6.01/1 NEW 1 AUTOLUBE SYSTEM FOR AUTOMATIC LUBRICATION OF THE PUMP 1 WATER INLET FILTER 1 PUSH TO LOCK REGULATOR KNOB Hydrostatic Pressure Testing Cyclic Pressure Testing Burst Strength Testing Centralized Lubrication Transfer of Coolants, Electrolytes and Other Non Corrosive Liquids Operation of Jacks, Clamps & Presses Portable Systems for Construction, Mining & Defence Equipments Typical Applications • • • • • • • SERIES ‘N’ SINGLE HEAD PNEUMATICALLY OPERATED SERIES ‘NE’ SINGLE HEAD ELECTRICALLY OPERATED SERIES ‘N2H’ DOUBLE HEAD PNEUMATICALLY OPERATED SERIES ‘N2HE’ DOUBLE HEAD ELECTRICALLY OPERATED Hydro Pneumatic Pumps Series ‘N’
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6.01/1
NEW
1 AUTOLUBE SYSTEM FOR AUTOMATIC LUBRICATION OF THE PUMP1 WATER INLET FILTER1 PUSH TO LOCK REGULATOR KNOB
Hydrostatic Pressure TestingCyclic Pressure TestingBurst Strength TestingCentralized LubricationTransfer of Coolants, Electrolytes and Other Non Corrosive LiquidsOperation of Jacks, Clamps & PressesPortable Systems for Construction, Mining & Defence Equipments
Typical Applications
•••••••
SERIES ‘N’SINGLE HEAD PNEUMATICALLY OPERATED
SERIES ‘NE’SINGLE HEAD ELECTRICALLY OPERATED
SERIES ‘N2H’DOUBLE HEAD PNEUMATICALLY OPERATED
SERIES ‘N2HE’DOUBLE HEAD ELECTRICALLY OPERATED
Hydro Pneumatic PumpsSeries ‘N’
6.01/3
P2
=INTENSIFICATION RATIO A1
A2
=INTENSIFICATION RATIO 2A1
A2
WATER TANK
SUCTIONSTRAINER
DISCHARGENON RETURN
VALVE
P2
SYSTEM
DIA D1AREA A1
P1
AIR INLET23 TO 6 Kg/cm
VALVE ‘C’2/2 PLUNGER
SPRING PILOTVALVE
PNEUMATIC CIRCUIT DIAGRAM FOR SERIES ‘N’
HYDRO PNEUMATIC PUMP
FIG. 4
DASH 1 INTENSIFIER
FIG. 2
DASH 2 INTENSIFIER
FIG. 3
DIA D2AREA A2
DIA D2AREA A2
P2DIA D1
AREA A1
P1
AIR PRESSURE REGULATOR
AIR INLET
DIA D2AREA A2
DIA D2AREA A2
AIR PRESSURE REGULATOR
AIR INLET
=P x A P x A1 1 2 2
=P P x2 1 A2
A1
=P x 2A P x A1 1 2 2
=P P x2 1 2A1
A2
SUCTIONNON RETURN
VALVE
ISOLATIONVALVE
DRAINVALVE
VALVE ‘B’2/2 PLUNGERSPRING PILOT VALVE
AIR PRESSUREREGULATOR
VALVE ‘A’5/2 PILOT - PILOTMASTER VALVEP1
SILENCERS
A1
A2
D1
D2=OR ( (
2
D1
D2= 2OR ( (
2
INLETFILTER
AIR FILTER (40 )WITH AUTO DRAIN
F
F
OIL RESERVOIR OFAUTOLUBE PUMP
3/2 HAND SLIDE VALVE
6.01/4
Principles of Operation for Series ‘N’ Single head pneumatically operated.
