STAUFF STA-CK-SKK User manual

Direct Accumulator Charging Kit
STA-CK-SKK
INSTRUCTION MANUAL

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STA-CK-SKK
Operating Instructions available online
Only use “gas approved" test hose
For use with nitrogen (N2) gas only
Safety goggles must be worn at all times
STAUFF pressure gauges are safety pattern type according to AS1349
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43
5
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Description
STAUFF's accumulator direct charging kit - SKK is an essential instrument for the verication, pressurisation and nitrogen gas bleeding of
STAUFF accumulators tted with a SKK gas valve connection. Pre-charge pressure can be easily checked by coupling the safety gauge directly
to the SKK gas valve connection on the STAUFF accumulator.
Features
The standard kit is delivered in a storage case containing the following:
11 x Charging valve
2
1 x SKK Test coupling 1/4" NPT (for regulator connection)
31 x Safety pattern pressure gauge according to AS1349-1986
41 x 2 Metre hose
5
1 x Safety goggles
6 1 x Operating instructions
Available pressure gauges
▪ 0 - 25, 0 - 100, 0 - 250 & 0 - 400 bar kit
Application
▪For checking and pre-charging of accumulators with
M16 x 2.0 (Test 20) or M16 x 1.5 (Test 15) or M12 x 1.65 (Test 12) STAUFF Test coupling connection (optional)
Maximum working pressure of this equipment (excluding individual pressure rating of gauges) is 400 bar.

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Operating Instructions available online
Safety Instructions and Recommendations
1. Before using the charging head carefully read the directions and safety instructions in this guide.
2. In all cases observe the pressure limits indicated on the accumulator pressure vessels. If necessary refer to the applicable operating
instructions.
3. Before attempting to check the pre-charge pressure, the accumulator in the hydraulic circuit under pressure has to be isolated and
discharged on the hydraulic side. If required immobilize it and dene a safety zone.
4. Only use nitrogen gas with a purity ≥ 99,8% (N2) to pressurise the accumulator.
5. STAUFF always recommends the use of a nitrogen gas regulator on the nitrogen gas bottle.
6. The charging valve (1) and pressure gauge (3) are tools for checking gas pressure and pre-charging accumulators. In cases where
the gauge and gauge adaptor will be left on the accumulator, make sure that the gauge tted is rated for the maximum system
pressure of the hydraulic circuit.
7. Never use an accumulator in a hydraulic system without it rst being pre-charged with the correct nitrogen gas pressure.
Failure to do this will result in bladder or diaphragm damage.
8. Ensure safety goggles are worn when either checking or pre-charging accumulators.
9. To ensure optimum efciency and performance of the hydraulic circuit, the pre-charge pressure must be checked frequently.
STAUFF recommends the pressure be checked initially at intervals of 1 month, 3 months and then 6 months after installation.
Depending on the amount of loss of pressure (if any) over this time, a planned maintenance schedule for monitoring the pressure
can then be put into operation (check annually).
Only use “gas approved" test hose
For use with nitrogen (N2) gas only
Safety goggles must be worn at all times
STAUFF pressure gauges are safety pattern type according to AS1349
Only use “gas approved" test hose
For use with nitrogen (N2) gas only
Safety goggles must be worn at all times
STAUFF pressure gauges are safety pattern type according to AS1349

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STA-CK-SKK
Operating Instructions available online
Connection Flow Chart
A
C
E
D
B
F
*
Pre-Charging -Typical Installation
High Pressure Gas Hose DN4
Length: 2000 mm
Test Coupling / 1/4” BSPP Connection
4
STAUFF SKK Gas Valve Coupling
SKK Test Coupling
1/4" NPT
(for regulator connection)
* Ensure appropriate thread sealing
compound is applied prior to
connection
2
Optional
STAUFF Recommend
the use of a Nitrogen
Gas Regulator
Safety Pattern
Pressure Gauge
+ Adaptor
SMD G1/4"
3
Charging Valve
1
Checking - Typical Installation

