Bladder Type Accumulator Rexroth

Operating instructions

RE 50170-B/10.08

Material no. R901200926

Bladder-type accumulatorType HAB..-4X

The data specified above only serve to describe the product. No statement concerning a certain condition or suitability for a certain application can be derived from our information. The information given does not release the user from their own judgment and obligation of verification. It must be remembered that our products are subject to a natural process of wear and aging.

© This document, as well as the data, specifications and other information set forth in it, are the exclusive property of Bosch Rexroth AG.It may not be reproduced or given to third parties without its consent.

The cover page shows a sample configuration. The delivered product may differ from the picture shown.

The original operating manual was drawn up in the German language.

RE 50170-B/10.08 | Type HAB..-4X Bosch Rexroth AG 3/32

BG: Пускането в експлоатация на този продукт може да се извърши едва тогава, когато разполагате с това упътване за употреба на Вашия език и сте разбрали неговото съдържание. Ако това не е така, обърнете се към Вашия партньор Bosch Rexroth или към компетентен сервиз.Ще го намерите в www.boschrexroth.com.

CS: Tento výrobek smí být uveden do provozu jedině tehdy, máte-li k dispozici tento návod k obsluze ve své jazykové verzi a rozumíte celému jeho obsahu. Pokud tomu tak není, obraťte se na svou kontaktní osobu u firmy Bosch Rexroth nebo na příslušné servisní středisko. To naleznete také na internetové adrese www.boschrexroth.com.

DA: Dette produkt må først tages i brug, når du har modtaget og læst driftsvejledningen på dit sprog og har forstået indholdet. Hvis det ikke er tilfældet, bedes du kontakte din kontaktperson hos Bosch Rexroth eller den ansvarlige kundeserviceafdeling. Den kan du finde på hjemmesiden www.boschrexroth.com.

DE: Die Inbetriebnahme dieses Produkts darf erst dann erfolgen, wenn Sie diese Betriebsanleitung in Ihrer Sprachversion vorliegen und den Inhalt verstanden haben. Ist dies nicht der Fall, wenden Sie sich bitte an Ihren Bosch Rexroth Ansprechpartner oder die zuständige Servicestelle. Diese finden Sie auch unter www.boschrexroth.com.

EL: Το προϊόν επιτρέπεται να τεθεί σε λειτουργία μόνο εάν διαθέτετε τις παρούσες οδηγίες χρήσης στη γλώσσα σας και εφόσον έχετε κατανοήσει το περιεχόμενό τους. Εάν δεν πληρούνται αυτές οι προϋποθέσεις, απευθυνθείτε στους κατά τόπους αντιπροσώπους της Bosch Rexroth ή σε κάποιο εξουσιοδοτημένο σέρβις. Για τα σχετικά στοιχεία επισκεφτείτε την ιστοσελίδα www.boschrexroth.com.

EN: This product may only be commissioned if these operating instructions are available to you in your language version and if you have understood its content. If this is not the case, please contact your Bosch Rexroth contact partner or the responsible service point. You can also find them under www.boschrexroth.com.

ES: La puesta en servicio de este producto únicamente podrá realizarse cuando disponga de las instrucciones de servicio en su idioma y haya entendido su contenido. En caso contrario, diríjase a su persona de contacto de Bosch Rexroth o al servicio técnico competente, que podrá encontrar también en la dirección www.boschrexroth.com.

ET: Toodet tohib kasutada ainult siis, kui teil on käesolevast kasutusjuhendist oma emakeelne versioon ja te saate selle sisust aru. Kui see nii ei ole, pöörduge oma Bosch Rexrothi esindaja või vastava teeninduse poole. Nende kontaktandmed leiate aadressilt www.boschrexroth.com.

FI: Älä ota tuotetta käyttöön ennen kuin olet saanut käyttöohjeen omalla kielelläsi ja ymmärrät sen sisällön. Ota muussa tapauksessa yhteyttä Bosch Rexroth -yhteyshenkilöösi tai valtuutettuun huoltoliikkeeseen. Yhteystiedot löydät osoitteesta www.boschrexroth.com.

FR: Ce produit ne doit être mis en service que lorsque vous disposez des présentes instructions de service en votre langue et que vous avez compris son contenu. Si cela n‘est pas le cas, veuillez vous adresser à votre interlocuteur Bosch Rexroth ou au service compétent. Vous trouvez les coordonnées également sur le site www.boschrexroth.com.

HU: A terméket csak akkor helyezheti üzembe, ha rendelkezik magyar nyelvű használati útmutatóval, és annak tartalmát megértette. Egyéb esetben forduljon a Bosch Rexroth kapcsolattartójához vagy az illetékes szervizhez. Ezeket is megtalálja az alábbi címen: www.boschrexroth.com.

IT: La messa in servizio di questo prodotto può essere eseguita solo se si dispone del presente manuale d‘uso nella propria lingua e se ne è stato compreso il contenuto. In caso contrario rivolgersi al referente Bosch Rexroth o al punto di assistenza competente. Questi sono anche riportati sul sito www.boschrexroth.com.

LT: Pradėti naudoti šį produktą leidžiama tik turint šią vartotojo instrukciją Jums suprantama kalba. Jei instrukcijos nesuprantate, prašome kreiptis į savo Bosch Rexroth konsultantą arba atsakingą aptarnavimo tarnybą. Informaciją apie juos rasite adresu www.boschrexroth.com.

LV: Šīs ierīces ekspluatāciju drīkst sākt tikai tad, ja šī ekspluatācijas instrukcija Jums ir pieejama Jūsu valodā un Jūs esat izpratis tās saturu. Pretējā gadījumā lūdzam vērsties pie attiecīgās „Bosch Rexroth“ kontaktpersonas vai kompetentā servisa dienestā. Nepieciešamā informācija ir pieejama arī mūsu mājas lapā internetā www.boschrexroth.com.

NL: U mag het product pas in bedrijf stellen, nadat u de bedieningshandleiding in uw taal in handen en de inhoud daarvan begrepen heeft. Is dit niet het geval, neem dan a.u.b. contact op met uw Bosch Rexroth contactpersoon of de servicepartner. Deze vindt u ook op www.boschrexroth.com.

4/32 Bosch Rexroth AG Type HAB..-4X | RE 50170-B/10.08

NO: Dette produktet må ikke tas i bruk før du har mottatt og lest bruksanvisningen på ditt språk, og forstått innholdet. Hvis dette ikke er tilfellet, ta kontakt med din kontaktperson hos Bosch Rexroth eller ansvarlig kundeserviceavdeling. Den kan du finne på www.boschrexroth.com.

PL: Przed uruchomieniem niniejszego produktu należy zapoznać się z instrukcją obsługi w odpowiedniej wersji językowej. W przypadku, gdy nie dołączono instrukcji w danym języku, należy zwrócić się z zapytaniem do osoby kontaktowej Bosch Rexroth lub do odpowiedniego punktu obsługi. Listę takich punktów można znaleźć na stronie www.boschrexroth.com.