6.3.1 The heart of “MERCURY” pumps is an air to liquid Intensifier or Booster which is diagrammatically shown in Fig. 2.
The pneumatic cylinder of large diameter D1 is coupled to an hydraulic cylinder of small diameter D2. When regulated compressed air at pressure P1 is applied on D1, the pressure of liquid in D2 increases as per Pascals Law.
The ratio is called the intensification ratio.
6.3.0
x D2
= =P1 x A1 P2 x A2 Where A1
P2 = P1 x 2
4A2
A1
x D12
4
A2
A1
=and A2
For high ratio pumps, area A1 is increased by coupling two pneumatic cylinders D1 to a single hydraulic cylinder D2 as shown in Fig. 3. Low pressure, low ratio pumps are called Dash 1 (Fig. 2) and high pressure, high ratio pumps are called Dash 2 (Fig. 3). Dash 1 and Dash 2 pumps can be identified by the last digit in the model number.
The air to liquid intensifier shown in Fig. 2 and Fig. 3 is converted into a pump by automatically reciprocating the pneumatic cylinder by suitable valves as shown in Fig. 4.
When regulated air at pressure P1 is supplied through 5/2 pilot-pilot master Valve A, the cylinder piston starts moving to the right. When the piston presses the inbuilt 3/2 plunger Valve B, a pilot signal is given to the right end of Valve A, causing it to reverse and the cylinder piston starts moving to the left. When the piston presses inbuilt 3/2 plunger spring Valve C, a pilot signal is given to left end of Valve A, causing it to reverse and the piston starts moving to the right. Hence the pneumatic piston starts reciprocating continuously as long as compressed air is supplied.
On the liquid side of the pump, a suction and discharge non return valve assembly is fitted. When the piston moves to the left, vacuum is created in the hydraulic cylinder and liquid is sucked in due the opening of suction non return valve. When the piston moves to the right, the suction non return valve shuts and the sucked liquid is discharged through the discharge non return valve. The constant reciprocation of the cylinder causes suction and discharge of liquid in pulses. The discharged liquid is fed into the product which has to be pressurised.
As liquid fills into the product, the pressure starts rising and when it reaches value P2, the forces in the pump balance and the pump stops reciprocating automatically. If there is any leakage in the output line, then the pump starts reciprocating automatically to compensate for the leakage and maintain output pressure P2.
Automatic lubricating system
With every operation of Valve A, an air signal is given to the AUTOLUBE Pump. The Pump injects oil at high pressure directly into the cylinder. This guarantees lubrication of the cylinder and valves. The quantity of lubrication can be infinitely varied by adjusting the stroke limiting nut on the pump.
6.3.2
6.01/66.01/5
P2
ISOLATION VALVE
PRODUCT UNDER TEST
DRAIN VALVE
NON RETURN VALVE
PREFILLCENTRIFUGALPUMP
WATER TANK
AUTOLUBE
HYDRO PNEUMATICPUMP
OUTPUT PRESSUREGAUGE
REGULATOR TO ADJUSTOUTPUT PRESSURE
AIR INLET23 TO 6 Kg/cm
NON RETURN VALVE
SUCTIONFILTER
P1
SUCTION STRAINER
HAND SLIDE VALVE
AIR FILTER (40 )
F
F
Typical Applications
6.4.1
6.4.0
6.4.2
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
FIG. 5
Typical Pressure Testing Circuit
Hydrostatic Pressure Testing
One of the most popular applications of “MERCURY” Hydro Pneumatic Reciprocating Pumps is for pressure / burst testing of Castings, Valves, Hoses, Pressure Vessels etc.
The general layout of a hydrostatic pressure testing setup is shown in Fig.5.
The product under test (ex. casting) is first prefilled with water using a low pressure, high discharge “CENTRIFUGAL PUMP”. When all trapped air escapes and the casting is fully filled, the “DRAIN” valve and the “CENTRIFUGAL PUMP” are switched “OFF” and the “HYDRO PNEUMATIC PUMP” is switched “ON” by sliding “Hand Slide Valve” forward. When pressure in gauge P2 rises to the value set in regulator P1, the “ISOLATION” valve is closed and after a slight delay the “HYDRO PNEUMATIC PUMP” should be switched “OFF” by sliding “Hand Slide Valve” backward. Any leakage in the product is detected by drop in pressure gauge P2.
