Fawcett Christie Hydraulics (I) Pvt.

Limited
No. 21/C, KIADB 1
st
Phase, Bangalore - Mysore Highway,
Kumbalagodu, BANGALORE 560 074.
Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in
Precharging of Accumulators 1/3


IMPORTANT

Use nitrogen gas only.

All accumulators are supplied Unprecharged unless specifically requested at the time of
ordering. Prior to installation in the hydraulic circuit all accumulators must be precharged
with Nitrogen.

Check model number of accumulator on label for working pressure.

Always use the nitrogen pressure regulator valve when accumulator shell pressure rating is
lower than gas pressure in nitrogen cylinder. The commercial nitrogen cylinders available
with 130-140bar.

Precharge vary with operating conditions check with Fawcett Christie if no precharge has
been Previously recommended, for a guide the following values can be used. Storage
application: 90% of minimum allowable system pressure. Pulsation application 70% of mean
pumping pressure. Shock application: 90% of flow pressure at accumulator position.

N.B. Precharge must never be below 20% of maximum system pressure.

Ensure bladder has been lubricated with system fluid before commencing Precharging



PRECHARGING PROCEDURE

The following procedures should be adopted for safe Precharging of accumulators. All
Precharging Equipment specified is detailed

For accumulators having a shell working pressure less than the nitrogen source refer to
fig. 2.

For accumulators having a shell working Pressure equal to or greater than the nitrogen
source refer to fig. 3 see note 4.

For Accumulator fitted with permanent charging set refer to fig 4.

For transfer barrier accumulators refer to Fig. 5.












Fawcett Christie Hydraulics (I) Pvt. Limited
No. 21/C, KIADB 1
st
Phase, Bangalore - Mysore Highway,
Kumbalagodu, BANGALORE 560 074.
Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in
Precharging of Accumulators 2/3

Procedure I - using a Nitrogen pressure regulator valve PRV) fig. 2.
A Remove protective cap(1) fitted and the sealing cap (2).
B Attach NPRV (3) to nitrogen cylinder (4).
C
Attach charging set (5) to accumulator gas Valve assembly (6) and connect charging
hose (7) between NPRV (3) and charging set connection
D
Back off handle (8) anti clockwise until loose, check gas bleed valve (9) on charging
set is closed and screw hand wheal (10) clockwise to open gas valve.
E
Open nitrogen cylinder valve by turning key (11). cylinder pressure will register on
right hand gauge (12). This pressure should be checked against the required
precharge pressure.
F
Turn handle(8) clockwise until outlet pressure on left hand gauge(13) registers
10% higher than the required precharge pressure. When pressure on the charging
set and outlet gauges are equal, close Nitrogen Cylinder Valve.
G Turn hand wheel (10) anti-clockwise to seal gas valve.
H
Crack bleed valve(9) to exhaust gas from charging hose and remove hose from
charging set and replace hose connection Sealing cap.
I
Close bleed valve, turn hand wheal (10) clockwise to open gas valve and crack bleed
valve (9) to vent down to required precharge pressure. Close bleed valve
J
Turn hand wheal (10) anti-clock wise to reseal gas valve, crack bleed valve and
remove charging set from the accumulator
K
Test accumulator gas valve for leaks using a leak detection spray or soapy water
solution.
L Replace, sealing cap(2)and tighten with pliers and protective cap (1) if fitted


Procedure II Nitrogen pressure regulator Valve not used. Fig. 2,3,4 and 5.
M
Remove protection cap(1) if fitted and the sealing cap (2) and attach charging set
to accumulator gas valve assembly.
N
Connect charging hose (7) to nitrogen cylinder (4) using the appropriate adaptor
and attach the free end to the charging set.
O Turn hand wheel (10) clockwise to open gas valve and slowly open nitrogen.
P
Allow pressure on the gauge (14) to read slightly in excess of required precharge
then close nitrogen cylinder valve. To complete procedure follow steps g to h
above.




Fawcett Christie Hydraulics (I) Pvt. Limited
No. 21/C, KIADB 1
st
Phase, Bangalore - Mysore Highway,
Kumbalagodu, BANGALORE 560 074.
Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in
Precharging of Accumulators 3/3



Procedure III Permanent charging set fitted Fig,4 & 5
q
Follow above steps, adopting either procedure I or II depending on accumulator
working pressure, connecting the charging set to the gas value set as shown in
fig.4 & fig.5.







