Charging and testing unit

FPU
for Bladder, Piston and Diaphragm
Accumulators

1. DESCRIPTION 1.2. DESIGN

1.1. FUNCTION The HYDAC charging and testing unit
FPU-1 for bladder, piston and diaphragm Spindle
The HYDAC charging and testing unit FPU accumulators consists of:
is used to charge accumulators with Release valve
nitrogen or to check or to change the zzValve body Check Valve
existing pre-charge pressure in zzSpindle
accumulators. zzCheck valve
For this purpose the charging and testing
unit is screwed onto the gas valve of the zzRelease valve
hydraulic accumulator and connected via a zzPressure gauge
hose to a commercial nitrogen bottle.
If the nitrogen pressure is only to be Pressure gauge

checked or reduced, the charging hose

does not need to be connected. The unit
has a screw-type fitting with a built-in
pressure gauge, check valve and a spindle
for opening the accumulator gas valve to
control the pressure
HYDAC piston and diaphragm
accumulators can be charged and checked
without the need for adapters. Bladder
accumulators, however, require an A3 Adaptor G Pressure reducer Charging and testing unit FPU-1
adapter.
Information on how to check the pre-
charge pressure, on testing intervals and
other instructions relating to operation can
be found in the Operating Manual. G1 Charging hose Adapter A
Please read the operating manual!
No. 3.501.BA

Hydraulic accumulator

Nitrogen bottle

Fluid connection
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 2. TECHNICAL SPECIFICATIONS 2.3. HIGH PRESSURE
2.1. MODEL CODE VERSIONS
Not all combinations are possible. Order example.
For further information, please contact HYDAC.
FPU-1-350 / 250 F 2.5  G2  A1 K
Charging and testing unit
FPU-1-350 = Standard (pmax = 350 bar)
FPU-2-800 = High-pressure version (pmax = 800 bar)
Pressure gauge display range
  10 = 0 - 10 bar ( 0 - 145 psi)
  25 = 0 - 25 bar ( 0 - 363 psi)
  100 = 0 - 100 bar (0 - 1450 psi)
  250 = 0 - 250 bar (0 - 3625 psi)
  400 = 0 - 400 bar (0 - 5800 psi)
1000 = 0 - 1000 bar (0 - 14500 psi high-pressure version)
Charging hose
F = for nitrogen bottle 200 bar with connection W24.32x1/14
(DIN 477, Part 1)
FM = for nitrogen bottle 300 bar with connection M30x1.5
(DIN 477, Part 5 up to April 2002)
FW = for nitrogen bottle 300 bar with connection W30x2
(DIN 477, Part 5 from April 2002)
FH = for pressure booster systems with connection 9/16-18UNF
Charging hose length The FPU-2 was designed specifically for
Standard high pressure applications.
2,5 = 2.5 m Just like the FPU-1, the FPU-2 is
4,0 = 4 m universally applicable.
High pressure version It can be screwed onto HYDAC piston and
6,0 = 6 m diaphragm accumulators directly to charge
others on request and/or to check the accumulator.
Adapter G for nitrogen bottles (only FPU-1) For use with a bladder accumulator, the
see table section 3.4. high pressure adapter A3H must be used.
Adapter A This is not included in standard delivery.
A3 = 7/8-14UNF, incl. in FPU-1 scope of delivery as standard
A3H = 7/8-14UNF (high pressure version), not incl. in FPU-2 scope of delivery
for others, see table section 3.3. 2.3.1 Technical specifications
Protective case Model code:
Accessories - please give full details when ordering (see section 4.) see section 2.1.
Max. operating pressure:
2.2. STANDARD TYPES FPU-1 To enable nitrogen bottles from different 800 bar
The basic version of the FPU-1 is the countries to be used, HYDAC provides a Pressure gauge display range:
minimum equipment required to test selection of adapters as accessories. The
0 - 1000 bar (0 - 14500 psi)
and set the pre-charge pressure (p0) at following standard types are available
the hydraulic accumulator. It comprises (others on request): Material:
the FPU-1, a charging hose and the Stainless steel 1.4313
Models with protective case and
adapter A3 for bladder accumulators. The adapter G
following standard types are available
(others on request): Designation Part no. 2.3.2 Standard types FPU-2
Models without protective case FPU-1-350/250F2.5G2A3K 2114309 Models without protective case
Designation Part no. FPU-1-350/250F2.5G3A3K 2114308 Code Part no.
FPU-1-350/010F2.5A3 2114486 FPU-1-350/250F2.5G4A3K 2103046 FPU-2-800/1000F6 4043456
FPU-1-350/010F4A3 2115056 FPU-1-350/250F2.5G5A3K 2117038 FPU-2-800/1000F6A3H 4043455
FPU-1-350/025F2.5A3 2114481 FPU-1-350/250F2.5G6A3K 2115420
FPU-1-350/025F4A3 2116876 FPU-1-350/250F2.5G7A3K 2120010 Models with protective case
FPU-1-350/100F2.5A3 2114310 FPU-1-350/250F2.5G8A3K 2115216 Code Part no.
FPU-1-350/100F4A3 2115657 FPU-1-350/250F2.5G9A3K 2115833 FPU-2-800/1000F6K 4029954
FPU-1-350/250F2.5A3 2114306 FPU-1-350/250F2.5G10A3K 2115403 FPU-2-800/1000F6A3HK 4023260
FPU-1-350/250F4A3 2114311 FPU-1-350/250F2.5G11A3K 3104265
FPU-1-350/400F2.5A3 2115646 FPU-1-350/250F2.5G12A3K 3738731
FPU-1-350/400F4A3 2119673 FPU-1-350/250F2.5G13A3K 3820014