PT: A colocação em funcionamento deste produto apenas pode ser efectuada, quando tiver o manual de instruções na sua língua e se tiver compreendido o conteúdo do mesmo. Se não for esse o caso, dirija-se à sua pessoa de contacto da Bosch Rexroth ou ao respectivo ponto de assistência. Encontra-os em www.boschrexroth.com.

RO: Aveţi voie să puneţi în funcţiune acest produs, doar după ce aţi primit acest manual de utilizare în limba dumneavoastră şi aţi înţeles conţinutul său. Dacă aceste condiţii nu sunt îndeplinite, adresaţi-vă persoanei dumneavoastră de contact de la Bosch Rexroth sau la service-ul Bosch Rexroth competent. Găsiţi aceste service-uri la www.boschrexroth.com.

RU: Ввод в эксплуатацию данного продукта разрешен только тогда, когда это руководство по эксплуатации будет получено Вами на русском языке и усвоено Вами. Если у Вас нет руководства по эксплуатации, обратитесь, пожалуйста, к ответственному за Ваш регион представителю Bosch Rexroth или в соответствующий сервисный центр. Его Вы найдете на сайте www.boschrexroth.com.

SK: Tento výrobok sa smie uviesť do prevádzky až vtedy, keď ste dostali tento návod na prevádzku k dispozícii vo vašej jazykovej mutácii a obsahu ste porozumeli. V opačnom prípade sa, prosím, obráťte na vašu kontaktnú osobu v Bosch Rexroth alebo na zodpovedné servisné miesto. Nájdete ich tiež na www.boschrexroth.com.

SL: Z uporabo tega izdelka lahko pričnete šele, ko ste prebrali ta navodila za uporabo v vašem jeziku in razumeli njihovo vsebino. Če navodila za uporabo niso na voljo v vašem jeziku, vas prosimo, da se obrnete na kontaktno osebo podjetja Bosch Rexroth oz. pooblaščeni servis. Te lahko najdete tudi na www.boschrexroth.com.

SV: Denna produkt får inte tas i drift förrän du har mottagit en bruksanvisning på ditt språk och förstått innehållet i den. Om detta inte är fallet ber vi dig kontakta din kontaktperson på Bosch Rexroth eller ansvarig kundservice. Dessa hittar du också på www.boschrexroth.com.

ZH: 使用该产品前，请您确保已拥有一份贵国语言版使用说明书并已理解其内容。如果尚未拥有，请向博世力士乐合作伙伴或相关服务部门索取，也可登录 www.boschrexroth.com 下载。


Content

Content1 About this manual ...........................................................................................6

1.1 Related documentation .............................................................................61.2 Abbreviations used ...................................................................................61.3 Signs and symbols used ...........................................................................6

2 Principle safety instructions ..........................................................................72.1 Intended use .............................................................................................82.2 Non-intended use......................................................................................82.3 Qualification of staff ..................................................................................82.4 You have to observe the following ............................................................92.5 Obligations of the operator......................................................................11

3 Scope of delivery ..........................................................................................124 Product description ......................................................................................12

4.1 Performance and device description.......................................................124.2 Identification of the bladder-type accumulator ........................................14

5 Transport and storage ..................................................................................155.1 Transport of the bladder-type accumulator .............................................155.2 Storage of the bladder-type accumulator ................................................16

6 Installation .....................................................................................................166.1 Unpacking ...............................................................................................166.2 Installation conditions..............................................................................176.3 Required tools .........................................................................................176.4 Installation of the bladder-type accumulator ...........................................18

7 Commissioning .............................................................................................227.1 Preparation of the commissioning...........................................................237.2 Initial commissioning ...............................................................................237.3 Recommissioning after non-operational periods.....................................24

8 Operation .......................................................................................................259 Maintenance and servicing ..........................................................................25

9.1 Maintenance ...........................................................................................259.2 Servicing .................................................................................................279.3 Spare parts list ........................................................................................28

10 Decommissioning .........................................................................................2811 Disassembly and replacement ....................................................................28

11.1 Required tools .........................................................................................2811.2 Preparation of the disassembly...............................................................2911.3 Realization of the disassembly ...............................................................29

12 Disposal .........................................................................................................3012.1 Environmental protection ........................................................................30

13 Extension and transformation .....................................................................3114 Fault finding and troubleshooting ...............................................................31

14.1 Fault finding procedure ...........................................................................3114.2 Fault table ...............................................................................................32

15 Technical data ...............................................................................................3316 Appendix ........................................................................................................33

16.1 Address register ......................................................................................3316.2 Accessories.............................................................................................33


About this manual

About this manual1 This manual contains information about the safe and appropriate transport, installation, commissioning, maintenance, disassembly and independent troubleshooting of simple malfunctions of the HAB..-4X bladder-type accumulator.Please read this manual thoroughly, particularly chapter 2 on "Principle safety instructions", before working with the HAB..-4X bladder-type accumulator.

Related documentation1.1 The HAB..-4X bladder-type accumulator is a machine and system component.

Please also observe the manuals of the other machine and system fcomponents as well as the documentation provided by the machine or system manufacturer.Please also observe the following documentations: f

Related documentationTable 1: Documentation ContentData sheet RE 50170 Technical data, operating conditions, limits of performance,

project planning information concerning HAB..-4X bladder-type accumulators

Data sheet RE 07008 General information on hydraulic productsData sheet RE 07900 General information on the installation, commissioning and

maintenance of hydraulic systemsData sheet RE 90220 General information on hydraulic fluids on mineral oil basis

You can find this operating manual as well as the related documentation in the media directory under www.boschrexroth.com\various\utilities\mediadirectory.

Please also observe the generally valid legal and other relevant provisions fof the European and/or national legislation as well as the provisions on the prevention of accidents and on environmental protection valid in your country.

Abbreviations used1.2 AbbreviationsTable 2:

Abbreviation MeaningType HAB..-4X HAB bladder-type accumulator, series 4X

RD Rexroth document in the German languageRx Rexroth document in a different language

Signs and symbols used1.3 This manual uses the following signs and symbols:

Activity symbol: The text following this sign describes activities that can be fperformed in any order.Numbered activities: The text following this sign describes activities that are to 1. be performed in the order indicated.


Principle safety instructions

The indented text given after activities/an activity describes their/its result.

1st category bullet point •2nd category bullet point –

This pictogram is used to mark important information and remarks. The text contains useful information you should particularly observe, since it improves the operating sequence or is required as background information!

In this manual, warning notices can be found before an instruction if there is a risk for personal injuries or material damage. The measures described for the prevention of danger have to be complied with.Warning notices are structured as follows:

Type of dangerConsequences

Prevention measure f

Warning sign (warning triangle): Draws attention to the danger •Signal word: Indicates the severity of the danger •Type of danger: Indicates the type or source of the danger •Consequences: Describes the consequences in case of non-compliance •Prevention measure: Indicates how the danger can be avoided •

The signal words have the following meanings:

Meaning of signal wordsTable 3: Signal word Application

DANGER! Marks an immediately threatening great danger which will cause severe injuries or even death, if it is not prevented.

