Diaphragm Accumulators Operating & Maintenance Instructions

Guidelines for Selection, Installation and Operation

General
Hydraulic Diaphragm Accumulators from Stauff Corporation have been in use in numerous Gas Losses
branches of industry for many years and are proven components. Optimal function and long Inadequate gas pressures can also be due to gas losses as a consequence of permeation proc-
service life are however only achieved if specific selection criteria are observed and incorrect esses. As elastic separating materials are not leak-proof in the absolute sense, gas molecules
installations and incorrect operating conditions are avoided. pass through the membrane, are dissolved in the operating fluid and transported to the reservoir
where there can again separate from the fluid. The gas losses increase proportionally with the
For improved understanding of the following sections, the most important operating pressure and exponentially with the temperature. With conditions that are otherwise
expressions and terms are briefly explained here. the same, gas losses will result in a faster reduction of the pre-charge on smaller hydraulic ac-
cumulators than on larger accumulators.
Operating pressure
Normally the accumulator operates between P1 and P2 Estimates on possible gas losses can be determined on initial installations by monitoring the pre-
charge on regular intervals. From this information it is possible to estimate maintenance intervals.
P0 = pre-charge pressure (normally 90% of P1)
P1 = minimum operating pressure A pre-charge pressure that is too low from the start will be further reduced by gas pressure
P2 = maximum operating pressure losses, and, under operating conditions that otherwise remain the same, a diaphragm accumula-
P3 = system relieve pressure setting tor will not be able to store the same volume of fluid. Diaphragms or bladders as separating
P4 = maximum working pressure of accumulator components are overloaded resulting in a reduction in the service life. The damping capacity of
Pm= mean operating pressure the hydraulic accumulator will be reduced, and any pressure peaks that occur can exceed the
permissible excess operating pressure. For this reason, the magnitudes of the pre-charge pres-
Permissible excess operating pressure P4 sure losses are to be checked and increased at intervals to suit the application. The check can be
Max. pressure for which the accumulator is designed and that can be found in the technical performed very easily by using the pre-charge kit STDA-CK-M-1.
documentation and the marking (rating plate, lettering).

Gas filling pressure Correct Installation

Before the diaphragm accumulator can be installed in a hydraulic system, it must be pre-charged
with dry nitrogen gas. The pre-charge pressure is normally 95% to 90% of P1 at operating Safety –related equipment
temperature. It is important that the maximum working pressure of the accumulator is not exceeded and that a
safety pressure relieve device is installed in the system.
Permissible pressure ratio
P 2 /P 0 or P3/P0 = pressure ratio < 8:1, 6:1, 4:1 depending on accumulator size. Figure stipulated Fastening/Mounting
by the manufacturer in relation to the compression ratio of the diaphragm accumulator, e.g. 8:1; Accumulators must be securely fastened in order to prevent any vibration or stress on the ac-
this figure should not be exceeded (use pressure as absolute figures). cumulator fluid port. Special brackets and clamps are available.

Aspects on the selection of a diaphragm accumulator

Selection in relation to the perm. excess operating pressure P4 Operating states to be avoided
The diaphragm accumulator is to be selected such that the permissible excess operating pres-
sure P4, is in all circumstances above the upper operating pressure P2 to be expected and also Excessively high pressure ratio
above any pressure peaks that may occur. An excessively high pressure ratio between the maximum operating pressure P2 and the pre-
charge pressure P0 is to be avoided for various reasons. The max. permissible compression
Pressure peaks or pressure increase occur, e.g., due the switching of multiway valves and the ratio and maximum pressure differential ΔP stated by the manufacturer takes into account a
resulting retardation of oil masses, retardation of fast moving masses, pressure translation in reasonable service life of diaphragms or bladders. If the ratio is exceeded, a significant reduction
differential circuits, etc. in the service life cannot be excluded. A further reason is that accumulator has a progressive
characteristic curve, i.e. with increasing pressure the increase in the fluid volume stored per
In this respect it is highlighted that pressure peaks may be so short that they can often not be pressure unit becomes less and less. Expressed in a different way, the accumulator becomes
measured with the aid of clamped measuring instruments such as pressure gauges. Safety “harder and harder”. In an application with volume storage, an increasing amount of (lost) energy
valves also do not always react to such short pressure peaks. must be expended to store less and less additional fluid.