After the test time, the drain valve is opened to release pressure and drain the water.
OTHER APPLICATIONS
Some of the other applications where “MERCURY” Hydro Pneumatic Pumps can be used as a low cost alternative to hand operated and motorised hydraulic pumps are:
Cyclic Pressure / life Testing of Pressure Gauges, Pressure Switches, Hoses etc.
Burst Strength Testing of pressurised vessels such as LPG / Nitrogen / Oxygen gas cylinders, storage tanks, hoses, pipes etc.
Seat leakage test of Control Valves.
Operation of Single Acting Hydraulic Cylinders used in lifting platforms, hydraulic clamps, compression moulding presses etc.
Isostatic Pressing of powder metal and ceramics.
Transferring of liquids from barrels, storage tank etc.
Pumping oil or grease in centralized lubrication systems.
6.02/1
FIG. 6
Technical Specification for Series ‘N’ Single Head Pneumatically operated
Hydro Pneumatic PumpsSeries ‘N2H’, Dual Head Pneumatically operated
FIG. 7
WATER TANK
SUCTIONSTRAINER
SUCTIONNON RETURN
VALVE
P2
ISOLATIONVALVE
DRAINVALVE
SYSTEM
AIR INLET23 TO 6 Kg/cm
A2
INLETFILTER
AIR FILTER (40 )WITH AUTO DRAIN
F
F
OIL RESERVOIR OFAUTOLUBE PUMP
3/2 HAND SLIDE VALVE
DISCHARGENON RETURN
VALVE
Pneumatic Circuit Diagram
P1
AIR PRESSURE REGULATOR
Series ‘N2H’ pumps have liquid chambers at both ends. The pump cycles similar to Series ‘N’ pumps as described in page 6.01/4.
The advantage of these pumps is that there is a constant discharge compared to the pulsating discharge of Series ‘N’ pumps. Additionally the output flow is double compared to similar size Series ‘N’ pump.
Description
INLETFILTER
SUCTIONNON RETURN
VALVE
DISCHARGENON RETURN
VALVE
SILENCER
VALVE ‘A’5/2 PILOT-PILOT MASTER VALVE
2/2 PLUNGER-SPRINGVALVE
VALVE ‘B’VALVE ‘C’
2/2 PLUNGER-SPRINGVALVE
6.02/3
G
F
EDA B C
M(M
AX.)
EXHAUST
SILENCERS
REGULATOR T
O A
DJU
ST
OUTPUT P
RESSURE
AIR
INLET
PORT ‘K
’ BSP
3/2 H
AND S
LID
E V
ALVE
LIQ
UID
‘J’ BSP
DIS
CHARGE
SUCTIO
N F
ILTER
5/2 P
ILOT-P
ILOT
MASTER V
ALVE
AUTOLUBE
PUMP
‘L’ DIA
HOLES
2/2 P
LUNGER-
SPRIN
G P
ILOT
VALVE
LIQ
UID
SUCTIO
N‘H
’ BSP
FIG. 8
Technical Specification for Series ‘N2H’ Dual Head Pneumatically operated
Series ‘NE’ pumps have a magnet imbedded in the piston. Two magnetic reed switches are mounted at each end of the cylinder barrel. The master valve is a 5/2 Double solenoid valve. The switching ON signal to each solenoid comes from its respective reed switch causing the pump cylinder to continuously reciprocate.