Models with protective case

Designation Part no.
FPU-1-350/010F2.5A3K 2115365
FPU-1-350/010F4A3K 3013690
FPU-1-350/025F2.5A3K 2114305
FPU-1-350/025F4A3K 2116738
FPU-1-350/100F2.5A3K 2115314
FPU-1-350/100F4A3K 2114842
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FPU-1-350/250F2.5A3K 2114302
FPU-1-350/250F4A3K 2114303
FPU-1-350/400F2.5A3K 2114307
FPU-1-350/400F4A3K 2114304

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3. DIMENSIONS
3.1. GAS-SIDE CONNECTION OF THE CHARGING AND TESTING UNIT FPU-1 USING
ADAPTERS FOR HYDAC ACCUMULATORS

D4 adapter
(see section 4.)

Bladder accumulators Bladder accumulators Gas valve Piston and diaphragm

330-0.5 / 400-0.5 ≥ 1l to ISO 10945 accumulators
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 3.2. GAS-SIDE CONNECTION OF THE CHARGING AND TESTING UNIT FPU-2
USING ADAPTERS FOR HYDRAULIC ACCUMULATORS

Bladder accumulator Piston and diaphragm

≥1l accumulators
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3.3. CHARGING HOSES 3.3.3 Pressure hose for pressure booster systems
Charging hoses are designed for the particular maximum permitted
operating pressure marked on them and 10,000 charging processes. Charging hose FH
(HYDAC charging hoses comply with DIN EN ISO 4413 and
DIN EN 853 to 857)

3.3.1 Charging hoses for nitrogen bottles up to 200 bar

Charging hose F
Connection to DIN 477, Part 1

Type Length [m] Part no.

Charging hose FH 6 6169682

Type Length [m] Part no.

Charging hose F 2.5 236514
4 236515
10 373405
15 2115552
20 2109765
28 2109574

3.3.2 Charging hoses for nitrogen bottles up to 300 bar

Charging hose FM
Connection to DIN 477, Part 5 up to April 2002

Charging hose FW
Connection to DIN 477, Part 5 from April 2002

knurl

Type Length [m] Part no.