Correct selection of the pre-charge pressure P0 Insufficient spacing of the pre-charge pressure P0 from the lower
The magnitude of the pre-charge pressure is dependent on the operating pressures to be Operating pressure P1
expected and the type of application. If the pre-charge pressure (P0) is greater than the lower operating pressure (P1), the diaphragm
accumulator empties itself completely during each operating cycle. Particularly on diaphragm
The following figures can be used as general guidance: accumulators, the sealing elements on the diaphragm sit on or hit the inside of the housing in the
area of the fluid connection. Continuous contact can cause flash to form or cause other material
• with pulsation damping deformations that can in turn destroy the diaphragm.
Po = 0.6 to 0.8 x Pm (Pm = mean operating pressure)
It is important to note that the pre-charge pressure can increase dramatically through an increase
• with surge damping or volume storage of temperature.
Po = 0.6 to 0.9 x P1 (p1 = lower working pressure)
Briefly passing the pre-charge pressure during starting and shut down cannot be avoided for
It is to be ensured that the pre-charge pressure does not exceed the value 0.9 x P1 also at the functional reasons, it is strongly recommended to consult the manufacturer, as special designs
operating temperature. The pre-charge pressure established and specified at room temperature are available for difficult applications.
increases with increasing temperature in accordance with gas laws.
Sudden complete draining of a hydraulic accumulator
As a rule of thumb, a pressure increase of 10% for a 30 °C (86F) temperature increase can be Applications in which a diaphragm accumulator can empty suddenly and without control are to be
expected. avoided. One of the possible disadvantages has already been described earlier. If the pre-charge
pressure P0 is too close to the minimum operating pressure P1 then this can result in damage to
If the pre-charge pressure is too low this may result in a drop in performance from the accumula- the bottom of the diaphragm.
tor and result in high flexing loads on the diaphragm and shortened life of the diaphragm.
The result of a very high discharge rate from the accumulator may reduce the output stored
volume due to a premature closure of the fluid port by the diaphragm.

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 Operating & Maintenance Instructions Diaphragm Accumulators

Raised temperatures Pre-Charging Procedure

The usual operating conditions for diaphragm accumulators is between -10°C and +80 °C.
Higher temperatures are possible with separating components (bladders, diaphragms) made of General Information
special materials. However, here the progressively increasing gas losses with raised tempera- ƒƒ The condition of the accumulator is primarily determined by periodic checking of the pre-charge
tures must be taken into account. In addition, a reduction in the permissible maximum working pressure.
pressure is to be expected, as the strength figures for the housing material must be reduced.
ƒƒ Hydraulic Accumulators are pressure vessels and only qualified personnel should perform
Low temperatures maintenance.
At temperatures below -10°C, the elasticity of the standard materials (NBR) for diaphragms and
bladders reduces and there is a risk of fractures. If usage at such low temperatures cannot be ƒƒ Drain all fluid completely from accumulator before performing any maintenance.
avoided, special diaphragm materials must be used e.g. ECO. Please consult the manufacturer.
It is also to be noted that not all housing materials are suitable or approved for low tempera- ƒƒ DO NOT weld or braze directly on the accumulator shell.
tures, as a drop in the notch impact strength can occur. In usage a differentiation is to be made
between temperatures due to weather conditions and low temperatures of the medium stored. ƒƒ DO NOT use automotive type valve cores as high pressure accumulator gas valves.

Incompatible fluids ƒƒ The most accurate pre-charge readings can only be taken when fluid pressure is at “0 PSI”.
Hydraulic accumulators are designed as standard for use with mineral oil. If other fluids like wa-
ter or even aggressive chemicals are to be used, special material combinations may be required. ƒƒ Always observe the maximum working pressure and operating temperature ranges.
Please consult Stauff for questionable compatibility. Using a fluid that is not compatible with the
housing or the diaphragm will result in damage. Do not use oxygen for pre-charging the Accumulator!