WARNING! Marks a potential danger which may cause severe injuries or even death, if it is not prevented.

CAUTION! Points out to a potentially dangerous situation which may cause moderate and minor injuries or material damage, if it is not prevented.

If this information is not observed, this may lead to deteriorations in the operating sequence.

Principle safety instructions2 The HAB..-4X bladder-type accumulator was manufactured according to the state of the art. Nevertheless, there is a risk of personal injuries and material damage, if you do not observe the following principle safety instructions and the warning notices given before instructions in this manual.

Warning notices

SIGNALWORD



Read this manual thoroughly and completely, before working with the fHAB..- 4X bladder-type accumulator.Keep the manual so that it is accessible for all users at all times. f

Intended use2.1 Rexroth bladder-type accumulators are intended to be built in hydraulic drive systems for the purposes of energy storage, shock and vibration absorption, compensation of leakage losses or volume compensation.Bladder-type accumulators are pressure equipments in the sense of the Pressure Equipment Directive 97/23/EC.The HAB..-4X bladder-type accumulator is exclusively intended to be built in a machine and/or system or to be assembled with other components to form a machine and/or system.For the project planning, the principles of the Pressure Equipment Directive and the Machinery Directive, within the EU, as well as other local provisions, outside the EU, are to be observed.The bladder-type accumulator must only be put into operation, if it is built into the machine/system it is intended for and after it was confirmed that the machine/system complies with the provisions of the Machinery Directive, the Pressure Equipment Directive and other locally applicable provisions.Observe the technical data, operating conditions and limits of performance indicated in the data sheet RE 50170.Repair works must only be carried out by the manufacturer or by authorized dealers and agencies. If this condition is not complied with, the warranty expires.The HAB..-4X bladder-type accumulator is a technical working device and not intended for any private use.The intended use also includes that you have completely read and understood this operating manual and particularly chapter 2 "Principle safety instructions".

Non-intended use2.2 Non-intended use is any use of the HAB..-4X bladder-type accumulator other than the use described in the chapter "Intended use".The bladder-type accumulator must not be modified in any way whatsoever; otherwise the warranty expires! This is particularly true for welding and soldering works, mechanical machining or the installation or addition of non-original replacement or other accessory parts. The operating pressure of the bladder-type accumulator must not exceed the maximum operating pressure indicated in the technical data sheet. The bladder-type accumulator must not be charged with a gas other than nitrogen 99.99 percent by volume. The bladder-type accumulator must not be operated with group 1 hydraulic fluids (explosive, inflammable, fire-accelerating, toxic) or with corrosive fluids.

Qualification of staff2.3 The installation, commissioning, disassembly and servicing (including maintenance and care) require basic mechanical and hydraulic knowledge as well as knowledge of the corresponding technical terms. In order to ensure operational safety, these activities may therefore only be carried out by qualified skilled or instructed persons or under the guidance of a skilled person.



Persons are regarded as skilled if, due to their professional training, their know-how and their experience as well as their knowledge of the relevant provisions, they can assess the works assigned to them, recognize possible dangers and take suitable safety measures. A skilled person has to observe the relevant specific professional provisions.

You have to observe the following2.4 • Observe the provisions on accident prevention and environmental protection

valid in your country and at the workplace.Only use Rexroth products, when they are in a technically perfect condition. •Check the product for obvious defects. •You may principally not modify or reconstruct the HAB..-4X bladder-type accumulator. •Only use the HAB..-4X bladder-type accumulator in the performance range •which is specified in the technical data sheet RE 50170 and on the type cap.Persons who install, operate, disassemble, or maintain Bosch Rexroth products •must not be under the influence of alcohol, other drugs or medications that could affect their ability to react.The HAB..-4X bladder-type accumulator may strongly heat up during operation. Let •cool down the bladder-type accumulator before touching it. If this is not possible, protect yourself by means of heat-resistant protective clothing, e.g. gloves.The warranty only applies to the delivered configuration. •In case of incorrect installation, non-intended use and/or improper handling, the •warranty expires.Make sure at all times that the bladder-type accumulator is positioned safely •and secured against unintended rolling or falling.Never load the product mechanically in an improper way: •

Do not place any objects on the product. –Never use the product as a handle or step. –Do not apply further loads. –

• Bladder-type accumulators may fall during transport. Due to their weight, this is associated with a risk of considerable injuries.When bladder-type accumulators with a capacity of 10 l or more are lifted, there •is a risk of personal injuries due to their weight. Use appropriate lifting gear for the transport of bladder-type accumulators.

• Always depressurize and de-energize the relevant part of the system prior to installing a bladder-type accumulator. Secure the system against restarting. For this, always observe the operating manual and other technical documentation relating to the system.Never carry out any welding, soldering or mechanical works on the bladder-type •accumulator.Before installing the bladder-type accumulator, check it for transport damage. •Make sure that the sealing and the sealing surface of the fluid connection are intact. •During installation, ensure utmost cleanliness in order to avoid that dirt may •penetrate the hydraulic lines and lead to wear and tear, malfunctions or a complete failure.

General remarks

During transport

During installation



Allow the product to acclimatize for some hours prior to installation, since •otherwise condensed water may be generated.Secure the bladder-type accumulator against unintended rolling or falling during •installation in order to avoid any personal injuries or material damage to the bladder-type accumulator.Fasten the bladder-type accumulator safely by means of mounting clamps •according to RE 50170 in order to relieve the pipe union and in order to avoid loosening or damage due to vibrations.Immediately wipe off any oil leaking during installation in order to avoid a slip hazard. •

• Make sure that the system is depressurized before charging the bladder-type accumulator with nitrogen.Only charge the bladder-type accumulator with nitrogen 99.99 percent by •volume. If the bladder-type accumulator is charged with different gases - particularly with air or oxygen -, the bladder-type accumulator might explode.Always use the charging and test device according to RE 50170 for charging •the bladder-type accumulator.Do not put into operation the product, unless it is completely installed. •Always observe the operating manual of the machine/system. •

• Within the framework of the intended use of the hydraulics system, only authorized personnel may operate the adjustment elements of components and parts.Restrict the access to the direct operating area of the system to persons •authorized by the operator. This is also valid, when the system is at standstill.Make sure that the type cap is always installed and legible. Otherwise, further •operation is not allowed.In case of an emergency, an error or other irregularities, switch off the system •and secure it against restarting.The bladder-type accumulator must not be operated with corrosive fluids. •Otherwise, there is a risk of reduction of the wall thickness and thus a danger of bursting for the pressure vessel.Make sure that no forces are applied to the bladder-type accumulator. The •effects of external forces may lead to damage on the oil connection and the uncontrolled release of pressurized fluids. Make sure that the ambient temperature of the bladder-type accumulator does •not exceed or fall short of the ambient temperature indicated in the technical data or on the type cap.

• Close the fluid connection and cover the gas port by means of the cover cap provided.Never use solvents or aggressive cleaning agents. •Only clean the bladder-type accumulator with a dry non-fiber cloth. •Do not use pressure washers to clean it. •

• The operator is obliged to submit the bladder-type accumulator to regular inspections according to the locally applicable provisions. Check which provisions or ordinances are to be complied with in your country and/or for your application.Repair works on the HAB..-4X bladder-type accumulator must only be carried •out by the manufacturer or by authorized dealers and agencies. If this condition is not complied with, the warranty expires.