Charging hose FM 2.5 3019417
4 3019418
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Charging hose FW 2.5 3019419

4 3019420

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 3.4. ADAPTERS A1 TO A13 FOR FPU-1 A3 (Part no. 291533)
The FPU-1 is universally applicable because as well as HYDAC
piston and diaphragm accumulators, bladder accumulators can
also be charged and tested using the A3 adapter supplied as
standard.
Additional adapters can be used to charge and test other brands
of accumulator.
The following adapters are to be used exclusively with FPU-1,
see section 3.1.

A4 (Part no. 291536)

A5 (Part no. 291531)

A1 (Part no. 361619)

A2 (Part no. 361605) A6 (Part no. 2108819)

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A7 (Part no. 2110629) A11 (Part no. 3018210)

A8 (Part no. 2124524) A12 (Part no. 3203185)

A9 (Part no. 2128638) A13 (Part no. 3911267)

A10 (Part no. 2128849)

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 3.5. ADAPTERS G2 TO G13 FOR FPU-1
The FPU-1 can be used with nitrogen bottles from various countries. Depending on the particular country of manufacture for the
nitrogen bottles (see list of countries), HYDAC offers the following G adapters, exclusively for use with the FPU-1.
The FPU-2 is connected to a pressure booster system.

G 2 (Part no. 236376) G 6 (Part no. 2103423) G 10 (Part no. 2103427)

G 3 (Part no. 2103421) G 7 (Part no. 236377) G 11 (Part no. 3018678)

G 4 (Part no. 236374) G 8 (Part no. 2103425) G 12 (Part no. 3195556)

G 5 (Part no. 236373) G 9 (Part no. 241168) G 13 (Part no. 3787884)

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List of countries
Country Type / part no.
G1 1) G2 G3 G4 G5 G6 G7 G8 G9 G10 G11 G12 G13
236376 2103421 236374 236373 2103423 236377 2103425 241168 2103427 3018678 3195556 3787884
Africa 3) 
Albania 
Algeria 
Argentina 
Australia 
Austria 
Bahamas 
Bahrain 
Bangladesh 
Barbados 
Belgium 
Bolivia 
Brazil 
Bulgaria 
Burma 
Canada 
Chile 
China 
Colombia 
Costa Rica 
Cyprus 
Czech Republic 
Denmark 
Djibouti 
Dominican Republic 
Ecuador 
Egypt 
Ethiopia 
Fiji 
Finland 
France 
Gabon 
Gambia 
Germany 
Ghana 
Great Britain 
Greece 
Guatemala 
Guinea 
Guyana 
Honduras 
Hong Kong 
Hungary 
India 
Indonesia 
Iran 
Iraq 
Ireland 
Israel 
Italy 
Ivory Coast 
Jamaica 
Japan 
Jordan 
Kenya 
Korea 
Kuwait 
Lebanon 
Libya 
Malawi 
Malaysia 
Malta 
Mauritius 
Mexico 
Morocco 
Netherlands 
New Zealand 
Nigeria 
Norway 
Oman 
Pakistan 
Paraguay 
Peru 
Philippines 
Poland 
Portugal 
Puerto Rico 
Qatar 
Romania 
Russia 
Saudi Arabia 
Singapore 
Spain 
Sri Lanka 
Sudan 
Surinam 
Sweden 
Switzerland 
Syria 
Taiwan 
Tanzania 
Thailand 
Trinidad/Tobago 
Tunisia 
Turkey 
Ukraine 
United Arab Emirates 
Uruguay 
USA 
Venezuela 
Vietnam 
Yugoslavia 2) 
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Zambia 
1)
= already fitted to hose
2)
= Bosnia, Herzegovina, Croatia, Macedonia, Slovenia
3)
= Angola, Botswana, Lesotho, Mozambique, Namibia, Somalia, South Africa, Swaziland, Zimbabwe

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 4. ACCESSORIES 4.4. INTERMEDIATE PIECE GSV6-10-CE FOR FPU-1
4.1. PROTECTIVE CASE Intermediate piece for installing the gas safety valve GSV 6 between the 200 bar nitrogen
bottle and the charging and testing unit FPU-1.
for storing the charging and testing unit
FPU and adapters – with foam insert and
prefabricated recesses to hold all parts and
any accessories (adapters, tools, etc.).
Different configurations are available,
depending on customer requirement.
Weight approx. [kg]
Without With case
case
FPU-1 1.4 3
(basic
version)
FPU-2 8.2 14.2