Maintenance
Along with the external inspection for corrosion damage and correct mounting, the maintenance
of a hydraulic accumulator is limited to the regular checking and correction, if necessary, of the
pre-charge pressure. While for volume storage, variations in the gas filling pressure is mostly to
be noticed in the form of inadequate function, for pulsation damping or surge damping, incorrect
precharge pressure can remain undetected for long periods and cause damage to the accumula-
tors or the system. Rule of thumb: Initially, check pre-charge pressure on monthly bases, then
increase intervals, if no pressure loss is detected, to maintain proper pre-charge pressure.

To check, suitable charge devices should be used that are offered by the manufacturer for the
various types of gas connections (M28x1,5 or Schrader ® valve). Suitable charge kits are also
used to pre-charge the accumulator with dry Nitrogen.

If only the magnitude of the pre-charge pressure is to be determined, this task can also be
performed on the fluid side, if it is possible to slowly fill or drain the hydro accumulator.

During slow filling, the filling process will be seen to slow down considerably when the gas filling
pressure is reached. During discharge, the slow drop in pressure, a sudden pressure drop to zero
occurs, which can be clearly seen on a pressure gauge. This process can be performed if neces-
sary within a system without removing the accumulator.

Pre-charge the accumulator with zero pressure on the fluid port.

Installation
ƒƒ The accumulator in a hydraulic circuit should be placed as near as practical to the source of
shock or potential energy requirement.

ƒƒ An installation space of 200mm (approximately 8 inches) should be maintained above the gas
valve of the accumulator for any testing and charging devices that maybe required

ƒƒ Normally an accumulator should be installed in a vertical position with the oil port connection
facing downward (this is what Stauff recommends), however, a diaphragm accumulator may be
mounted in any position without causing any harm to the accumulator, (horizontally or verti-
cally)

ƒƒ All accumulators must be installed securely by using clamps and support brackets that are
designed specifically for mounting the accumulator

ƒƒ When installing an accumulator using “U” bolt type clamps, care should be exercised so as not
to distort the accumulator with excessive force

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 Diaphragm Accumulators Operating & Maintenance Instructions

Pre-Charging Diaphragm Accumulators with US Style Cored Gas Valve

1. Isolate the accumulator from the system and make sure hydraulic fluid pressure is zero.

A 2. Remove the gas valve protection guard and then the gas valve cap from the accumulator.

3. To charge the accumulator, use a charging hose and gauge assembly similar to Stauff Charging Kit # STBA-CK-B-P3 rated for
3,000 psig minimum (higher pressure kits are available).
B

4. Before using the charging assembly (Figure 1.) make sure that valve A is completely open (counter-clockwise), ensure that bleed
valve B (Figure 1.) is completely closed ( clockwise) and that the non-return valve C (Figure 1.) is capped.
C

5. Connect the charging unit to the gas fill valve on the accumulator by means of knurled cap D (Figure 1.).

6. Make sure the valve on the nitrogen bottle is completely closed, then fit the nitrogen gas valve adapter/hose assembly (included
in Stauff charging kit # STBA-CK-B-P3) onto the nitrogen bottle (Figure 2.)

7. Connect the other end of gas hose to the non-return valve C (Figure 1.), after taking off the cap.
D
Figure 1.
8. Turn valve A (Figure 1.) clockwise until it stops (Do not over Torque).

9. SLOWLY open the valve on nitrogen bottle (Figure 2.) and allow the nitrogen gas to flow into the accumulator. The pressure
gauge should begin to register pressure.

10. Once the desired gas pre-charge pressure has been reached, close valve on nitrogen bottle (Figure 2.).

11. Open valve A (Figure 1.) (Fully counter-clockwise) to bleed the trapped pressure in the gas line to zero by means of bleed valve
B (Figure 1.), open valve B (turn counter-clockwise) until gauge reads 0 psig.

