Roth BA-BLAK-CE-EN User manual

OPERATING INSTRUCTION
BLADDER ACCUMULATOR
Type: BA-BLAK-CE-EN
Language: English
Edition: 09-2016
Revision: 01
Translated from German original

Operating instruction bladder accumulator BLAK - English
General
Roth pressure equipment - identification
in accordance with the serial number on the nameplate and the according report, see
•Acceptance report, Pressure Equipment Directive 2014/68/EU
TÜV Technische Überwachung Hessen GmbH
Explanation
Roth bladder accumulator = Roth pressure equipment
Translation
If sold to a country in the EEA, this operating instruction must be translated into the language of the
country in which the machine is to be used.
Should the translated text contain incongruities, the original operating manual (German) must be
consulted or the manufacturer contacted for clarification.
Copyright
No part of this publication may be reproduced, transmitted, sold or communicated without prior
permission. Damages will be claimed for violations.
All rights reserved.

Operating instruction bladder accumulator BLAK - English 1
0 Contents
0.1 Table of Contents
0 Contents____________________________________________________________________ 1
0.1 Table of Contents_____________________________________________________________ 1
0.2 Table of figures_______________________________________________________________ 1
1 Designated application_________________________________________________________ 2
1.1 Overview of standard Roth pressure equipment _____________________________________ 2
1.2 Notes on designated application _________________________________________________ 3
2 Function ____________________________________________________________________ 4
2.1 General functional description ___________________________________________________ 4
2.2 Filling and testing the pressure equipment _________________________________________ 4
2.2.1 Isochore behavior of N2________________________________________________________ 5
3 Safety______________________________________________________________________ 6
3.1 Notes / Explanations __________________________________________________________ 6
3.2 Identification / Nameplate_______________________________________________________ 6
3.3 Safety systems_______________________________________________________________ 7
3.4 Safety precautions ____________________________________________________________ 7
3.5 Responsibilities of the operator __________________________________________________ 7
4 Dangers ____________________________________________________________________ 9
4.1 General hazard notes__________________________________________________________ 9
4.2 Installation of spare and wearing parts ____________________________________________ 9
4.3 Cleaning, maintenance and repair work ___________________________________________ 9
5 Installation _________________________________________________________________ 10
5.1 Scope of delivery ____________________________________________________________ 10
5.2 Transport and packaging ______________________________________________________ 10
5.3 Storage____________________________________________________________________ 10
5.4 Assembly / Commissioning ____________________________________________________ 11
6 Maintenance________________________________________________________________ 12
6.1 General maintenance notes____________________________________________________ 12
6.2 Initial operating, repeated inspection and periods of repeated inspection_________________ 12
7 Disturbance, causes, troubleshooting (qualified staff only) ____________________________ 13
8 Emergencies _______________________________________________________________ 14
9 Dissembling / disposal ________________________________________________________ 14
Notes __________________________________________________________________________ 15
0.2 Table of figures
Figure 1-1 Overview of standard Roth pressure equipment _____________________________ 2
Figure 2-1 Isochore behavior of N2 ________________________________________________ 5

2 Operating instruction bladder accumulator BLAK - English
1 Designated application
1.1 Overview of standard Roth pressure equipment
The pressure equipment essentially consist of the following components:
1. Accumulator shell
2. Gas bladder
3. Valve on gas side
4. Valve on oil side
Figure 1-1 Overview of standard Roth pressure equipment