During commissioning

During operation

During cleaning

During maintenance and servicing



Carry out the maintenance works prescribed at the intervals stipulated in the •operating manual of the entire system. If no other instructions are given, we recommend maintenance intervals according to chapter 9.1 “Maintenance”.Make sure that the hose lines, connections and components are not loosened as long •as the system is pressurized and energized or that the bladder-type accumulator is not still under hydraulic pressure. Secure the system against restarting.Secure the bladder-type accumulator against unintended falling or rolling. •For the discharging of the bladder-type accumulator, always use the charging •and test device according to RE 50170. The uncontrolled release of charging gas results in a risk of suffocation and a risk of injury due to entrained components. During discharge, make sure that the working space is sufficiently ventilated.Always use the charging and test device according to RE 50170 for the •charging of the bladder-type accumulator.Only charge the bladder-type accumulator with nitrogen 99.99 percent by •volume. If the bladder-type accumulator is charged with a gas not complying with the intended use, the bladder-type accumulator might explode.After the servicing works are completed, make sure that the fluid connection is •correctly connected again and the gas port is covered.

• Make sure that the hose lines, connections and components are not loosened as long as the system is pressurized and energized or that the bladder-type accumulator is not still under hydraulic pressure. Secure the system against restarting.For the discharging of the bladder-type accumulator, always use the charging •and test device according to RE 50170. The uncontrolled release of charging gas results in a risk of suffocation and a risk of injury due to entrained components. During discharge, make sure that the working space is sufficiently ventilated.When bladder-type accumulators with a capacity of 10 l or more are •disassembled, there is a risk of personal injuries due to their weight. Use appropriate lifting gear for the disassembly of bladder-type accumulators.Put down the bladder-type accumulator safely and secure it against unintended •rolling or falling in order to avoid any injuries or damage.If a bladder-type accumulator can no longer be used, make the housing •unserviceable by drilling through the vessel wall in the cylindrical area in order to thus avoid that the pressure vessel be reused.

• Dispose of the hydraulic fluid according to the provisions valid in your country as well as according to the safety data sheets of the hydraulic fluids.

Obligations of the operator2.5 The bladder-type accumulator is supplied ex works with a primer coat. The operator is responsible for assuring a sufficient corrosion protection corresponding to the ambient conditions and requirements.The operator of the Bosch Rexroth products must instruct their staff at regular intervals regarding the following subjects:

Observation of and compliance with the operating manual as well as legal provisions •Intended use of the product •Compliance with instructions of the company safety policy and the operating •instructions from the manufacturer

During decommissioning

During disposal


Scope of delivery

Scope of delivery 3

The scope of delivery comprises:

1 HAB..-4X (2) bladder-type accumulator •1 operating manual •1 declaration of conformity (only for bladder-type accumulators with a capacity •of more than 1l)

The bladder-type accumulator is supplied with the following parts being mounted:

Cover cap on the gas valve (1) •Cover cap on the oil port (3) •

The bladder-type accumulator is supplied with a primer coat; the operator must ensure a sufficient external corrosion protection.

Product description4

Performance and device description4.1 Bladder-type accumulators are intended for the use in hydraulic systems. They are used for energy storage, shock and vibration absorption, compensation of leakage losses and volume compensation. The high compressibility of gases is used for the bladder-type accumulator.

1

3

2

Scope of deliveryFig. 1: Typ HAB..-4X bladder-type accumulator


Product description

Structure of the bladder-type accumulatorFig. 2:

Structure of the gas valveFig. 3:

Bladder-type accumulators consist of a seamless cylindrical pressure vessel (1) made of high-tensile steel. The accumulator is subdivided into a gas and a fluid side by an elastic bladder (2) mounted in the interior of the vessel.When the operating pressure is increased, fluid is flowing into the bladder-type accumulator and compresses the gas in the bladder until the gas pressure is identical to the fluid pressure. When the operating pressure is reduced, the gas expands again and feeds the hydraulic system with the fluid.An oil valve (3) is situated in the oil port (4) of the bladder-type accumulator; it is opened during operation. When the bladder-type accumulator is completely discharged, the expanding bladder pushes the valve into the “Closed” position. The exit of the bladder into the oil channel and its destruction are thus avoided.

1

2

3

4

5

6

8

7

5.1

5.2

5.35

5.4


Product description

By means of the gas valve (5), the bladder is charged with nitrogen to the specific gas charge pressure p0. It consists of a sealing cap (5.1), a gas valve insert (5.2), a gas valve body (5.3) and a gas valve support (5.4). The gas valve support is firmly integrated into the gas bladder.The type cap (6) contains the technical data and features of the bladder-type accumulator.The holding nut (7) serves to fix the bladder and the type cap. In order to protect the gas valve, a protective sleeve (8) is provided on the gas port.More detailed information on operating conditions, port dimensions and limits of performance is given in the data sheet RE 50170.

Identification of the bladder-type accumulator4.2 The bladder-type accumulator can be identified with the help of its type cap. The operation of the bladder-type accumulator is only admissible, when the type cap is installed and fully legible.The following examples shows the type cap of a bladder-type accumulator:

1 34

5

6

7

8

9

1011

13

14

15

16

17

12

182

Type cap of a bladder-type accumulatorFig. 4:


Transport and storage

Symbol according to DIN ISO 12191 Warning notice 12 Material number3 Maximum operating pressure4 Applicable standard - information 5 n.a. for accumulators having a capacity of 1 lAdmissible operating temperature6 CE sign - information n.a. for 7 accumulators having a capacity of 1lType8

Fluid group9 Warning notice 210 Date of manufacture (month/year)11 Pre-filling pressure12 Weight13 Company address14 Capacity15 Test pressure16 Note concerning operating manual17 Area/Works number18

Transport and storage5

Transport of the bladder-type accumulator5.1

Risk of health hazards!When bladder-ty.pe accumulators with a capacity of 10 liters or more are lifted, there is a risk of personal injuries due to their weight.

Use appropriate lifting gear for the transport of bladder-type accumulators. f

Crush injuries and fractures!Due to the roundly shaped external contours, bladder-type accumulators may roll or fall down, as the case may be. This may lead to severe personal injuries and to material damage.

Make sure that the bladder-type accumulator is positioned safely and secured fagainst unintended rolling or falling.

Risk of damage!Impacts and shocks may damage the bladder-type accumulator.

Do not apply mechanical forces to the product. fDo not apply any other external forces. fNever use the product as a handle or step. fDo not place any objects on the product. f

Risk of damage!The transport on the gas valve, in a vertical position, may lead to damage to the gas valve and the bladder.

Never lift the bladder-type accumulator on the gas valve. fAlways use appropriate lifting gear for the transport. f

Before the transport, close all openings with the help of appropriate safety caps/devices in order to prevent dirt or water from penetrating into the bladder-type accumulator.