4.2. GAS SAFETY VALVE

FOR FPU-1
Provides protection by reducing the
pressure in a controlled way if pressure
exceeds the permitted level unexpectedly,
see catalogue section: Weight: 0.5 kg
zzSafety Equipment
for Hydraulic Accumulators
No. 3.552 Description Quantity Item Part no.
4.3. ADAPTER D4 FOR FPU-1 Intermediate piece GSV6-10-CE - - 242558
For screw connector D on bladder Seal kit for intermediate piece - - 2117287
accumulators < 1 l (see section 3.) consisting of:
D4 = 5/8-18UNF (Part no. 366374)
O-ring 20x2.5x2 2 12 -
Seal ring 20x11.5x2 1 13 -
Seal ring 14x8.5x2 1 14 -

4.5. PRESSURE REDUCER

For adjusting the required pre-charge pressure between the nitrogen bottle and the
accumulator.
4.5.1 Pressure reducer for 200 bar nitrogen bottles
Inlet: connection W24, 32x1/14-DIN477, Part 1
Outlet: male thread W24, 32x1/14-DIN477, Part 1
Bottle pressure [bar] Pressure after reducer [bar] Part no.
20 635409
200 100 635411
200 635412

4.5.2 Pressure reducer for 300 bar nitrogen bottles

Inlet: connection W30x2-DIN477, Part 5
Outlet: male thread W24, 32x1/14-DIN477, Part 5
Bottle pressure [bar] Pressure after reducer [bar] Part no.
20 6004020
100 6004021
300
200 6004022
270* 6004023
* for pressures after reducer > 200 bar, the outlet has an external thread W30x2-DIN477, Part 5
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5. SPARE PARTS, ADAPTERS AND TOOLS 5.4. SPARE PARTS FOR FPU-2
5.1. SPARE PARTS FOR FPU-1 The scope of delivery for FPU-2 already
includes additional seals as replacements.

6. NOTE
The information in this brochure relates to
the operating conditions and applications
described.
For applications and/or operating
conditions not described, please contact
the relevant technical department.
Subject to technical modifications.

Description Quantity Item Part no.

Seal kit for FPU-1 1 - 2117669
consisting of:
O-ring 6x1 1 1 -
Seal ring 1 2 -
O-ring 15x2 1 5 -
Seal ring 1 6 -
O-ring 11x2 1 7 -
O-ring 9x2 1 8 -
O-ring 11x2.5 1 9 -
O-ring 5.7x1.9 1 10 -
Pressure 0 - 10 bar 635139
gauge
0 - 25 bar 635140
0 - 100 bar 1 3 635141
0 - 250 bar 635142
0 - 400 bar 635143

5.2. ADAPTERS FOR FPU-1

Description Quantity Item Part no.
Seal kit for adapters A1-13 1 - 3269153
consisting of:
O-ring 11x2 3 7 -
O-ring 9x2 3 8 -
Seal ring 9.3x13.3x1 3 11 -
Seal ring 27x32x2 1 12 -
O-ring 6x1.2 1 13 -
O-ring 19x2 1 14 -
Seal ring for adapter A9 1 15 -
Seal ring 6x13x2 1 50* -
* only suitable for adapters A7 up to May 2006

5.3. TOOLS FOR FPU-1

Designation Part no.
Wrench 14x15 1011065 HYDAC Technology GmbH
Industriegebiet
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Allen key SW6 1005164 66280 Sulzbach/Saar, Germany

Torque wrench 3136470 Tel.: +49 (0) 68 97 / 509 - 01
Valve tool for gas valve 616886 Fax: +49 (0) 68 97 / 509 - 464
Internet: www.hydac.com
E-Mail: [email protected]
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