12. Remove hose from non-return valve C (Figure 1.) and replace cap.

13. Close the bleed valve B (Figure 1.) and wait a few minutes for pressure to stabilize.

14. Screw valve A (Figure 1.) clockwise until pressure can be read on gauge. This should be slightly higher than the required pres-
sure.

15. Adjust to desired pressure by means of bleed valve B (Figure 1.), then remove charging unit from the accumulator gas valve and
from the nitrogen bottle (after making sure that the nitrogen bottle valve is completely closed.
Figure 2.
16. Reinstall the gas valve cap and protective guard cap on the accumulator. The accumulator is now ready for use.

NOTE: Allow the accumulator to rest for approximately 10-15 minutes after gas pre-charging. This will allow gas tempera-
ture to adjust and equalize. Recheck gas pressure and adjust if necessary. Check accumulator gas valve for any leaks
with soapy water. Always wear safety glasses.

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 Operating & Maintenance Instructions Diaphragm Accumulators

Pre-Charging Diaphragm Accumulators with Metric M28 x 1.5 Gas Valve

1. Isolate the accumulator from the system and make sure hydraulic fluid pressure is zero. B

2. Remove gas valve protection cap and guard from the accumulator. A

3. To charge the accumulator, use a charging and gauge kit similar to Stauff’ Charging Kit # STDA-CK-M-P3 rated for 3,700 psig
minimum.

DANGER: DO NOT attempt to remove the accumulator gas valve screw with a hexagon wrench, as it could be ejected C
under very high pressure.

4. Before using the charging assembly (Figure 1.) make sure that hex valve B is completely closed (clockwise) and visually check
that the engaging hex on the bottom of the assembly is fully extended. Ensure that bleed valve A (Figure 1.) is completely closed
(clockwise) and that the non-return valve C (Figure 1.) is capped.
D
5. Connect the charging unit to the gas fill valve on the accumulator by means of knurled cap D (Figure 1.), connect by turning Figure 1.
clockwise.

6. Make sure that the valve on the nitrogen bottle is completely closed, then fit the nitrogen gas valve adapter/hose assembly
(included in Stauff Charging Kit # STDA-CK-M-P3) onto the nitrogen bottle (Figure 2.).

7. Connect the other end of gas hose to the non-return valve C (Figure 1.), after taking off its cap.

8. Turn valve B (Figure 1.) counter-clockwise a minimum of three complete turns, thereby opening the hex gas valve (Do not over
Torque).

9. SLOWLY open valve on nitrogen bottle (Figure 2.) and allow the nitrogen gas to flow into the accumulator. The pressure gauge on
the charging assembly will begin to register a pressure increase in the accumulator.

10. Once the desired gas pre-charge pressure has been reached, close the valve on nitrogen bottle (Figure 2.). The reading on the
gauge should be slightly higher than the required pressure.

11. Adjust to desired pre-charge pressure by means of bleed valve A (Figure 1.) turn counter-clockwise and slowly bleed nitrogen
until pre-charge pressure setting is reached, then close bleed valve A (Figure 1.) by turning clockwise until completely closed.

12. Close valve B (Figure 1.) clockwise until fully closed (to a maximum 14.75 foot pounds of torque) making sure the socket-head-
ed gas valve is tight, bleed the trapped pressure in the gas line to zero by means of bleed valve A (Figure 1.), open valve A (Figure
1.), counter-clockwise until the gauge reads 0 psig, close bleed valve A (Figure 1.) by turning clockwise until completely closed. Figure 2.

13. Disconnect the end of gas hose from the non-return valve C (Figure 1.) and replace its cap, remove the gas valve adapter / hose
assembly from the nitrogen bottle (Figure 2.).

14. Remove the charging unit from the gas fill valve on the accumulator by means of knurled cap D (Figure 1.) turn counter-clock-
wise until removed.

15. Using the 6mm hexagon wrench supplied in Stauff’ Charging Kit # STDA-CK-M-P3, ensure that the metric M28x1.5 socket-
headed gas valve is firmly tightened to a maximum of 14.75 foot pounds of torque.