Close openings

CAUTION!

WARNING!

CAUTION!

CAUTION!


Installation

The bladder-type accumulator must only be transported separately, without the accumulator manifold or safety block.Bladder-type accumulators may be transported by means of a fork lift or appropriate lifting gear.

Make sure that the load capacity of the lifting gear is sufficient in order to fsafely carry the weight of the bladder-type accumulator.

The weight indicated only refers to the bladder-type accumulator; weight of mounting accessories are not taken into account. Details as regards the weight of the bladder-type accumulator are given on the type cap of the bladder-type accumulator as well as in the technical data sheet RE 50170.Before transporting the bladder-type accumulator after a test run, pressurize it with 2 bars. If the bladder-type accumulator is transported with a higher pressure, it must be declared as hazardous material.

Storage of the bladder-type accumulator5.2 The bladder-type accumulator is supplied with a primer coat; the operator must ensure a sufficient corrosion protection during storage.

• The storage facilities must be free from etching substances and gases.The storage facilities must be dry. •The ideal storage temperature amounts to +5 °C to +20 °C. •The temperature should ideally be constant. •

The maximum shelf life of the bladder-type accumulator amounts to 5 years.Procedure after expiration of maximum shelf life:

Carry out a visual examination of the bladder-type accumulator and check for fany damage and corrosion.Replace by way of precaution the bladder, sealings and gas valve insert. fAfter the expiration of the maximum shelf life, make check the complete fbladder-type accumulator by a competent Rexroth service.Please note that the warranty period is not prolonged by the storage time!

Please note that, according to locally applicable provisions and ordinances, test intervals mostly refer to the date of manufacture and are also not prolonged by the storage time.

Installation6 The installation must only be carried out, after the hydraulic schematic of the system or an assembly drawing is available.

Unpacking6.1

Danger from falling parts!If the bladder-type accumulator is not unpacked as intended, it may roll out of the package and lead to injuries or damage.

Place the f package on a plain, carrying surface.

Transport

Weight

Transport after a test run

Requirements

Maximum shelf life

CAUTION!


Installation

Before opening the package and/or loosening the tension belts, make sure fthat the bladder-type accumulator(s) cannot roll away.Open the package and/or loosen the tension belts. fLift the bladder-type accumulator out of the package by means of appropriate gear. fDispose of the packaging in accordance with the provisions applicable in your country. f

Installation conditions6.2 Hydro-pneumatic accumulators must be sufficiently secured and fixed due to their heavy weight and the acceleration forces generated by the hydraulic fluid in the hydraulic accumulator.The accumulator is to be fixed so as to make sure a safe support during operation-related vibrations or in case of a potential pipeline break. Bosch Rexroth offers corresponding mounting clamps and consoles as accessories, see RE 50170.According to the Pressure Equipment Directive (97/23/EC), the bladder-type accumulator must be secured with a pressure control valve. Please note that utmost cleanliness must be ensured. The bladder-type accumulator and all other parts used must be installed in a clean way. The contamination of the hydraulic fluid may considerably affect the service life of the bladder-type accumulator.Clean the accumulator with dry, non-fiber cloths.The temperature of the bladder-type accumulator must correspond to the ambient temperature of the installation site. Allow the bladder-type accumulator to acclimatize in order to adapt to the temperature conditions.The bladder-type accumulator should preferably be installed vertically with the gas valve connection at the top. Above the gas valve, a clearance area of 200 mm must be observed in order to be able to connect the charging and test device.

Required tools6.3 For the installation of the bladder-type accumulator, you need:

Charging and test device according to RE 50170 •Open-end wrench: •Appropriate lifting gear •

Wrench sizes of open-end wrenchesTable 4: Bladder-type accumulator Capacity in liters

Open-end wrench: Wrench size

1 32 mm

2.5 - 6 50 mm10 - 50 70 mm

Fastening

Protection

Cleanliness

CleaningTemperature

Mounting position


Installation

Installation of the bladder-type accumulator6.4

Danger of personal injuries and material damage!The installation of the bladder-type accumulator requires basic mechanical and hydraulic knowledge.

The bladder-type accumulator must solely be installed by qualified personnel f(see "Qualification of staff" in chapter 2 "Principle safety instructions").

Risk of damage!Impacts and shocks may damage the bladder-type accumulator.

Do not apply mechanical forces to the product. fNever use the product as a lever, handle or step. fDo not place any objects on the product. f

Danger of bursting!Bursting of the bladder-type accumulator due to welding, soldering or other mechanical works may lead to severe injuries.

Do not attempt to make any modifications such as welding or soldering on the fbladder-type accumulator.

Risk of damage!The transport on the gas valve, in a vertical position, may lead to damage to the gas valve.

Never lift the bladder-type accumulator on the gas valve. fAlways use appropriate lifting gear for the transport. f

Fastening by means of a clampFig. 5:

Installation of the bladder-type accumulator in a vertical position

CAUTION!

CAUTION!

CAUTION!

CAUTION!


Installation

Fastening of the bladder-type accumulator by means of two clampsFig. 6:

The installation of the bladder-type accumulator comprises the following work steps:

Risk of poisoning and injuries due to leaking hydraulic fluid!The contact with hydraulic fluids leads to health hazards (e.g. eye injuries, skin lesions, poisoning during inhalation).Slipping may lead to severe injuries. When covers are removed, unpressurized residual oil may leak.

Immediately wipe off any leaking oil. fPrior to putting into operation the accumulator, check the lines for wear and ftear as well as for any damage.Wear protective gloves, safety goggles and appropriate work clothes. fImmediately consult a doctor, when hydraulic fluid comes into contact with fyour eyes or penetrates your skin.

Remove the cover cap on the oil port. fMake sure that the oil port is clean and free from foreign debris. fCheck that the port thread is intact. f

Crush injuries and fractures!Falling or rolling bladder-type accumulators may lead to severe injuries.

Use appropriate lifting gear for the lifting of the bladder-type accumulator. fSecure the bladder-type accumulator against unintended rolling. f

Fix the bladder-type accumulator by means of appropriate lifting gear so as to fguarantee a safe support.Put the bladder-type accumulator into the desired mounting position. The faccumulator must be secured in the vertical position by means of the lifting gear.Install the accumulator by either screwing the thread into the mounting adapter for fasten with flanges.

WARNING!

CAUTION!


Installation

Check that the thread interlocks after one rotation at the latest. fIf need be, lower the accumulator and screw it in manually until the end stop fof the thread. The end face of the port must fit tightly and completely to the counterpart.Lower the lifting gear further and make sure that the accumulator is fixed ffirmly on the oil port.Make sure that the accumulator is fixed in a vertical way. fTighten the accumulator by means of an open-wrench key until it fits tightly. fFasten the mounting clamps at the right positions. fRemove the lifting gear. f

The bladder-type accumulator is now mounted.