Operating instruction bladder accumulator BLAK - English 3
1.2 Notes on designated application
The Roth bladder accumulator (Roth pressure equipment) was manufactured exclusively for use as an
industrial and commercial component designed for acceptance and delivery of pressurised hydraulic
fluids in hydraulic systems.
Any use of the pressure equipment other than or beyond as described above or any conversion by the
operator or others shall be regarded as contrary to designated use, unless by prior written agreement
of the manufacturer.
The manufacturer shall accept no liability for damages arising from this.
The pressure equipment may only be used with non-corrosive fluids in group 2 (Art. 13, PED
2014/68/EU) on the fluid side and with nitrogen (N2) on the gas side. Wear allowance (e.g. corrosion)
is not considered. Exceptions may result from the declaration of conformity or from individual
manufacturer’s specifications of the pressure equipment.
Pursuant to ISO 4406 the degree of purity of the operating fluid shall be at least 19/17/14 (NAS 1638
Class 8) or better.
Depending on the mode of operation, the pressure equipment can be operated in the horizontal
position. Nitrogen (N2) Class 4.0 (99.99%) or better shall be used.
If permissible load cycling are specified for specific pressure ranges in the acceptance documentation,
the operator is responsible for compliance. If the pressure equipment is operated with different
operating parameters, it is possible that the test intervals for periodic tests will become shorter. Please
consult the manufacturer in such cases.
Intended use also includes compliance with the manufacturer’s operating, maintenance and
servicing instructions.
Furthermore, the operator is obliged to adhere to the legal state regulations according pressure
equipments in connection with the adherence of the mandatory tests prior to commissioning and
recurrent tests and must arrange these in compliance with the mandatory periods (see chapter 3.5).
The commissioning is prohibited until the entire system into which the pressure equipment
will be installed has been certified compliant with EU directives.
The fluids required for operation of the pressure equipment is procured and used by the
operator. Proper treatment of these fluids and the associated dangers are the sole
responsibility of the operator.
Furthermore, the selections of a fluid are into consideration low-risk operation based on
experience gained by the operator in the course of repeated use thereof in pressure
equipment.
We recommend you also concluding guarantee agreements with suppliers of the fluids.
Please request written approval from the “manufacturer” in cases of special uses or if you
have queries.
To prevent the bladder from touching the bladder connection, the pre-inflation pressure (P
0
)
must be at least 1/4 of the maximum operating pressure (P
2
).
To prevent the oil valve from closing and to extend the bladder’s service life, the pre-inflation
pressure (P
0
) should not exceed 9/10 of the minimum operating pressure (P
1
).

4 Operating instruction bladder accumulator BLAK - English
2 Function
2.1 General functional description
Roth pressure equipments are cylindrical pressure vessels with a separating element between gas
and fluid volumes (see Fig. 1-1).
They are used in hydraulic systems among others for energy accumulator.If the fluid pressure rises
above the gas filling pressure, hydraulic energy is stored in fluid form. This may be utilised for work
steps when the fluid pressure falls below the pressure of the compressed gas.
2.2 Filling and testing the pressure equipment
During or after filling with N2, use foaming agents to test all screwed connections, shut-off
valves, connections and joints for gas-tight sealing.
In principle, use Roth filling and testing device and observe the relevant operating
instruction.
The pre-inflation pressure (P0) depends on the ambient temperature (isochore behavior of N2, see
Chapter 2.2.1). Fill with N2 slowly up to 5 bar when pre-inflating the bladder, (bladder touching tank).
Ignoring this may incapacitate the bladder immediately.
The screw cap of the gas valve is to be mounted again after each filling procedure.
Never use oxygen or other flammable gases to fill the pressure vessel!

Operating instruction bladder accumulator BLAK - English 5
2.2.1 Isochore behavior of N2
Determining or controlling the pre-filling pressure (P
0
) at different ambient temperatures
General
Unless otherwise specified, the given P
0
refers to room temperatures of + 20°C. Should the actual
ambient temperature be different at the time of filling or checking P
0
, the diagram may be used to find
the pressure corresponding to that temperature when filling or checking.
Example
Assume a gas system at 155 bar of pressure at a gas temperature of + 20°C. If the gas temperature
rises to + 35°C, the intersection (155 bar at + 20°C) will shift to the next pressure-temperature curve to
intersect the vertical + 35°C temperature line. The fill or corrected pressure P
0
will need to be 166 bar
in this example.
Figure 2-1 Isochore behavior of N2

6 Operating instruction bladder accumulator BLAK - English
3 Safety
3.1 Notes / Explanations
Operating instruction, mandatory:
marked with a “book”.
Warnings:
marked with a warning triangle “danger”.
Explosion:
marked with a warning triangle “explosion”.
Notes:
marked with a “hand”.
Limitations:
Marked with a “stop“ symbol.
The vessel filled with N2 already, as given on the pressure equipment nameplate. Apply the separately included warning sign
(scope of delivery) to the pressure equipment after final assembly/final coating.
3.2 Identification / Nameplate
The pressure equipment has a nameplate and acceptance certificate attached. These show essential
technical data.
Changing data and markings without prior written approval of the manufacturer is strictly
prohibited. The pressure tank nameplate will always be binding should there be
discrepancies between data for different elements on the pressure tank.
Damaged or lost nameplates must be replaced.
Pressure equipment without nameplates is not allowed to be used!
Please provide the following with all your enquiries:
•Indication of the type
•Serial number
•Date of manufacture

