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Sprague Products 
Air-Driven Hydraulic Pumps

Rugged, Service-Proven and Virtually Maintenance Free
A variety of Sprague Products hydraulic pumps is offered for various liquid output pressure up to 33,500 psi (2311 bar). Sprague Products pumps service water, oil and most corrosive chemicals. Sprague Products pumps are rugged, service-proven and virtually maintenance-free.

The Sprague Products positive-displacement type pump converts air inlet pressure to hydraulic output pressure. The pump uses low pressure air to act on a large area piston to produce high hydraulic pressure with a small area piston.

In operation, the Sprague Products pump reciprocates rapidly until the system liquid pressure nears the desired level, then slows to a stop when the liquid pressure equals or balances the air pressure. This liquid-air pressure balance is maintained indefinitely in a holding condition with minimal energy consumption and with no increase in fluid temperature or parts movement.

In contrast, an electric motor-driven pump in a holding condition must continue to operate to maintain a pressure level. Excess liquid must be bypassed or recirculated back to the reservoir, resulting in energy-loss, heat build-up, and the need to bypass components and a larger reservoir.

The Sprague Products pump is efficient in operation and simple in design, providing the user with cost-effective and energy-saving benefits for many industrial and research applications when compared to other types of hydraulic pumps.

Hydrostatic testing
The Sprague Products air-driven pump offers economic advantages for the pressure testing of hoses, pipes, valves, fittings and other hydraulic vessels and products. The time-saving and performance advantages offered by Sprague Products pumps allow routine production testing to be converted from tedious hand-pump methods to automatic and precision testing methods.

Production machinery 
The Sprague Products air-driven pump delivers high pressure liquids required by production machinery for holding, clamping, forming, shearing, punching, etc. Example of application is a hydraulic press where long holding cycles are necessary or where the work stroke is short and a high force is required. High and low volume Sprague Products pumps can be combined to produce a combination of high speed and high force at low cost.

Eliminates central power source
Because Sprague Products air-driven pumps are relatively small, they can be installed directly on individual machines or test equipment in several or separate locations as direct power sources. Pumps so mounted eliminate need for a central power system, long plumbing runs and excess hydraulic power capacity.

Simpler design
Sprague Products pumps do the same job as other air-driven pumps but with fewer parts and seals, and therefore less maintenance.

For more information call 440- 838-7690 
or email sprague@sprague.curtisswright.com

How the pump works

Applying the priciple of differential areas
The Sprague Products pump develops high output pressures by applying the principle of differential areas. The pump has a large area air piston, air-driven at low pressures. This air piston drives a small area liquid piston that in turn pumps liquids at high pressures. 

 

The liquid output pressure is determined by the ratio between the area of the air drive piston, the area of the liquid driven piston and the applied operating air pressure. 

The area relationship of the air piston to the liquid piston is referred to as the pump ratio. This pump ratio is indicated in the dash number which follows the pump model basic number: 

Example: S-216-J-10 pump has an approximate ratio of 10 to 1 or 10 psi liquid pressure for each 1 psi of operating air pressure.

In operation, an #-216-J-10 pump using 100 psi of input air pressure will produce a maximum liquid output pressure of 1000 psi; 80 psi air will produce an output pressure of 800 psi; 60 psi air…600 psi output, and 40 psi air…400 psi output.
By regulating the incoming air supply at the pressure regulator, the liquid output can be infinitely adjusted through the pump''s pressure range.

Wetted section materials
The materials used in the wetted section of the Sprague Products basic pump are compatible to most liquids to be serviced. Pump components and materials included:

• Liquid Body: 303 Stainless Steel
• Liquid (driven) Piston: 416 Stainless Steel Chrome Plated
• Piston O-Ring: Nitrile
• Piston Back-up Ring: Teflon (or equivalent compound)
• Check Valve Body: 416 Stainless Steel
• Check Valve Poppet: 17-4ph Stainless Steel
• Check Valve Spring: 302 Stainless Steel
• Check Valve Seal: Nitrile

Accessories
For optimum efficiency, certain accessories are recommended for use with pump. Noise can be dampened by installing muffler at pump''s air exhaust port. For "J" type lubricated pumps and boosters, install an air control unit (filter, pressure regulator with air gauge and lubricator) in the supply line. For "JN" type non-lubricated pumps and boosters, install an air control unit (without lubricator) in the air supply line. These and other related accessory items are available from Sprague Products.

How the pump works

Applying the principle of differential areas
The PowerStar™ 4 pumps develop high output pressures by applying the principle of differential areas. The pump is a large area air piston (air-driven at low 20 to 100 psi pressures). This air piston drives a small area liquid piston that pumps liquids to high pressures.

The liquid output pressure is determined by the ratio between the area of the air drive piston, the area of the liquid drive piston and the applied driving air pressure. The relationship of the area of the air piston to the liquid piston is referred to as the pump ratio which is indicated by the number following the air module number (P4).