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STA-CK-SKK
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Operating Instructions available online
General
1. Recommendation: Before proceeding to any operation concerning the initial pressurisation of an accumulator, consult the applicable
operating instructions.
2. Pressurisation limits: Ensure that the SKK Charging Kit and any associated pressure gauge tted are rated for the intended pressure
for both pre-charging and pressure checking. Refer to the manufacturers specications.
The nitrogen gas pressure varies as a function of the gas temperature. After each ination and deation of nitrogen gas, wait for
the temperature to stabilise before checking the pressure (this may take several minutes depending on the accumulator size).
Never exceed the maximum stated design pressure (PS or DP) of the accumulator as stamped on the vessel. If in doubt consult the
manufacturer or check manufacturer’s operating instructions or specication manual.
3. Taking into account the temperature inuence on the pre-charge pressure: In order to observe the working pressures of the
accumulator it is advised to adjust the ination pressure (P0) according to the operating or control temperature.
Bladder Accumulators
Refer to page 4 for connection ow chart
▪ Remove the protection cap on the SKK gas valve coupling (F) tted to the gas side of the accumulator
▪Select the safety pattern pressure gauge and adaptor (3) and couple directly to the SKK gas valve coupling (F) on the STAUFF
accumulator – pressure should now be indicated on the gauge
▪ To remove, uncouple the gauge from the STAUFF accumulator
Pre-charging Accumulators Instruction
General
Note: The following information applies to pre-charging new accumulators or after a bladder change when no gas pressure is present
inside the accumulator.
Prior to pre-charging an accumulator it is important that the inside of the accumulator shell be lubricated. New STAUFF accumulators are
already lubricated internally during the manufacture / assembly process. For older units or accumulators that have been repaired and a new
bladder installed, STAUFF recommend that the accumulator be lubricated with enough system uid to evenly coat the inside of the shell.
To ensure good lubrication lay the accumulator horizontally and rotate on its axis.
The pre-charge setting is recommended to be set to 80% - 90% of the minimum system working pressure if no specic pressure has been
calculated.
Checking the Pre-charge Pressure
Only use “gas approved" test hose
For use with nitrogen (N2) gas only
Safety goggles must be worn at all times
STAUFF pressure gauges are safety pattern type according to AS1349

6www.stauff.com
STA-CK-SKK
Operating Instructions available online
Only use “gas approved" test hose
For use with nitrogen (N2) gas only
Safety goggles must be worn at all times
STAUFF pressure gauges are safety pattern type according to AS1349
Applying the Pre-charge Pressure (Accumulator has no gas)
Charging Valve Connected Directly to Regulator
Typical Installation
Remove any plastic plugs that are tted to the accumulator uid port. Remove the accumulator gas valve protection cap and gas valve screw
cap tted to the gas side of the accumulator. Prepare a container to catch any uid which may drain from the uid port during charging.
Refer to page 4 for connection ow chart
▪ Ensure regulator used is tted with STAUFF SKK test coupling (2)
▪Make sure main valve on nitrogen gas bottle is closed
▪ Connect SDA adaptor end (C) of charging valve to SKK test coupling (2) tted on regulator
▪Connect gauge + adaptor (3) to charging valve (A)
▪Connect the test coupling on one end of the hose to the SKK gas valve coupling (F) on the accumulator
▪ Connect the other end of the hose 1/4” BSPP to the charging valve (B) and tightened with a spanner
▪Slightly open the valve on the nitrogen gas source until a small amount of gas can be heard coming from the bleed valve (D) which
should be open
▪ After 5 seconds (0.7 Ltr - 4 Ltr) and 10 to 20 seconds (10 Ltr - 55 Ltr) slowly close the bleed valve (D), allow pressure to increase
▪Slowly increase the pressure from the nitrogen gas source by opening its valve until the indicated pressure increases to the desired
setting. Wait until temperature and pressure are stable, and if needed increase the pressure again to the required setting. When the
pre-charge pressure (P0) is reached and stabilised, close the valve of the nitrogen gas source
▪Disconnect the hose end connected to the SKK gas valve coupling (F) and then disconnect from the charging valve (B)
▪Remove the gauge and adaptor (3) from the charge valve (A) and then attach it to SKK gas valve coupling (F) on the accumulator.
Check to ensure the pre-charge pressure is correct.
▪ After conrming the pre-charge pressure is correct, remove the gauge and gauge adaptor (3) from the SKK gas valve coupling on
the accumulator (F)
Important: Whilst the gas hose (4) is connected to the SKK gas valve coupling (F), the SKK gas valve coupling is always open. Before
attempting to remove any of the charge equipment, the gas hose (4) connected to the SKK gas valve coupling (F) must rst be
removed. Failure to do so will drain the nitrogen gas pressure from the accumulator.