Procedure IV Precharging of Diaphragm Accumulator (Fig.6)
R
Remove protection cap (1) if fitted attach the charging set to the accumulator on
the M28xl.5 Gas valve stem (2).
S
Connect charging hose(7) to nitrogen cylinder (4) using the appropriate adaptor
and attached the free end to the charging set.
T Turn Hand wheel (10) anti-clockwise to open the gas valve.
U
Allow pressure on the gauge (14) to read slightly in excess of required Precharge.
Then close nitrogen cylinder valve.
V Turn hand wheel (10) clockwise to seal gas valve.
W
Crack bleed valve (9) to exhaust gas From charging hose and remove hose from
charging set and replace hose connection sealing cap.
X
set the required precharge by releasing the gas operating hand wheel and Bleed
Valve.
Y
Tighten the accumulator Allen bolt (15) test for leakage using spray soapy water
solution





Fawcett Christie Hydraulics (I) Pvt. Limited
No. 21/C, KIADB 1
st
Phase, Bangalore - Mysore Highway,
Kumbalagodu, BANGALORE 560 074.
Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in
Installation of Accumulators


Inspection of Accumulator :

All Fawcett Christie accumulators are thoroughly inspected prior to dispatch from our factory and are
ready for installation following pre charging.
After unpacking the accumulators, inspection of the accumulators for possible damage during transit.
Check the, all nuts, screws, locking rings, bleed screws, adaptors and fittings, for tightness. check
that the maximum pressure of the accumulator is equal to or greater than the maximum pressure of
the system.(see interpretation of markings).



2. Installation recommendations.
All accumulators are supplied un-pre charged from the factory unless requested. Prior to applying
hydraulic pressure to the system all accumulators must be pre charged with nitrogen. It will be
necessary to check the gas pre charge pressure at regular intervals.
The provision of a safety block fitted between the accumulator and fluid pressure line to enable
isolation of hydraulic system pressure.
The location of the gas-charging valve with regard to the potential for accidental damage and safe
discharge of high-pressure gas.
The provision of a warning label (in addition to that provided on the accumulator nameplate) stating
"PRECHARGED WITH N2 GAS AT ....BAR".
It is necessary to ensure that the accumulator is protected from overpressurisation. General
protection is usually provided by the hydraulic system relief valve, which should be set at no higher
than 10% above the maximum working pressure (MWP) of the accumulator. Specific protection for
the accumulator can be provided in the following ways:
A hydraulic relief valve located in a safety block will prevent both liquid and gas side
overpressurisation. A fusible plug will relive gas side pressure in the event of a fire. And a burst disc
will relieve gas side overpressurisation.
On storage applications a check valve fitted between pump and accumulator will ensure non-reversal
of the pump.
For maximum efficiency and service life, accumulators should be mounted vertically where possible,
fluid port facing down.
For fluid port and gas connection threads see our catalogue. If it is necessary to adapt to another
size, special adaptors are available.

A range of clamps, support brackets and other accessories are available to assist in installation. Their
use is strongly recommended.




Fawcett Christie Hydraulics (I) Pvt. Limited
No. 21/C, KIADB 1
st
Phase, Bangalore - Mysore Highway,
Kumbalagodu, BANGALORE 560 074.
Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in
Installation of Accumulators


Inspection of Accumulator :

All Fawcett Christie accumulators are thoroughly inspected prior to dispatch from our factory and are
ready for installation following pre charging.
After unpacking the accumulators, inspection of the accumulators for possible damage during transit.
Check the, all nuts, screws, locking rings, bleed screws, adaptors and fittings, for tightness. check
that the maximum pressure of the accumulator is equal to or greater than the maximum pressure of
the system.(see interpretation of markings).



2. Installation recommendations.
All accumulators are supplied un-pre charged from the factory unless requested. Prior to applying
hydraulic pressure to the system all accumulators must be pre charged with nitrogen. It will be
necessary to check the gas pre charge pressure at regular intervals.
The provision of a safety block fitted between the accumulator and fluid pressure line to enable
isolation of hydraulic system pressure.
The location of the gas-charging valve with regard to the potential for accidental damage and safe
discharge of high-pressure gas.
The provision of a warning label (in addition to that provided on the accumulator nameplate) stating
"PRECHARGED WITH N2 GAS AT ....BAR".
It is necessary to ensure that the accumulator is protected from overpressurisation. General
protection is usually provided by the hydraulic system relief valve, which should be set at no higher
than 10% above the maximum working pressure (MWP) of the accumulator. Specific protection for
the accumulator can be provided in the following ways:
A hydraulic relief valve located in a safety block will prevent both liquid and gas side
overpressurisation. A fusible plug will relive gas side pressure in the event of a fire. And a burst disc
will relieve gas side overpressurisation.
On storage applications a check valve fitted between pump and accumulator will ensure non-reversal
of the pump.
For maximum efficiency and service life, accumulators should be mounted vertically where possible,
fluid port facing down.
For fluid port and gas connection threads see our catalogue. If it is necessary to adapt to another
size, special adaptors are available.