Fastening of the bladder-type accumulator by means of a consoleFig. 7:

The installation of the bladder-type accumulator on a console comprises the following work steps:

Fasten the console at the right position. fFasten the mounting clamps at the right positions. f


Use appropriate lifting gear for the lifting of the bladder-type accumulator. fFor lifting the bladder-type accumulator, always use appropriate lifting gear. fSecure the bladder-type accumulator against unintended rolling. f

Fix the bladder-type accumulator by means of appropriate lifting gear so as to fguarantee a safe support.

Installation of the bladder-type accumulator on a console

CAUTION!


Installation

Lift the bladder-type accumulator by means of appropriate lifting gear. fPut the bladder-type accumulator on the console. The accumulator must be fsecured in the vertical position by means of the lifting gear.Make sure that the accumulator is fixed in a vertical way. fFasten the mounting clamps at the right positions. fRemove the lifting gear. f



Remove the cover cap from the oil port of the bladder-type accumulator. fConnect the hydraulic lines to the oil port of the bladder-type accumulator by fexerting counter-pressure with an open-end wrench on the oil valve.Tighten the hydraulic lines by exerting counterpressure with an open-end fwrench on the oil valve until they fit tightly.


The horizontal installation of the bladder-type accumulator comprises the following work steps:

Fasten the holding device of the bladder-type accumulator at the right positions. f



Put two appropriate transport belts around the bladder-type accumulator so fthat they do not run over accessories (e.g. valves), and that the bladder-type accumulator is not suspended by the accessory devices.Lift the bladder-type accumulator by means of appropriate lifting gear. fMake sure that the bladder-type accumulator is in an exactly horizontal position. fFasten the mounting clamps at the right positions. fRemove the lifting gear. f

WARNING!

Installation of the bladder-type accumulator in a horizontal position

CAUTION!


Commissioning



Remove the cover cap from the oil port of the bladder-type accumulator. fConnect the hydraulic lines to the oil port of the bladder-type accumulator by fexerting counter-pressure with an open-end wrench on the oil valve.Tighten the hydraulic lines by exerting counterpressure with an open-end fwrench on the oil valve until they fit tightly.


Commissioning7

Danger of personal injuries and material damage!The commissioning of the bladder-type accumulator requires basic mechanical and hydraulic knowledge.

The bladder-type accumulator must solely be commissioned by qualified fpersonnel (see "Qualification of staff" in chapter 2).

Danger of personal injuries and material damage!If the bladder-type accumulator was not mounted correctly, persons may be injured and the product or the system may be damaged, when the bladder-type accumulator is put into operation.

Make sure that the bladder-type accumulator was mounted correctly by fqualified staff before you put it into operation.

Material damage!Contaminated hydraulic fluid may lead to wear and tear as well as to malfunctions.

Please note that utmost cleanliness is very important during commissioning. fMake sure that the hydraulic system is only filled with a filtered fluid. fAvoid any contamination, when the ports are closed. f

Concerning the commissioning of the bladder-type accumulator, please comply with the operating manual of the hydraulic system.For the commissioning of the bladder-type accumulator, you need the Bosch Rexroth charging and test device according to RE 50170.

DANGER!

WARNING!

CAUTION!

WARNING!


Commissioning

Preparation of the commissioning7.1 The examination prior to the commissioning as well as prior to recurrent tests are to be carried out according to national rules.

Make sure that the hydraulic accumulator is intact. fBy means of the information given on the type cap, make sure that the fbladder-type accumulator corresponds to the specifications given on the hydraulic schematic or the system's bill of materials.Check that the fluid used in the hydraulic system corresponds to the fspecification given in the technical data sheet and on the type cap of the bladder-type accumulator.Make sure that the maximum operating pressure of the hydraulic accumulator is fequal to or greater than the maximum operating pressure of the hydraulic circuit.Check whether the operating temperatures are within the limits mentioned on fthe type cap.Cover the bladder-type accumulator with a final coating in order to ensure the frequired corrosion protection. The product is only supplied with a primer coat.Lay out ready the Bosch Rexroth charging and test device according to fRE 50170 and its operating manual.

Initial commissioning7.2 In order to put into operation an HAB..-4X bladder-type accumulator, proceed as follows:Whenever the bladder-type accumulator is put into operation, it must be brought to the prescribed pre-filling pressure indicated in the scheme.

Control of the pre-filling pressureFig. 8:

Protective sleeve1 Sealing cap 2

To adjust the pre-filling pressure, proceed as follows:

Make sure that the system is depressurized. f

Risk of injury and suffocation!Risk of suffocation due to uncontrolled release of a greater volume of gas and risk of injury due to entrained components.

Make sure that the working space is sufficiently ventilated. fAlways use the charging and test device according to RE 50170 for the control fof the pre-filling pressure.

Setting the pre-filling pressure

2

1

DANGER!


Commissioning

Remove the protective sleeve and the sealing cap from the gas side of the fbladder-type accumulator.Screw the charging and test valve for hydraulic accumulators onto the gas fvalve of the bladder-type accumulator. When doing this, always observe the operating manual of the charging and test device.

Risk of explosion!Risk of severe injuries due to explosion of the hydraulic accumulator during the charging of the bladder-type accumulator with improper gas.

Only charge the bladder-type accumulator with nitrogen 99.99 percent by volume. f

Connect a nitrogen bottle to the charging valve via the tube of the charging fand test device.The prescribed pre-filling pressure is indicated in the hydraulic schematic. fOpen the stop valve of the gas bottle until the prescribed pre-filling pressure fis indicated on the gauge of the charging valve. Always keep an eye on the pressure gauge during the charging process.Close the stop valve of the gas bottle. fThe pre-filling pressure depends on the temperature. During the charging, the fbladder-type accumulator heats up. Wait until the accumulator cools down.Check the pre-filling pressure and correct it, if necessary. fEnter the pre-filling pressure p f 0 in the field provided on the type cap.Remove the charging and test valve. fScrew the sealing cap and the protective sleeve back on the accumulator. f

The pre-filling pressure is now checked and set.

f Commission the bladder-type accumulator with the system according to the operating manual of the machine.

Recommissioning after non-operational periods7.3 Check whether the pre-filling pressure corresponds to the value p f 0 indicated on the type cap. For this, proceed as described in chapter 9.1 "Maintenance".Check the oil valve for tightness. fMake sure that the accumulator does not present any signs of corrosion and fthat the coating is intact.Commission the bladder-type accumulator with the system according to the foperating manual of the machine.

Commissioning the bladder-type accumulator

DANGER!


Operation

Operation8 The HAB..-4X bladder-type accumulator must only be operated within the defined limits of performance, see the technical data sheet of the bladder-type accumulator (RE 50170).The bladder-type accumulator must only be operated, when it is in a technically perfect condition.In order to guarantee that the bladder-type accumulator may be operated reliably for a long period of time, Bosch Rexroth recommends to regularly check and maintain the bladder-type accumulator. Please observe the information given in chapter 9.1 "Maintenance" as well as the maintenance instructions of the system manufacturer.Any change in operating speeds, temperatures, power consumption as well as increasing noises are indicators for wear or damage to the accumulator/system.In order to guarantee a high operating safety and the availability of the system, it is recommended to continuously monitor these values.