The liquid side of the pump is identical to the pneumatically operated pump as described in page 6.01/5
Description
+
230 VAC
MAGNETIC PISTON
6.02/5
FIG. 10
M(M
AX.)E
XHAUST
SILENCERS
REGULATOR T
O A
DJU
ST
OUTPUT P
RESSURE
3/2 H
AND S
LID
E V
ALVE
AIR
INLET P
ORT
‘K’ BSP
SUCTIO
N F
ILTER
AUTOLUBE
PUMP
5/2 S
OLENOID
-SOLENOID
MASTER V
ALVE
REED S
WIT
CH
‘L’ DIA
HOLES
A B
C
D E
F
G
LIQ
UID
SUCTIO
N‘H
’ BSP
LIQ
UID
DIS
CHARGE
‘J’ BSP
Technical Specification for Series ‘NE’ Single Head Electrically operated
59-0
01E
59-0
02E
59-0
03E
59-0
04E
59-0
05E
59-0
42E
59-0
06E
59-0
07E
59-0
08E
59-0
09E
59-0
10E
59-0
11E
59-0
25E
59-0
51E
59-0
52E
59-0
53E
59-0
12E
59-0
13E
59-0
14E
59-0
15E
59-0
16E
SE
AL
KIT
No
.
80-1
0-1
E80-1
4-1
E80-1
6-1
E80-2
0-1
E80-2
8-1
E80-3
2-1
E100-1
0-1
E100-1
4-1
E100-1
6-1
E100-2
0-1
E100-2
8-1
E100-3
2-1
E100-5
6-1
E160-1
6-1
E160-2
0-1
E160-2
8-1
E160-3
2-1
E160-4
0-1
E160-5
6-1
E160-1
4-2
E160-2
0-2
E
64
32
25
16 8
6.25
100
51
39
25
12.75
9.75
3100
64
32
25
16 8
260
128
320
160
125
80
40
31
500
255
195
125
64
49
15
500
320
160
125
80
40
1300
640
303
303
303
303
303
318
313
313
313
313
313
313
350
390
390
390
390
390
390
558
558
343
343
343
343
343
358
359
359
359
359
359
359
394
440
440
440
440
440
440
639
639
446
540
540
540
540
545
479
539
539
539
539
539
473
530
530
530
530
530
530
690
690
63
63
63
63
63
63
75
75
75
75
75
75
75
115
115
115
115
115
115
115
115
98
98
98
98
98
98
118
118
118
118
118
118
118
185
185
185
185
185
185
185
185
76
67
67
67
67
90
76
67
67
67
67
90
90
90
90
90
90
82
82
76
76
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
¾”
½”
½”
½”
½”
¾”
¾”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
½”
½”
½”
½”
½”
½”
½”
½”
12
12
12
12
12
12
14
14
14
14
14
14
14
18
18
18
18
18
18
18
18
245
245
245
245
245
245
260
260
260
260
260
260
260
382
382
382
365
365
365
365
365
0.60
1.20
1.60
2.50
4.90
5.60
0.50
1.10
1.40
2.20
4.30
4.80
12.30
1.20
1.90
3.10
4.00
5.00
9.80
0.80
1.60
479
475
473
467
453
388
656
653
651
646
634
536
397
1440
1436
1187
1182
934
906
1201
1196
FREE A
IRCONSUMPTIO
NLITRES / M
IN.
FREE
DISCHARGE
LITRES / M
IN.
M E
F G
HBSP
A B
C D
JBSP
KBSP
Ø L
OUTPUT
PRESSURE 2
AT 5Kg/cm
RATIO
MODEL
No.
215
215
215
215
215
215
215
215
215
215
215
215
215
163
163
177
280
280
280
280
280
6.02/6
WATER TANK
SUCTIONSTRAINER
SUCTIONNON RETURN
VALVE
P2
ISOLATIONVALVE
DRAINVALVE
SYSTEM
A2
INLETFILTER
OIL RESERVOIR OFAUTOLUBE PUMP
DISCHARGENON RETURN
VALVE
Hydro Pneumatic PumpsSeries ‘N2HE’, Dual Head Electrically operated
Pneumatic Circuit Diagram
FIG. 11
Description
Series ‘NE’ pumps have a magnet imbedded in the piston. Two magnetic reed switches are mounted at each end of the cylinder barrel. The master valve is a 5/2 Double solenoid valve. The switching ON signal to each solenoid comes from its respective reed switch causing the pump cylinder to continuously reciprocate.