16. Reinstall the gas valve cap and protective guard cap on the accumulator. The accumulator is now ready for use.

17. Note: When charging Stauff Diaphragm accumulators with a North American style gas valve please refer to pre-charging
instructions for Stauff Diaphragm Accumulators with North American Style Gas Valves.

NOTE: Allow the accumulator to rest for approximately 10-15 minutes after gas pre-charging. This will allow gas tempera-
ture to adjust and equalize. Recheck gas pressure and adjust if necessary. Check accumulator gas valve for any leaks
with soapy water. Always wear safely glasses.

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 Diaphragm Accumulators Operating & Maintenance Instructions

Checking Pre-Charge Pressure

General Information
The condition of the accumulator is primarily determined by periodic checking of pre-charge pressure. Only qualified personnel should perform any maintenance on accumulators. Nitrogen gas pre-
charge pressure should be checked at least once during the first week of operation to assure that no leak has developed. The pre-charge pressure and ambient temperature should be recorded at
installation. If there is no loss of gas pre-charge pressure, it should be rechecked in approximately 4 months. Thereafter, it should be checked annually. Check pre-charge if the system is acting
sluggishly. If pre-charge is low, check the gas valve for leakage and recharge.

Pre-Charge Checking Procedure for Diaphragm Accumulators with Metric M28 x 1.5 Gas Valve
B
1. Use appropriate valving in the hydraulic system, to discharge all hydraulic fluid from accumulator.
A
2. To check or adjust pre-charge pressure, HYDRAULIC PRESSURE MUST BE REDUCED TO 0 PSIG. Pre-charge pressure should
be checked periodically. Charging and checking should be done with an accumulator gauge assembly kit similar to Stauff Part #
STDA-CK-M-P3.

C DANGER: DO NOT attempt to remove the accumulator gas valve screw with a hexagon wrench, as it could be ejected
under very high pressure.

3. Follow pre-charging instructions for Diaphragm Accumulators with M28x1.5 Style Gas Valves instructions #4 through #15.

4. Reinstall the gas valve cap and protective guard cap on the accumulator. The accumulator is now ready for use.
D
Figure 1. NOTE: Allow accumulator to rest approximately 10-15 minutes after gas pre-charging. This will allow gas temperature
to adjust and equalize. Recheck gas pressure and adjust if necessary. Check accumulator gas valve for any leaks with
soapy water. Always wear safely glasses.

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 Operating & Maintenance Instructions Diaphragm Accumulators

Checking Pre-Charge Pressure

General Information
The condition of the accumulator is primarily determined by periodic checking of pre-charge pressure. Only qualified personnel should perform any maintenance on accumulators. Nitrogen gas
pre-charge pressure should be checked at least once during the first week of operation to assure that no leak has developed. The pre-charge pressure and ambient temperature should be recorded
at installation. If there is no loss of gas pre-charge pressure, it should be rechecked in approximately 4 months. Thereafter, it should be checked annually. Check pre-charge if the system is acting
sluggishly. If pre-charge is low, check the gas valve for leakage and recharge.

Pre-Charge Checking Procedure for Diaphragm Accumulators with US Style Gas Valve
A
1. Use appropriate valuing in the hydraulic system, to discharge all hydraulic fluid from accumulator.

2. To check or adjust pre-charge pressure, HYDRAULIC PRESSURE MUST BE REDUCED 0 PSIG. Pre-charge pressure should B
be checked periodically. Charging and checking should be done with an accumulator gauge assembly kit similar to Stauff Part #
STBA-CK-B-P3.
C
3. Follow pre-charging instructions for Diaphragm Accumulators with US Style Gas Valve - instructions #4 through #15.

4. Reinstall the gas valve cap and protective guard cap on the accumulator. The accumulator is now ready for use.

NOTE: Allow accumulator to rest approximately 10-15 minutes after gas pre-charging. This will allow gas temperature to
adjust and equalize. Recheck gas pressure and adjust if necessary. Check accumulator gas valve for any leaks with
soapy water. Always wear safely glasses. Figure 1. D

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