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STA-CK-SKK
7
Operating Instructions available online
Only use “gas approved" test hose
For use with nitrogen (N2) gas only
Safety goggles must be worn at all times
STAUFF pressure gauges are safety pattern type according to AS1349
Only use “gas approved" test hose
For use with nitrogen (N2) gas only
Safety goggles must be worn at all times
STAUFF pressure gauges are safety pattern type according to AS1349
Applying the Pre-charge Pressure (Accumulator has no gas)
Charging Valve Connected Directly to Regulator
Optional Installation - Only applies to SKK-20 & SKK-12 Charging Kits
Remove any plastic plugs that are tted to the accumulator uid port. Remove the accumulator gas valve protection cap and gas valve screw
cap tted to the gas side of the accumulator. Prepare a container to catch any uid which may drain from the uid port during charging.
Refer to page 4 for connection ow chart
▪ Ensure regulator used is tted with STAUFF SKK test coupling (2)
▪Make sure main valve on nitrogen gas bottle is closed
▪ Connect SDA adaptor end (C) of charging valve to SKK gas valve coupling (F) tted on STAUFF accumulator
▪Connect gauge + adaptor (3) to charging valve (A)
▪ Connect the 1/4” BSPP end of the hose to the charging valve (B) and tightened with a spanner
▪ Connect the other end of the test hose (4) to the SKK test coupling (2) tted to the regulator
▪Slightly open the valve on the nitrogen gas source until a small amount of gas can be heard coming from the bleed valve (D) which
should be open
▪ After 5 seconds (0.7 Ltr - 4 Ltr) and 10 to 20 seconds (10 Ltr - 55 Ltr) slowly close the bleed valve (D), allow pressure to increase
▪Slowly increase the pressure from the nitrogen gas source by opening its valve until the indicated pressure increases to the desired
setting. Wait until temperature and pressure are stable, and if needed increase the pressure again to the required setting. When the
pre-charge pressure (P0) is reached and stabilised, close the valve of the nitrogen gas source
▪ Disconnect the SDA adaptor (C) of charge valve from the SKK gas coupling (F) tted on the STAUFF Accumulator
▪Remove the gauge and adaptor (3) from the charge valve (A) and then attach it to SKK gas valve coupling (F) on the accumulator.
Check to ensure the pre-charge pressure is correct.
▪ After conrming the pre-charge pressure is correct, remove the gauge and gauge adaptor (3) from the SKK gas valve coupling on
the accumulator (F)
Maintenance of the STA-CK Charging Valve (1)
It is recommended to check the various connections and adaptors at regular intervals for cleanliness, detection of possible defects, thread
wear and sealing parts.
Please contact your local STAUFF ofce for further information.

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AUSTRALIA
STAUFF Corporation Pty Ltd
Tel.: [phone]
[email protected]
INDIA
STAUFF India Pvt Ltd
Tel.: [phone]
sales@staufndia.com
POLAND
STAUFF Polska Sp. z o.o.
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[email protected]
BRAZIL
STAUFF Brasil Ltda
Tel.: [phone]
[email protected]
IRELAND
STAUFF Ireland
Tel.: [phone]
sales@staufreland.com
RUSSIAN FEDERATION
STAUFF LLC
Tel.: [phone]
[email protected]
CANADA
STAUFF Canada Ltd
Tel.: [phone]
[email protected]
ITALY
STAUFF Italia S.r.l
Tel.: [phone]
[email protected]
THAILAND
STAUFF (Thailand) Co Ltd
Tel.: [phone]
[email protected]
CHINA
STAUFF China
Tel.: [phone]
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KOREA
STAUFF Korea Ltd
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UNITED KINGDOM
STAUFF UK Ltd
Tel.: [phone]
[email protected]
FRANCE
STAUFF S.A.S.
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MALAYSIA
STAUFF South East Asia Sdn Bhd
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[email protected]
UNITED STATES
STAUFF Corporation
Tel.: [phone]
[email protected]
GERMANY
Walter Stauffenberg GmbH & Co. KG
Tel.: [phone]
[email protected]
NEW ZEALAND
STAUFF Corporation (NZ) Ltd
Tel.: [phone]
[email protected]
VIETNAM
STAUFF Vietnam Ltd
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