut for hook wrench using hook wrench
Fig. 7
Remove slotted nut and retaining ring
Fig.8
Push oil valve far enough into housing until the sealing ring and
washer can be removed
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6
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Bosch Rexroth AG
Bosch Rexroth AG
Assembly and repair instructions
RE 50140-R/05.05
Disassembly and assembly
Fig. 10
Remove retaining ring, take it out, by carefully pushing ring
together
Fig. 9
Remove sealing ring and washer
Fig. 12
Fold bladder somewhat and withdraw by turning slightly
Fig. 11
Remove oil valve from container
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Bosch Rexroth AG
Bosch Rexroth AG
RE 50140-R/05.05
Assembly and repair instructions
7
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Cleaning and testing
−
Clean all metallic parts on accumulator using an organic
reducer.
−
Visual inspection of oil valve parts (valve tappet, spring, nut,
damping screw).
−
Check valve for sluggishness.
−
Clean bladder, e.g. using isopropanol. Visual inspection of
bladder for faults.
−
Inner inspection of container for signs of corrosion. In event
of coated containers, check condition of coating. Replace
parts deemed to be bad, O-rings must always be replaced
(see exploded view of accumulator parts).
Assembly of accumulator
1 l
4 l
> = 10 l
Slotted round nut for hook
wrench
90 +50
200 +60
440 +80
Bleeder screw
3 +1
3 +1
30 +10
Hexagon nut
80 +20
80 +20
80 +20
Valve insert
0.3 +0.2
0.3 +0.2
0.3 +0.2
Sealing cap
30 +10
30 +10
30 +10
Tightening torques in Nm
Fig. 13
Drain air from bladder by pressing it together.
Fig. 14
Carefully moisten bladder and container on inside with used
medium (roll container).
Charge accumulator with medium. Up to 4l accumulator
approx. 10 % of volume; for larger accumulators approx. 5% of
volume.
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8
/12
Bosch Rexroth AG
Bosch Rexroth AG
Assembly and repair instructions
RE 50140-R/05.05
Assembly of accumulator
Charge accumulator with medium. Up to 4l accumulator
approx. 10 % of volume; for larger accumulators approx. 5% of
volume.
Lubricate bladder and carefully insert into housing. When
inserting the housing do so at a slight angle; the bladder
must not be folded or twisted. For accumulators as from 10 l
volumes use corresponding assembly linkage.
Without illustration:
Mount type label and fastening nut without tightening nut.
Fig. 10 + 11 (see Page 6)
Check valve for sluggishness. Insert into accumulator housing,
and do with rubber ring. Center complete oil valve on retaining
ring and then pull outwards.
Fig.15
Install in this sequence again: O-ring, washer and spacer
sleeve.
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Bosch Rexroth AG
Bosch Rexroth AG
RE 50140-R/05.05
Assembly and repair instructions
9
/12
Fig. 17
Bleeder screw with sealing ring
Fig. 16
Screw on slotted nut and center the parts on the oil valve using
a plastic hammer
Assembly of accumulator
Fig. 19
Tighten hexagon nut WAF 32 on gas valve
Fig. 18
Mount bleeder screw with sealing ring
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10
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Bosch Rexroth AG
Bosch Rexroth AG
Assembly and repair instructions
RE 50140-R/05.05
Fig. 20
Mount protective cap onto oil valve.
Without illustration:
Dip new gas oil valve into oil and screw in.
Before charging the accumulator with nitrogen, you must first
rotate it through its axis so that the entire interior surface of the
container is wetted.
Directly after this preload bladder to 1.0 to 1.5 bar with nitrogen
(charge accumulator in horizontal position in accordance with
instructions for inflation and testing device)
Assembly of accumulator
Note the following when storing the accumulator:
−
Charge immediately with nitrogen
−
Store in cool and dry location
−
Seal opening on medium side
−
Protect gas valve against impacts and damage

The accumulator position is optional
Note:
Mark accumulator with a sign so that the accumulator must be
charged to the corresponding inflation pressure before initial
startup.
If the container is put into storage in excess of 5 years then all
rubber parts must be replaced.
Storage
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