Maintenance and servicing9

Danger of personal injuries and material damage!The maintenance and servicing of the bladder-type accumulator requires basic mechanical and hydraulic knowledge.

The bladder-type accumulator must only be maintained and serviced by fqualified personnel (see "Qualification of staff" in chapter 2).

The installation, maintenance and servicing of the bladder-type accumulator must only be carried out by the manufacturer or by authorized dealers and agencies. If this condition is not complied with, the warranty expires!Before the transport, close all openings with the help of appropriate safety caps/devices in order to prevent dirt or water from penetrating into the bladder-type accumulator.

Maintenance9.1

Slip hazard!Slipping may lead to severe injuries. When covers are removed, unpressurized residual oil may leak.

Immediately wipe off any leaking oil. f

Risk of poisoning and injuries due to leaking hydraulic fluid!The contact with hydraulic fluids leads to health hazards (e.g. eye injuries, skin lesions, poisoning during inhalation).

Prior to putting into operation the accumulator, check the lines for wear and ftear as well as for any damage.Wear protective gloves, safety goggles and appropriate work clothes. fImmediately consult a doctor, when hydraulic fluid comes into contact with fyour eyes or penetrates your skin.

Maintenance

Close openings

DANGER!

WARNING!

WARNING!


Maintenance and servicing


Always use the charging and test device for the control of the pre-filling fpressure.

Risk of explosion!Risk of severe injuries due to explosion of the hydraulic accumulator during the charging of the bladder-type accumulator with inadmissible gas.

Only charge the bladder-type accumulator with nitrogen 99.99 percent by volume. f



Risk of injury!Parts flying around due to the residual pressure that is still present after the discharge may lead to severe injuries.

Check the residual pressure in the bladder-type accumulator after the heating fup to the ambient temperature, before opening the gas valve.

Maintenance activities for the bladder-type accumulatorTo check the pre-filling pressure of the bladder-type accumulator, proceed as follows:

Make sure that the system is depressurized. fThe pre-filling pressure p f 0 is indicated on the type cap of the bladder-type accumulator.


Make sure that the working space is sufficiently ventilated. fAlways use the charging and test device for the control of the pre-filling fpressure.

Remove the protective sleeve and the sealing cap from the gas side of the fbladder-type accumulator.Screw the charging and test valve for hydraulic accumulators onto the gas fvalve of the bladder-type accumulator. When doing this, always observe the operating manual of the charging and test device.Check whether the pre-filling pressure indicated on the charging and test fdevice corresponds to the value p0 indicated on the type cap. If the two values differ, set the pre-filling pressure as described in chapter 7.2 "Initial commissioning".Remove the charging and test valve for hydraulic accumulators from the gas fvalve of the bladder-type accumulator.Screw the sealing cap and the protective sleeve back on the accumulator. f

The pre-filling pressure is now checked and set.

Control of the pre-filling pressure

DANGER!

DANGER!

DANGER!

WARNING!

CAUTION!


Maintenance and servicing

After having been charged with gas, Bosch Rexroth hydraulic accumulators are almost maintenance-free. In order to guarantee a failure-free operation and a long service life, however, the following tasks are to be carried out:

Inspection of the pre-filling pressure •Inspection of safety devices, fittings •Inspection of line connections •Inspection of accumulator fixation •

If the accumulator is to be disassembled for maintenance tasks (replacement of bladder), the accumulator must be depressurized first.

Table 5: Maintenance intervals for the bladder-type accumulatorInspection Interval Maintenance activitiesInspection of the pre-filling pressure with external visual examination

Test 1: Within one week as of commissioning

Inspection of the pre-filling pressureInspection of tightness, oil valveVisual examination of corrosion protectionTest 2:

Within 3 months as of commissioning, if no gas losses during test 1Test 3: Annual test, if no gas losses during test 2

Internal visual examination

Once every ten years Inspection of the pressure vessel according to national provisions

In order to guarantee a safe operation and a long service life of the bladder-type accumulator, a maintenance schedule is to be drawn up for the unit, the machine or the system. The maintenance schedule must guarantee that the operating conditions of the bladder-type accumulator stay in the prescribed limits during the entire duration of use.Particularly the compliance with the following operating parameters must be guaranteed:

Operating pressure •Operating temperature range •Surface temperature •External pressure •

Changes of these parameters increase the wear of the bladder-type accumulator. For this reason, the cause must be found and eliminated immediately.In order to guarantee a high operating safety of the bladder-type accumulator in the machine/system, we recommend continuous automatic controls of the parameters mentioned above.Further information on the maintenance is given in the operating manual of the system.

Servicing9.2 Repairs on the HAB..-4X bladder-type accumulator must only be carried out by the manufacturer or by authorized dealers and agencies. If this condition is not complied with, the warranty expires. Authorized dealers and agencies carry out the repairs at their premises.

Maintenance tasks

Maintenance intervals

Maintenance schedule of the system


Decommissioning

Spare parts list9.3 In case of questions concerning repair works, please contact the competent Rexroth service or the central service department:Bosch Rexroth AG Service Industriehydraulik Competence Center Lohr Bgm.-Dr. Nebel-Str. 8 97816 Lohr am Main, Germany Phone: +49 (0) 93 52 - 18 0 [email protected] addresses of our sales and service network are given under:www.boschrexroth.com/adressen

Decommissioning10 The bladder-type accumulator is a component that must not be decommissioned. For this reason, the chapter does not contain any information in this manual. How to disassemble and replace the bladder-type accumulator is described in chapter 11 "Disassembly and replacement".

Disassembly and replacement11 Discharge the accumulator via the discharge facility of the system. Please note that the pre-filling pressure still exists on the gas side after hydraulic relief Please decide whether a remaining gas pressure in the bladder-type accumulator is required or reasonable.For safety reasons, we recommend to discharge the gas pressure and to clearly mark this on the accumulator, if the system is decommissioned for a longer time or forever.In order to keep the accumulator depressurized, the gas valve insert must be removed.

Required tools11.1 For the disassembly of the bladder-type accumulator, you need:

Charging and test device according to RE 50170 •Open-end wrench key, information concerning the wrench sizes is given in •chapter 6 "Installation"Appropriate lifting gear •


Disassembly and replacement

Preparation of the disassembly11.2 Decommission the overall system as described in the operating manual of the system.Then prepare the disassembly of the bladder-type accumulator by proceeding as follows:

Depressurize the hydraulic system. fMake sure that the relevant parts of the system are depressurized and de-energized. f

Realization of the disassembly11.3 In order to disassemble the bladder-type accumulator, proceed as follows:

Slip hazard!Slipping may lead to severe injuries. When covers are removed, unpressurized residual oil may leak.

Immediately wipe off any leaking oil. f

Risk of poisoning and injuries due to leaking hydraulic fluid!The contact with hydraulic fluids leads to health hazards (e.g. eye injuries, skin lesions, poisoning during inhalation).

Prior to putting into operation the accumulator, check the lines for wear and ftear as well as for any damage.Wear protective gloves, safety goggles and appropriate work clothes. fImmediately consult a doctor, when hydraulic fluid comes into contact with fyour eyes or penetrates your skin.