Operation
In operation, the P45 pump using 100 psi of input air pressure could produce a maximum liquid output of 520 psi; 80 psi air - 416 psi output; 60 psi air - 312 psi output; and 40 psi air - 208 psi output. Output pressures will vary and be reduced by 5 to 10% through internal friction depending on the lubricity of the liquid. 


By regulating the incoming air supply at the pressure regulator, the liquid output can be infinitely adjusted through the pump''s pressure range.

Pump Performance

Solid lines indicate approximate flows at various driving air pressures. Dotted lines indicate air consumption.
Examples:

1. With 100 psi (6.8 bar) driving air, the pump will consume 50 SCFM (1l41 NM3/MIN) at an operating pressure of 1,000 psi (68 bar) and will produce an outlet flow of 358 Cu.In./Min. (5.9 LPM).
2. If the volume of compressed air is reduced to 20 SCFM (.57 NM3/MIN), the flow will be reduced to 225 Cu.In./Min. (15.3 Liters). Shaded area indicated flow reduction.

Notes:
Most air compressors will produce 4 to 5 SCFM of compressed air per horsepower at 100 psi.

All air-driven pumps will operate on low air volumes as long as the supply of air is sufficient to overcome minor internal leakage and operate the air selector valve.

Performance charts are based upon air supply pumping potable water with flooded suction.

Selecting a Gas Booster
In general, an air or gas charging application requires a specific volume to be brought to a specific pressure within a given amount of time. The adjacent Tables will assist you in selecting the most efficient ratio Sprague Products booster for your application requirements. A typical hose pressure testing application:

1. Hose with one cubic foot volume is to be pressure tested at 500 psig. Pressure level is to be reached in three minutes. Available shop air is 150 psi.
2. Using Table 1, Low Pressure Gas Boosters Performance, page 22, find the required receiver pressure of 500 psi. Compare the figures found in the 500 psi discharge pressure column to the desired time of three minutes. The column figures nearest to three minutes is 2 minutes, 45 seconds with a discharge rate of 4.4 standard cubic feet per minute. So, the 5:1 ratio booster will do this job more efficiently than a 15:1 ratio booster. 
   
   
3. Note that the booster driving air pressure and above calculations are based on 100 psi, so the shop air pressure of 150 psi must be reduced to 100 psi driving air to operate the booster. Shop air of 150 psi should still be supplied to the inlet port of the compressing portion of the booster. The higher the precharge inlet pressure, the faster the discharge outlet pressure will be reached.
4. For the above hose test, the S-86-JN-5 booster or S- 486-JN-5 booster power unit could be used

How the Sprague Products Boosters Work
The Sprague Products gas booster is a piston-type, air-operated booster. It uses a mechanically operated, snap-action air selector valve to cycle the booster.

The Sprague Products booster, like Sprague Product air-driven hydraulic pumps, employ the piston differential areas principle - a large area air piston, driven at low air pressure to drive a small area compression piston which converts input gas to higher pressure, lower volume output gas.

The booster gas output or discharge pressure developed by the compression piston is determined by the ratio between the area of the air piston, the operating air pressure and the available precharge pressure. The function of the precharge pressure to the booster is to charge the high pressure cylinder inside the booster with gas, reducing the time required to reach higher pressures, and the time to return the compression piston and the air piston for the next compression cycle.

The Sprague Products booster works rapidly to reach the required pressure then stops at a pressure balance. The booster will hold the pressure balance indefinitely with minimal energy consumption, heat build-up or parts movement. When a pressure imbalance occurs, the booster will automatically restart to restore the pressure balance.

By using a pressure regulator on the operating air supply line, the outlet gas pressure can be accurately adjusted to any pressure level between the precharge pressure and the maximum discharge pressure.

With some Sprague Products booster models, the pumping or high pressure section is cooled with exhaust air piped from the air-driving section of the booster. In other boosters the pumping section employs external fins to dissipate the heat.

Compared to other air-operated gas boosters on the market, the Sprague Products booster does the same job but with fewer moving parts and seals, thus less maintenance is required over its service life.

Cost Effective Shop Air and Bottled Gas

Application Efficiency Ratio
Sprague Products pneumatic boosters offer a cost effective way to compress shop air or bottled gas to meet various requirements for higher pressure, lower volume air or gas.

Industrial applications include charging accumulators, inflating high pressure tires or charging shock struts from lower pressure supply sources, the transferring of gas from a supply cylinder to another container or the actuating of air chucks in machine tools. Where production machinery or test setups require higher air pressures than normally provided by the shop air system, Sprague Products boosters can provide the extra muscle needed to operate the equipment.

The Sprague Products booster can be installed as a component or can be supplied as a complete, ready-to-use power package. Use of the Sprague Products booster power unit eliminates the need to develop the basic power supply circuit, the time to select and buy the needed accessories and the time required to test and troubleshoot the circuit.

Because of their compact size and low cost, Sprague Products boosters can be combined in high-low combinations to meet higher flow and pressure requirements. Sprague Products boosters and other Sprague Products pneumatic products are designed to a 4 to 1 minimum safety factor.