A range of clamps, support brackets and other accessories are available to assist in installation. Their
use is strongly recommended.




Fawcett Christie Hydraulics (I) Pvt. Limited
No. 21/C, KIADB 1
st
Phase, Bangalore - Mysore Highway,
Kumbalagodu, BANGALORE 560 074.
Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in
Commissioning of Accumulators


Use only oxygen-free, dry nitrogen gas


All accumulators are supplied un-pre charged unless a pre charge pressure is specified when ordering.
Prior to applying hydraulic pressure to the system all accumulators must be pre charged with
nitrogen.


Check details of accumulator on label and shell for maximum working pressure. The maximum
hydraulic pressure must not exceed the MPW of the accumulator.


Always use the nitrogen pressure regulator valve when accumulators shell pressure rating is lower
than gas pressure in nitrogen cylinder


Pre charges vary with operating conditions. check with our technical department if no pre charge has
been previously recommended. For a guide the following values can be used :
- storage application : 90% of minimum allowable system pressure
- shock application : 60% of flow pressure at accumulator position
- pulsation damper : 70% of mean pumping pressure


NB : Allowing pre charge to fall below 20% of maximum system pressure may cause premature failure
of the bladder.
- Ensure that the bladder and shell inner are adequately lubricated with system fluid before
commencing pre charging. This is especially important where the system fluid is of low viscosity eg.
water based


When a new accumulator has been in service for a short period, the pre charge should be checked to
ensure there is no leakage. Subsequent checks should only be at 6 monthly intervals.


When checking the pre charge of an accumulator installed in a system, the accumulator must be
isolated from the system pressure and the fluid removed by carefully opening the bleed valve and
collecting the fluid in a suitable receptacle. Alternatively, shut the system down and release the fluid
pressure back to tank



Fawcett Christie Hydraulics (I) Pvt. Limited
No. 21/C, KIADB 1
st
Phase, Bangalore - Mysore Highway,
Kumbalagodu, BANGALORE 560 074.
Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in
Assembling Bladder Accumulator 1/2

Parts list
B1 Fluid Port Assembly
B6 Flanged Washer
B7 Locking Ring
B8 Bleed Adaptor (if fitted) *
B9 Bleed Valve (if fitted) *
C1 Shell
D1 Bladder
D2 Gas Valve Assembly
D3 Locknut
D4 Protective Cap
D5 O Ring
E1 Anti Extrusion Ring
E2 O Ring
E3 Bonded Seal (if fitted) *
E4 Back-up Ring
* The Bleed Adaptor, Valve and
Bonded Seal are not fitted on all
models.

The following procedure has to be followed after Cleaning Clean all Metallic Components with
an Organic Solvent , Inspect all components for defects.
Expel all air from the Bladder by
rolling up from the opposite end to
the Stem, fit the Stem O Ring and
Gas Valve Assembly
Unroll the Bladder and lubricate
with System Fluid
Attach Pull Rod to Gas Valve
Assembly
Lubricate the Inside of the Shell
with System Fluid. (10%of the
Accumulator Volume)
Feed Pull Rod through Fluid End &
out of Gas End Opening. Guide the
Bladder into the Shell. Do not twist
the Bladder during this operation
Pull the Bladder Stem through the
Gas End Opening
Fit the Nameplate, Tighten Locknut
by turning clockwise
Fawcett Christie Hydraulics (I) Pvt. Limited
No. 21/C, KIADB 1
st
Phase, Bangalore - Mysore Highway,
Kumbalagodu, BANGALORE 560 074.
Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in
Assembling Bladder Accumulator 2/2
Fit the Gas Valve & Tighten
Clockwise
Insert the Fluid Port Assembly in to
the Shell through the Fluid End
Opening.
Insert the Anti-Extrusion Ring in to
shell
Slide the Anti-Extrusion Ring over
the Fluid Port Body and locate the
Fluid Port at the shell opening
Position O-ring inside the gap left
between the Shell and the Fluid Port
Body
Slide the PTFE Back Up- Ring on to
the Fluid Port body & position it
behind the O ring

Slide the Flanged Washer & Fit
Locking ring onto Fluid Port Body
and screw clockwise
Tighten the lock nut with right
spanners.
Fit The Bleed Valve & Seal on to
the Fluid port & tighten clockwise
with suitable tool.