Risk of injury!Parts flying around due to the residual pressure that is still present after the discharge may lead to severe injuries.

Check the residual pressure in the bladder-type accumulator after the heating fup to the ambient temperature, before opening the gas valve.

Risk of injuries due to disassembly under pressure!Damage of the bladder-type accumulators or risk of injury in case of disassembly of the bladder-type accumulator, when the hydraulic system is under pressure.

Prior to commencing any works, depressurize the system. f

WARNING!

WARNING!

DANGER!

WARNING!

DANGER!


Disposal

Risk of injury and suffocation!Risk of suffocation due to uncontrolled release of a greater volume of gas and frisk of injury due to entrained components.Always use the charging and test device for the control of the pre-filling fpressure.

f Make sure that the hydraulic system is depressurized.Remove the sealing cap and the protective sleeve from the gas side of the fbladder-type accumulator.Screw the charging and test valve for hydraulic accumulators onto the gas fvalve of the bladder-type accumulator.Discharge the pre-filling pressure in the bladder. When doing this, always fobserve the operating manual of the charging and test device.The pre-filling pressure depends on the temperature. During the discharging, fthe bladder-type accumulator cools down. Wait until the accumulator heats up to ambient temperature again.Discharge the pre-filling pressure generated during the heating up in the fbladder. When doing this, always observe the operating manual of the charging and test device.Remove the charging and test valve for hydraulic accumulators from the gas valve. fRemove, as the case may be, the gas valve insert. fScrew the sealing cap and the protective sleeve back on the accumulator. fFasten the bladder-type accumulator on the lifting gear. fDisconnect the bladder-type accumulator from the system. fLoosen the holding connections of the bladder-type accumulator. f

The bladder-type accumulator is now disassembled.

Disposal12 Avoid a reuse of the bladder-type accumulator as pressure vessel by drilling through its cylindrical part.For the disposal of the bladder-type accumulator, the following instructions have to be complied with:

Disassemble the bladder-type accumulator into its individual components for 1. them to be recycled.

Dispose separately of the bladder and the steel parts.2.

Environmental protection12.1 Careless disposal of the bladder-type accumulator and of the residual fluid therein contained can cause environmental pollution.

Dispose of the bladder-type accumulator in accordance with the provisions fapplicable in your country.Dispose of any hydraulic fluid residues according to the respective safety data fsheets valid for these hydraulic fluids.

Disassembly of the bladder-type accumulator

DANGER!


Extension and transformation

Extension and transformation13 The transformation or extension of the bladder-type accumulator is not allowed. If modifications were carried out on the bladder-type accumulator, it must no longer be operated.

Fault finding and troubleshooting14

Fault finding procedure14.1 Proceed systematically and in a targeted way, even under time pressure. Random and thoughtless disassembling and changing of setting values may in the worst case lead to a situation in which the original cause of the fault can no longer be determined.Get an overview over the function of the bladder-type accumulator in connection with the overall system.Try to clarify whether the bladder-type accumulator fulfilled the required function in the overall system before the fault appeared.Try to detect modifications of the overall system into which the bladder-type accumulator is built:

Have the application conditions or the area of application of the bladder-type •accumulator been modified?Have modifications (e.g. refittings) or repairs been carried out on the overall •system (machine/system, electrics, control) or the bladder-type accumulator? If yes: Which ones?Have/Has the bladder-type accumulator and/or the machine been operated •according to the intended use?How does the malfunction present itself? •

Get a clear image on the cause of the fault. If necessary, ask the direct operator or the machine operator.If you could not remedy the fault that occurred, please contact one of the addresses you find under www.boschrexroth.com or:

Bosch Rexroth AG Service Industriehydraulik [Industrial hydraulics] Competence Center Lohr Bgm.-Dr. Nebel-Str. 8 97816 Lohr am Main, GermanyPhone: +49 (0) 93 52 - 18 0


Fault finding and troubleshooting

Fault table for the HAB..-4X bladder-type accumulatorTable 6: Fault Possible cause RemedyGas pressure changes during operation

Leakage / gas valve leaks Visual examination;leak test with leak spray during final assembly

Gas valve broken/damaged Request a replacement gas valve and cap from the Bosch Rexroth Service group.Always use the charging and test device according to RE 50170 for the charging and discharging of the bladder-type accumulator.

Gas valve function impaired due to contamination

Charge the Bosch Rexroth service with the replacement of the gas valve with valve cap.

System-related change of pressure in dependence upon the temperature

Temperature-dependant changes of the gas charge pressure cannot be avoided. The gas charge pressure must be chosen in accordance with the operating temperatures expected.

Reduction due to permeation Refill gasCracks on the vessel Application out of specification Immediately decommission the system.

Replace the accumulator. The accumulator must not be put into operation again, see chapter 12 "Disposal".

Operation outside the prescribed temperature range

Immediately decommission the system.Replace the accumulator. The accumulator must not be put into operation again, see chapter 12 "Disposal".Check the operating temperature after commissioning.

Internal corrosion Use of inappropriate fluids Immediately decommission the system.Replace the accumulator. The accumulator must not be put into operation again, see chapter 12 "Disposal".Use an appropriate fluid.

Residual humidity in the vessel due to inappropriate storage conditions

Immediately decommission the system.Replace the accumulator. The accumulator must not be put into operation again, see chapter 12 "Disposal".Observe the prescribed storage conditions.

Abrasion and reduction of wall thickness

Use of inappropriate fluids Immediately decommission the system.Replace the accumulator. The accumulator must not be put into operation again, see chapter 12 "Disposal".Use an appropriate fluid.Ensure cleanliness.

Oil leakage at interfaces to the outside

Improper servicing Servicing must only be carried out by qualified persons.

O-ring of the sealing is damaged or hardened due to too high an oil temperature

Request a replacement gas valve and cap from the Bosch Rexroth Service group.Check the oil temperature.

Oil valve cracked due to non-tension-free assembly of the bladder-type accumulator

Replace the oil valve.

Improper environmental force effect. Contact Bosch Rexroth for consultationDamaging of the oil valve during transport Visual examination after transport.Improper force effects due to mobile applications.

Contact Bosch Rexroth for consultation

Impossible to assemble Wrong thread Replace the parts concerned.Thread damaged

Commissioning after expiration of shelf life not possible

Corrosion protection not sufficient Replace the bladder-type accumulator.

Fault table14.2


Technical data

Technical data15 The technical data of the HAB..-4X bladder-type accumulator are given in the technical data sheet RE 50170.

Appendix16

Address register16.1 The addresses of our sales and service network are given under: www.boschrexroth.com/adressen

Accessories16.2 A list with accessory parts for the HAB..-4X bladder-type accumulator is given in the technical data sheet RE 50170.

Bosch Rexroth AGHydraulicsZum Eisengießer 197816 Lohr am Main, GermanyPhone: +49 (0) 93 52 - 18 0 Fax: +49 (0) 93 52 - 18 40 [email protected]

Printed in GermanyRE 50170-B/10.08

Bladder Type Accumulator Rexroth

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