A variety of Sprague Products boosters have been developed to convert precharge low gas pressures to higher gas pressures.

Quiet, Low Air Consumption
Offset Your Air Pressure Needs
The PowerStar 4B gas booster used the differential piston area principle to operate. It features low air consumption, quiet operation, optional mechanical separation, and compatibility with a wide range of common gases. 

The PowerStar 4B booster is a reciprocating, single or double acting or dual stage air operated design, using an air-piloted unbalanced type air directional valve to cycle the booster. It is designed to make optimum use of commercially bottled gases as low as 50 psi. The booster is applicalbe across a variety of industries including aerospace, automotive, chemical, fire protection, agriculture, fluid power, machine tool, plastics, and packaging.

The Principles of Operation
The PowerStar™4B gas booster operates on the differential piston area principle. A large area piston, driven at low air pressures, drives a small area compression piston which converts input gas to higher pressure. The output gas or discharge pressure is determined by the ratio between the area of the drive piston, the operating air pressure and the available precharge pressure supply. 

The function of the precharge pressure is to charge the high pressure cylinder inside the booster with gas, reducing the time needed to reach higher pressures. In double-ended gas boosters, the precharge gas adds power to the compression stroke.

The Actual Operation 
The PowerStar™4B gas booster works rapidly at first, then slows and stops at a pressure balance. The booster holds the pressure balance indefinitely, assuming no leakage. When a pressure imbalance occurs, the booster automatically restarts and restores the pressure balance. During operation, exhaust air from the air drive section cools the high pressure boosting chamber.

The Gas Booster in Action 
Whether you use gas above normal cylinder pressure or require continuous high pressure and want to get the most out of the cylinder''s gas supply, the PowerStar™4B Series is for you! It assures the optimum use of commercially-bottled gas. Some units draw a vacuum.

Increase Air Pressure by 4 to 1
Offset Your Air Pressure Needs
Air amplifiers are air driven and can be used to increase available air pressure by a ratio of 4:1.

Outlet pressure up to 500 psi (35 bar) can be easily achieved. 

Wherever your air pressure is too low, use an air amplifier to increase local pressure. 

Save major changes to existing systems.

Amplifier Types (Weights & Porting)

Amplifier Air Differential Piston
When Greater Pressure is Required
When a compression ratio greater than 2:1 is required, an air amplifier with differential piston is used. 

A relatively small pressure applied to the large piston area, results in a much larger pressure generated on the smaller area at the base of the plunger.

Dividing the large area/small area gives the compression ratio.

Once the required pressure is achieved, the forces on top of the piston balance with the forces on the bottom of the plunger, and the air amplifier stroke stops.

No further energy is used to maintain the required pressure.

Unique Sprague Design Features:

• Simple design
• Small and robust
• Competitive
• Easy installation
• Few moving parts
• Little maintenance required
• No electrics required
• No mechanical drive required
• Continuous stop/start with no adverse effect
• No energy used once holding pressure is reached
• No heat generated once holding pressure is reached
• No cooling medium required
• Outlet pressure easily set with simple air regulator
• High pressures easily achieved.

Increase Air Pressure by 4 to 1
Offset Your Air Pressure Needs
Curtiss-Wright Flow Control, Sprague Products, introduces PowerStar™, an air driven air amplifier used for pressure testing, to increase force on clamps and presses, and in other factory applications. Curtiss-Wright Flow Control is an Curtiss-Wright Company. 

The PowerStar air amplifier design offers greater efficiency and is modular for increased versatility. It provides higher output pressure without expensive modifications to existing compressed air systems. The PowerStar air amplifier supplies up to 500 psi (35 bar) and flows to eight SCFM (226 liters N/min). 

The PowerStar is easy to install, without need of electrical or mechanical drive. Non-lubricated with no external muffler, it requires minimal maintenance. 

Curtiss-Wright Flow Control, Sprague Products, is a leading supplier of pumps and boosters to the petrochemical, utility, aerospace and industrial markets. 

Curtiss-Wright Incorporated is a group of technology-based manufucaturing businesses with significant concentration in speialty metals, complemented by aerospace and electornics, industrial, and consumer products.

Increase Air Pressure by 4 to 1
Offset Your Air Pressure Needs
Air amplifiers can be supplied as individual items or as a complete air amplifier station assembly. 

Common Control Arrangements:

• Inlet pressure regulation
• Outlet pressure regulation
• Maximum pressure control
• Remote stop/start
• Extra pressure at end of stroke

PowerStar 4 Air Amplifiers
Boost shop air or inert gas to 400 psi. Available for shipment now!

Hydraulic Valves 
Car Carrier Solutions
Mobile Hydraulic Directional Control Valves are used on car carriers to provide smooth operation, low pressure drop and rapid response for precise fluid control in a lightweight constructed valve. These valves are rated at 2000 psi and flows to 10 gpm. Lightweight aluminum construction.