Precharge the Accumulator with Dry
Nitrogen (~5% more than the
required pressure)
Isolate the Hose & & replace the
seal cap & set the Predetermined
precharge pressure using vent valve
Check for leakage, Replace the
Seal & protection Caps



Fawcett Christie Hydraulics (I) Pvt. Limited
No. 21/C, KIADB 1
st
Phase, Bangalore - Mysore Highway,
Kumbalagodu, BANGALORE 560 074.
Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in
Disassembling Bladder Accumulators - Stage-1
SAFETY NOTE:
THE ACCUMULATOR CAN ONLY BE REMOVED FROM THE SYSTEM PIPEWORK ONCE THE HYDRAULIC
PRESSURE HAS BEEN REMOVED FROM THE ACCUMULATOR
Parts list
B1 Fluid Port Assembly
B6 Flanged Washer
B7 Locking Ring
B8 Bleed Adaptor (if fitted) *
B9 Bleed Valve (if fitted) *
C1 Shell
D1 Bladder
D2 Gas Valve Assembly
D3 Locknut
D4 Protective Cap
D5 O Ring for Bladder Stem
E1 Anti Extrusion Ring
E2 O Ring for Fluid port
E3 Bonded Seal (if fitted) *
E4 Back-up Ring
* The Bleed Adaptor, Valve and
Bonded Seal are not fitted on all
models.

Isolation & Drain
(A) WITH SAFETY BLOCK
Close Isolating Valve.
Open the Manual/Drain Valve until Pressure
Gauge registers zero.
Remove Safety Block from the Accumulator.
B) WITH BLEED FACILITY
Isolate the Accumulator from the System.
Open Bleed facility, draining system fluid into a
suitable receptacle, until all fluid and Pressure
have been removed.
Remove the Accumulator from System Pipe work

A B
Removal of Precharge

Remove Protective Cap (D4) from the Bladder Stem by unscrewing anti-clockwise.
Remove Sealing Cap from the Gas Valve Assembly.
Connect Charging Set to the gas Valve Assembly, ensuring the spindle is fully
wound out before connecting.
Screw the top Operating Knob to depress the pin and open the valve core.
Release all the gas pressure by opening the Vent Valve.
Disconnect the Charging Set from the Accumulator.

Fawcett Christie Hydraulics (I) Pvt. Limited
No. 21/C, KIADB 1
st
Phase, Bangalore - Mysore Highway,
Kumbalagodu, BANGALORE 560 074.
Ph : 28437690 / 91 Fax : 080-26611716 Email : info@olaer.in
Disassembling Bladder Accumulators - Stage-2