Operating instruction bladder accumulator BLAK - English 7
3.3 Safety systems
The safety systems may be included in the delivery (see delivery papers) or constitute part of
the customer installation.
They will always be required and should be tested for effectiveness prior to commissioning.
3.4 Safety precautions
Safety-related measures that should be observed include:
•Safety systems to limit the pressure
•Shut-off systems
•Using approved pressure gauges
•Correct connection of pressure gauges and shut-off devices
•Compliance with safety stipulations when handling inflation substances
•etc.
The operator shall instruct the operating and maintenance staff on the proper operation of the
pressure equipment and monitor compliance with the safety precautions.
The responsible specialist superiors must instruct the operating, servicing and maintenance staff
before starting in their jobs or prior to commissioning of the pressure equipment and thereafter at
appropriate intervals of at least once per year. All services, maintenance and instruction courses must
be recorded in a control book.
Qualified technician (definition based on EN 60204-1)
•A person who, based on specific training, knowledge and experience and knowledge of pertinent
standards, will be in a position to assess assigned work and recognise potential hazards.
3.5 Responsibilities of the operator
The national implementations of framework Directive 89/391/EEC as amended and the
associated individual directives, including specifically Directive 2009/104/EC as amended, on
the minimum requirements for safety and health of employees working with work materials
must be observed and complied within the EEA (European Economic Area).
The BetrSichV [Operational Safety Ordinance] transposes Directives 89/391/EEC, 2009/104/EC
and other Directives on occupational safety at systems requiring supervision into German
law. The BetrSichV, and especially Section 3, deals with the “Special requirements for
systems requiring supervision” governing this pressure equipment. The operator is urged to
familiarise itself with this section, since basic requirements are described here which the
operator will be obligated to comply with!
The TRBS [Technical rules for operational safety] , especially TRBS 3146, TRBS 2141 Parts 1-3,
TRBS 1111, TRBS 1122 and TRBS 1201 Part 2 are other important guidelines that apply
here. We recommend testing the surfaces for cracks near the thread and its transition in the
course of internal routine testing in accordance with §16 and Annex 2, Section 4, Nos. 6.10
and 6.17. This is carried out ideally be performed by the manufacturer or by a “qualified
person” designated by the manufacturer. Please refer to Chapter 6.2 for more detail.
Also ensure that the pressure equipment is not operated outside of the permissible range of
operating pressures (see nameplate operating data). It is not permissible to operate the
pressure equipment at pressures exceeding this.

8 Operating instruction bladder accumulator BLAK - English
Also ensure that local regulation on
•the safety of staff (accident regulations)
•the safety of working material (protective equipment and maintenance)
•product disposal (waste disposal laws)
•material disposal (waste disposal laws)
•cleaning (cleaning agents and disposal)
•and environmental protection
will be complied with.
Local regulations must be observed during installation and commissioning carried out by the operator
itself (e.g. acceptance testing etc.).

Operating instruction bladder accumulator BLAK - English 9
4 Dangers
4.1 General hazard notes
Operations must remain within the maximum and minimum limits specified on the nameplate and in
the technical documentation.
The pressure equipment must be installed ensuring that operating staff will not be endangered by
escaping operating materials should parts of the safety system trigger.
Structural modifications
Structural modifications to the pressure equipment are prohibited. Mechanical reworking or welding is
prohibited.
4.2 Installation of spare and wearing parts
The manufacturer’s guarantees will lapse should parts that have not been tested or approved by the
manufacturer be installed.
Pressure-retaining components must only be replaced by or with the approval of the
manufacturer.
Renewed acceptance testing by a notified body will be required! The N2 concentration in the
environment may increase when N2 is filled or drained. Adequate ventilation must be
ensured.
4.3 Cleaning, maintenance and repair work
Cleaning, maintenance or repair work may only be carried out by qualified technicians.
These activities require that systems pressure must be relieved on the oil side, including securing
against accidental switch-on.
The gas side pressure must also be relieved before performing work on gas side components.