The liquid side of the pump is identical to the pneumatically operated pump as described in page 6.01/5
MAGNETIC PISTON
VALVE ‘A’5/2 SOLENOID-SOLENOIDMASTER VALVE
3/2 HAND SLIDE VALVE
AIR PRESSUREREGULATOR
AIR FILTER (40 )WITH AUTO DRAIN
F
F
P1
SILENCERS
AIR INLET23 TO 6 Kg/cm
+
230 VAC
6.02/7
‘L’ DIA
HOLES
5/2 S
OLENOID
-SOLENOID
MASTER V
ALVE
AUTOLUBE
PUMP
SUCTIO
N F
ILTER
A B C
REED S
WIT
CH
EXHAUST
SILENCERS
REGULATOR T
O A
DJU
ST
OUTPUT P
RESSURE
AIR
INLET
PORT ‘K
’ BSP
3/2 H
AND S
LID
E V
ALVE
M(M
AX.)
LIQ
UID
‘J’ BSP
DIS
CHARGE
G
F
ED
LIQ
UID
SUCTIO
N‘H
’ BSP
FIG. 12
Technical Specification for Series ‘N2HE’ Dual Head Electrically operated
59-0
76E
59-0
60E
59-0
61E
59-0
77E
59-0
78E
59-0
59E
59-0
63E
59-0
54E
59-0
72E
59-0
71E
59-0
73E
59-0
70E
59-0
55E
59-0
58E
59-0
75E
80-1
4-2
HE
80-1
6-2
HE
80-2
0-2
HE
80-2
8-2
HE
80-3
2-2
HE
100-1
4-2
HE
100-1
6-2
HE
100-2
0-2
HE
100-2
8-2
HE
100-3
2-2
HE
100-5
6-2
HE
160-2
0-2
HE
160-3
2-2
HE
160-4
0-2
HE
160-5
6-2
HE
31
24
15 7
5.25
50
38
24
11.75
8.75
2 64
24
15 7
155
120
75
35
26.25
250
190
120
58
43
10
320
120
75
35
303
303
303
303
318
313
313
313
313
313
350
390
390
390
390
343
343
343
343
358
359
359
359
359
359
394
440
440
440
440
727
727
727
727
727
764
764
764
764
764
764
773
773
773
773
63
63
63
63
63
75
75
75
75
75
75
115
115
115
115
98
98
98
98
98
118
118
118
118
118
118
185
185
185
185
99
99
99
99
122
99
99
99
99
122
122
114
122
114
114
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
¾”
½”
½”
¾”
¾”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
½”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
¼”
½”
½”
½”
½”
12
12
12
12
12
14
14
14
14
14
14
18
18
18
18
2.52
2.88
4.20
9.00
10.80
2.20
2.10
2.90
8.60
7.50
22.14
3.80
5.70
9.00
17.64
FREE A
IRCONSUMPTIO
NLITRES / M
IN.
FREE
DISCHARGE
LITRES / M
IN.
M E
F G
HBSP
A B
C D
JBSP
KBSP
Ø L
OUTPUT
PRESSURE 2
AT 5Kg/cm
RATIO
MODEL
No.
215
215
215
215
215
215
215
215
215
215
215
280
280
280
280
475
473
467
453
388
653
651
646
634
536
397
1436
1182
934
906
185
185
185
185
185
185
200
200
200
200
200
300
300
300
300
SE
AL
KIT
No
.
6.03/1
Tseries “AB” Air BoostersSpare Parts for Hydro Pneumatic Pumps