The following procedures to be followed after completion of Stage-1
Clamp the Accumulator in a
Steady & Safe Position
Remove the Protection & Seal
Caps
Fit the Precharging Equipment
Release all the gas pressure by
opening the Vent Valve.
Remove the Locknut , Gas Valve &
Nameplate from the Bladder Stem
by turning them anti-clockwise
Remove the Bleed valve fitted on
the Fluid Port
Unscrew the Locking Ring
Anti-clock wise
Remove the Locking Ring & the
Flanged Washer
Slide the fluid port forward, Remove
the O Ring & Backup Ring
Push the Fluid Port in & Slide the
Anti-Extrusion Ring off the Fluid
Port Assembly
Fold the Anti-Extrusion Ring until
removal from the Accumulator Shell
Remove The Fluid Port Assembly
from the Accumulator Shell
Squeeze the Bladder to deflate then
slowly remove through the Fluid
Port opening of the Shell.
INTERNATIONAL NETWORK
AUSTRALIA
Olaer Fawcett Christie Pty Ltd
Tel: + 61 2 9981 6888
Fax: + 61 2 9981 6144
E-mail: info@olaer.com.au
Website: www.olaer.com.au
BRAZIL
Flutrol-Com.e Controle de Fluidos Ltda.
Tel: + 55 11-5589 9053
Fax: + 55 11-5589 0884
Email: sales@utrol.com.br
Website: www.utrol.com.br
DENMARK
Oiltech AB
Tel: + 45 86 69 20 38
Fax: + 45 86 69 23 38
E-mail: oiltech@oiltech-olaer.dk
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GERMANY
Olaer industries GmbH.
Tel: + 49 6842 9204-0
Fax: + 49 6842 9204-15
E-mail: info@olaer.de
Website: www.olaer.de
ITALY
Olaer Italiana S.p.A.
Tel: + 39 011 991 85 11
Fax: + 39 011 997 80 97
E-mail: olacom@olaer.it
Website: www.olaer.it
POLAND
Oiltech Polska
Tel: + 48 22 612 04 73
Fax: + 48 22 610 74 82
Website: www.oiltech.pl
SPAIN
Olaer-Oiltech Iberica S.A.
Tel: + 34 933 361 412
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E-mail: olaer@olaer.es
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The Kanoo Group
Tel: + 971 2 6774444
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Olaer Speicher-Technik Ges.m.b.h.
Tel: + 43 7229 80306
Fax: + 43 7229 80306-21
E-mail: info@olaer.at
Website: www.olaer.at
CHINA
Olaer Tianjin Hydraulic Manufacturing
Company Ltd.
Plant A, 11 Jimei Industrial Park
Xiqing Economic Development Zone
Tianjin PRC
Tel: + 86 22 23889096
Fax: + 86 22 23889097
FINLAND
Oiltech Hydraulics Oy
Tel: + 358 9 682 0422
Fax: + 358 9 682 2376
E-mail: info@oiltech.
Website: www.oiltech.
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Olaer Nederland B.V.
Tel: + 31 76 5412453
Fax: + 31 76 5411502
E-mail: info@olaer.nl
Website: www.olaer.nl
KOREA
Hyundai Olaer Hydraulic Co. Ltd.
Tel: + 82 345 499 07 97
Fax: + 82 345 499 22 49
E-mail: hdolaer@hyundaiolaer.co.kr
SAUDI ARABIA
Yusuf Bin Ahmed Kanoo
Tel: + 966 3 857 1265
Fax: + 966 3 857 4407
E-mail: oilngas@kanoosa.com
SWEDEN
Oiltech AB
Tel: + 46 8 636 07 00
Fax: + 46 8 767 97 56
E-mail: info@oiltech.se
Website: www.oiltech.se
UNITED KINGDOM
Fawcett Christie Hydraulics Ltd,
Sandycroft Industrial Estate, Sandycroft,
Deeside, Flintshire,
CH5 2QP
Tel: + 44 1244 535515
Fax: + 44 1244 533002
E-mail: sales@fch.co.uk
Website: www.fch.co.uk
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S.A. Olaer Benelux N.V.
Tel: + 32 2 466 15 15
Fax: + 32 2 466 16 24
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Website: www.olaer.be
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Olaer CZ. s.r.o.
Tel: + 42 5 47125 601-3
Fax: + 42 5 47125 600
E-mail: info@olaer.cz
Website: www.olaer.cz
FRANCE
Olaer Industries S.A.
Tel: + 33 141 19 17 00
Fax: + 33 141 19 17 20
E-mail: olaer@olaer.com
Website: www.olaer.com
INDIA
Fawcett Christie Hydraulics Ltd.
Tel: + 91 80 6610508
Fax: + 91 80 6611716
E-mail: fch@vsnl.com
Website: www.fchindia.com
NORWAY
Oiltech AS
Tel: + 47 64 87 42 65
Fax: + 47 64 87 43 21
E-mail: oiltech@oiltech.no
SOUTH AFRICA
Fawcett Christie Hydraulics
c/o Rolton Products CC
Tel: + 27 11 474 3095
Fax: + 27 11 474 4384
E-mail: rolton@global.co.za
Website: www.fch.edx.co.za
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Olaer (Schweiz) AG
Tel: + 41 26 492 70 00
Fax: + 41 26 492 70 70
E-mail: info@olaer.ch
Website: www.olaer.ch
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OilAir Hydraulics Inc.
Tel: + 1713 937 89 00
Fax: + 1713 937 04 38
E-mail: sales@oilairhydraulics.com
Website: www.uidpower.com