10 Operating instruction bladder accumulator BLAK - English
5 Installation
5.1 Scope of delivery
The supplied pressure equipment / components include(s) technical documentation with operating
instructions, drawings and the declaration of conformity (acceptance report by the notified body in
case of individual acceptance tests).
Delivery
Incoming inspection:
•Check completeness as per the delivery note!
In case of damages:
•Check the delivery for damages (visual inspection)!
In case of complaints:
If the shipment damaged during transportation:
•Contact the most recent forwarder immediately!
•Keep the packaging (for possible inspection by the forwarder or for return shipment).
5.2 Transport and packaging
Ensure that the pressure equipment will not be damaged on the outside. Always ensure that the
pressure equipment, should it need to be returned to the manufacturer, will not be pressurized.
Use suitable transport equipment for onward transportation or installation. Adequate securing with
straps, for instance, is strictly necessary. Straps or magnetic devices must be attached to the tank
container for transportation (see Fig. 1-1, Pos. 1). Consult the drawing for the weight of the pressure
equipment or its components. Take note of the centre of gravity.
5.3 Storage
Intermediate storage (packaged)
The pressure equipment and the spare and replacement parts are delivered to allow for storage up to
3 months.
Storage conditions
Closed and dry room according to the designated operating conditions.
Storage / packaging for further transport
The pressure equipment and any accessories must be stored to ensure that they will be protected
from external factors and to exclude damage.
Optimal short-time storage conditions:
•Keep rooms dry and cool, protect from heat and flames.
•Store horizontally, do not stack
•Protected from mechanical stress
The operator of the pressure equipment may need to implement protective measures in cases of
longer times in storage or unfavourable storage conditions. Please consult the manufacturer for
relevant advice.
Long-term storage conditions:
•The elastomers must be replaced after more than 5 years in storage.
•Storing pre-inflated with Nitrogen P
0
is not recommended.
•Lightly oil parts that are not corrosion protected.
The connecting apertures of the pressure equipment must be closed in transportation or storage, to
prevent the intrusion of dirt or moisture and to prevent condensation.

Operating instruction bladder accumulator BLAK - English 11
The operator of the system must be on receipt of the pressure equipment assume responsibility for
storage in accordance with these instructions. Lengthy periods in transport or storage whilst packaged
should be avoided.
5.4 Assembly / Commissioning
Setup / Installation
The assembly if the pressure equipment is to be carried out by qualified staff and must be specially
trained for this kind of work.
A vertical arrangement with the oil side at the bottom is recommended. Different arrangements are
likely to increase wear.
Use fastening gear designed to handle the static and dynamic forces. Ensure that the connected lines
are not under stress.
Use fastening hardware that is designed to handle the static and dynamic forces.
Welding or soldering on the pressure equipment or mechanical modification is prohibited. No
additional forces or moments are allowed to impact on the pressure equipment. The pressure
equipment must not be exposed to flames or electrical / magnetic fields that may heat the equipment.
Ensure that the pressure equipment enclosure will not be deformed or otherwise damaged when fitting
the consoles / clamp.
Extensive damage may cause the pressure equipment to explode.
Do not install and operate the pressure equipment in rooms that are unprotected
against lightning and earthquakes.
Depending on operation, surface temperatures capable of causing burns may occur at the
limits of operating conditions. The operator should provide suitable protection.
Consult Chapter 6 for service notes and test schedules.
Use the fastening hardware provided by the manufacturer to ensure that all parts will be securely
fastened.
Before assembly:
•Check the delivery for transport damage to ensure that it is technically intact.
•Instruct the qualified staff.
Prior to commissioning, the operator should:
•Check the technical documentation for completeness as per Chapter 5.1.
•Completion of the infeed and outfeed systems and the parts of the system into which the
pressure equipment will be incorporated that have a safety functionality.
•Ensuring the functionality of installed instrumentation.
The operator should have the entire system acceptance tested (see Chapter 3.5) before
commissioning the pressure equipment. Adjust the pre-inflation pressure (P
0
) to match the
operating parameters (see Chapter 2.2). The pressure equipment will be delivered with a
transport / storage pressure of 2 to 5 bar or to customer requirements.
Observe Chapters 2 and 4 when filling or draining.
Uninstalling the pressure equipment
Measure and ensure that the oil and gas sides are depressurised before uninstalling. Remove all parts
fitted on the fluid side, such as reducers, screwed connections, accessories, etc.
Never open the bleed screw, when the hydraulic circuit to which the accumulator is
connected, is under pressure.
The fluids valve should now be open or easy to open by hand when the pressure equipment
is not under pressure. Strictly stop work if this is not the case and obtain technical advice
from the manufacturer.

12 Operating instruction bladder accumulator BLAK - English
6 Maintenance
6.1 General maintenance notes
The pressure equipment will be largely maintenance-free after filling.
To ensure perfect operation and long life of the pressure equipment, carry out the following services to
the schedule specified by the operator.
Weekly checks of the pre-inflation pressure (P
0
) in the first month of operation is recommended,
monthly checks will suffice thereafter. The checking intervals should ultimately be guided by the
pressure drop actually found after certain intervals.
The following monthly checks are furthermore recommended initially: The intervals may then be
adjusted, depending on experience gained:
•Check the accumulator anchoring.
•Check the connections for the lines.
•Inspect and assess the condition of the instrumentation, safety systems and seals.
•Use foaming agents to check all screwed connections, shut-off valves, connections and joints for
gas leakages.
•Check the N2 pre-inflation pressure (P
0
).
•Regularly check the internal coating for wear when using abrasive or corroding fluids.
6.2 Initial operating, repeated inspection and periods of repeated inspection
Initial operating
In Germany, the pressure equipment is subject to the Operational Safety Ordinance. §15 will apply to
commissioning.
Repeated inspection
§16 of the Occupational Safety Ordinance sets the schedule for routine testing (pay attention to the
according national directives of the set-up country, see Chapter 3.5).
Roth Hydraulics GmbH recommends the following periods:
•External tests every 2 years
•Internal tests every 5 years
•Pressure tests depending on the number of load cycles, but after 10 years at least.
The customer must agree on the intervals of repeated inspection with the local authorities.
Initiation and execution
The operator must be responsible for compliance with and execution of period of repeated inspection
(see Operational Safety Ordinance, Section 3).
.

Operating instruction bladder accumulator BLAK - English 13
7 Disturbance, causes, troubleshooting (qualified staff only)
Disturbance Cause Troubleshooting
Pressure equipment will
not supply hydraulic fluid •Oil valve closed
•Gas-side pressure too low
•Pressure relief open
•Open oil valve
•Check pre-inflation pressure
•Close pressure relief
Hydraulics pressure too
low •Shut-off valve closed
•Pump does not pump
•Open shut-off valve
•Check the pump functionality and
repair as necessary
N2 safety valve opens •Gas-side pressure too high
•Operation markedly increases the gas
temperature
•Fluid overflow
•Check the pre-inflation pressure and
settings of the plant
•Find reasons for the temperature
rise
•Depressurise the pressure
equipment
Gas valve leaking •The inflating pressure will drop if the gas valve leaks. Permitted pressure ratio
exceeded. The bladder may potentially be destroyed
•Gas valve and/or valve cap damaged •Replace gas valve and/or valve cap,
use original parts
Oil valve leaking •O-ring damaged or hardened due to
excessively high oil temperature •Replace O-ring, using original parts, check oil temperature if necessary
and take appropriate action
Bladder leaking •Diagnosing causes – see below •Replacing bladder and other
measures – see below
Premature failure (0 -
20 000 load cycles) •Foreign inclusions in rubber.
Manufacturing or material defect. Poor
vulcanisation
•Check gas valve
Bladder is brittle, rigid,
porous and carbonised. •Operating ratio greater than 1:4, thus
compression temperature too high; N2
heating up excessively. Oil temperature
too high
•Calculate new inflation pressure and
set; set oil temperature to
permissible value
Bladder is porous and
swollen •Unsuitable fluid, e.g. fire-inhibiting liquids
and buna bladder •Check fluid, consult manufacturer
Bladder carbonised on the
gas valve side •Inflow speed and operating pressure ratio
too high, due to pressure peaks in system
or too low inflation pressure. Heat
accumulation on gas valve side
inadequately dissipated
•Reduce inflow speed using flap or
increase inflation pressure
Bladder has abrading
areas •Inflation pressure too low. Particularly with
synthetic heavy fluids, the bladder may
rub on, due to greater buoyancy
•Check inflation pressure. Vertical
installation is recommended from 10
litre and up pressure equipment.
Bladder base has a tear,
hole etc. •Faulty oil valve •Replace oil valve and bladder
Distinct oil valve imprint on
bladder base. •Inflation pressure too high. Bladder base
hammers against fluid valve. Discharge
speed too high.
•Reset pre-inflation pressure
Bladder is creased •30 and 50 litre pressure equipment
assembly fault -
Valve disc of oil valve
jamming, potentially
damaging the bladder
•Using fluids leading to sticking / gumming •Regular functional test for mobility
of valve disc

14 Operating instruction bladder accumulator BLAK - English
8 Emergencies
This pressure equipment is a passive system, without own drives. The stored energy will be charged
or discharged by the connected active system of the operator.
Emergency measures such as the operation of Emergency-Off systems or fast pressure relief action
should therefore preferably be defined and documented in the work instructions of the operator.
9 Dissembling / disposal
Ensure that the pressure equipment is depressurised on the gas and oil sides before disposal.
Sort the pressure equipment by materials to be disposed in accordance with applicable local
environmental regulations.
Decontaminate and dispose of any contaminated parts according to local environmental regulations.

Operating instruction bladder accumulator BLAK - English 15
Notes

16 Operating instruction bladder accumulator BLAK - English
Notes

Operating instruction bladder accumulator BLAK - English
Technical changes reserved