Advanced Air Driven Pump System

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Sprague Products
Sprague Products

Division of Curtiss-Wright Flow Control Corporation Division of Curtiss-Wright Flow Control Corporation

10195 Brecksville Road, Brecksville, Ohio 44141 440-838-7690 FAX: 440/838-7513 www.cwfc.com
Sprague Products U.K.: 202 St. Andrews Road, Bridport, Dorset DT6 3B6 (0) 1308 422256 FAX: (0) 1308 427760
Sprague Products 2004
Part No: ADH-5M0704 T E C H N O L O G Y T H A T C H A N G E S E V E R Y T H I N G
 ADVANCED AIR DRIVEN PUMP SYSTEM DIMENSIONS, WEIGHTS & PORTING

HIGH EFFICIENCY AIR VALVE INTERNAL MUFFLER SINGLE ENDED DOUBLE ENDED
Will not hang-up Reduces noise
More liquid ow (less air consumption) Minimizes icing
.31 in x 62 in. SLOTTED HOLE 4 PLCS
Cools pump module (7.88 mm X 15.76 mm) B
.31 in x 62 in. SLOTTED HOLE 4 PLCS
(7.88 mm X 15.76 mm)
More compact 2.00 in. (50.80 mm)
AIR INLET
3/8 NPTF
3/8
LIQUID OUTLET
(SEE CHART) 4.05 in (102.93 mm)
2.00 in. (50.80 mm) AIR INLET
3/8 NPTF
3/8
1.40 in (35.57 mm) TYP
TYP.
TYP
TYP. TYP
TYP. TYP
TYP.
B B
PUMP MODULE LIQUID OUTLET
(SEE CHART)
LIQUID OUTLET
(SEE CHART)
8 Pressure ratios to 33,000 psi
EXHAUST EXHAUST
AIR

MAX. OUTLET PRESSURE

SER. NO.
MODEL NO.

PSIC
AIR

PSIC
6.34 in.
(161.04 mm) 6.34 in.

F4
(161.04 mm)

DATE
MAX. OUTLET PRESSURE
DATE
MAX. OUTLET PRESSURE

DA
DA
4.50 in. 4.50 in.
5.58 in. (114.30 mm) 5.58 in. (114.30 mm)

DA
DATE
(141.73mm) (141.73mm)

F4
F4

MODEL NO.
MODEL NO.

SER. NO.
SER. NO.

PSIC
EXHAUST EXHAUST
AIR AIR

A A
LIQUID INLET LIQUID INLET
(SEE CHART)
A .88 in. (22.42 mm) (SEE CHART)
.88 in. (22.42 mm)
LIQUID INLET
(SEE CHART)

STAINLESS STEEL 4.72 in. (119.91 mm)

4.63 in. (117.63 mm)
4.63 in. (117.63 mm)
Suitable for virtually
all services
.90 in. (22.86 mm) .90 in. (22.86 mm)
TYP TYP

6.03 in. 6.03 in.

(153.37 mm) (153.37 mm) 4.52 in.
4.52 in.
(114.68 mm) (114.68 mm)
5.92 in. 5.92 in.
TYP (150.37 mm)
(150.37 mm)

2.33 in. 2.33 in.

SELF-LUBRICATING SEALS TEFLON SEALS INTERNAL CHECK VALVES (59.18 mm)
TYP
(59.18 mm)
TYP
Suitable for clean rooms Oversize ow path permits
Compatible with most liquids
Eliminates pre-lubrication highest ow rates 3.08 in. (78.30 mm)
Maximum seal life 3.95 in. (100.33 mm) 3.08 in. (78.30 mm) 3.95 in. (100.33 mm)
Eliminates exhaust air contamination Easy to service TYP TYP
Easy to service 3.22 in. (81.78 mm) 3.22 in. (81.78 mm)
TYP
Other seals and materials available 7.46 in. (189.56 mm)
TYP 10.12 in. (256.92 mm)
7.78 in. (197.69 mm) 10.39 in. (263.88 mm)

NOTE: Double ended units, fully plumbed, available upon request.

Approx.
Pump Inlet Port Outlet Port Inlet Port Shipping
HOW THE PUMP WORKS Model Liquid Liquid Air Weight

The PowerStar 4 pumps develop high output pressures by In operation, the P45 pump using 100 psi of input air pressure P45 3/4 NPTF
3/4 1/2 NPTF
1/2 3/8 NPTF
3/8 16 lbs (7.26 Kg)
applying the principle of differential areas. The pump has a large could produce a maximum liquid output of 480 psi; 80 psi air P410 3/4 NPTF
3/4 1/2 NPTF
1/2 3/8 NPTF
3/8 16 lbs (7.26 Kg)
area air piston (air driven at low 5 to 100 psi pressures). This - 370 psi output; 60 psi air - 270 psi output; and 40 psi air - 180
P421 1/2 NPTF
1/2 3/8 NPTF
3/8 3/8 NPTF
3/8 16 lbs (7.26 Kg)
air piston drives a small area liquid piston that pumps liquids to psi output. Output pressures will vary and be reduced by 5 to
high pressures. 10% through internal friction depending on the lubricity of P434 1/2 NPTF
1/2 3/8 NPTF
3/8 3/8 NPTF
3/8 16 lbs (7.26 Kg)
the liquid. P464 1/2 NPTF
1/2 3/8 NPTF
3/8 3/8 NPTF
3/8 16 lbs (7.26 Kg)
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 By regulating the incoming air supply at the pressure regulator, P4114 3/8 NPTF
3/8 9/16-18 NBS 3/8 NPTF
3/8 16 lbs (7.26 Kg)
the applied driving air pressure. The relationship of the area of the liquid output can be innitely adjusted through the pumps
P4203 3/8 NPTF
3/8 9/16-18 NBS 3/8 NPTF
3/8 16 lbs (7.26 Kg)
the air piston to the liquid piston is referred to as the pump ratio pressure range.
which is indicated in the number following the air module P4333 3/8 NPTF
3/8 9/16-18 NBS 3/8 NPTF
3/8 16 lbs (7.26 Kg)
number (P4). DOUBLE ENDED Same Same Same 21 lbs (9.53 Kg)
Example: The P45 pump has a nominal ratio of 5 to 1 or
5 psi liquid pressure for each 1 psi of operating air pressure.

TEFLON is a registered trademark of the E. I. du Pont de Nemours & Co.

2 7
 PART IDENTIFICATION

Air Liquid Sep Air Pressure

COMPLETE UNIT EXAMPLES (using a 64:1 ratio):
Module Module Kit Controls Controls
Standard 64:1 ratio pump ............................ P464 P4 4F64 4SK64 4ACKIT P The modular PowerStar 4 System features The PowerStar 4 System is ideal for
Separated 64:1 ratio pump.......................... P4S64 Air Motor Module P4 1 A patented design Hydrastatic testing of pressure vessels using various
One common air motor module for all eight ratios liquids (avoid running the pump dry or sudden release
Double ended 64:1 ratio pump.............. S64P4S64 Liquid Pump Module 4F64 1
of outlet pressure)
Single Air & Liquid Module P464 1 1 Easy conversion to separated (non-contaminating)
Double ended 64:1 ratio pump conguration Low volume, high pressure testing
w/ air controls .....................................S64P4S64C Single Separated P4S64 1 1 1 Low volume, liquid transfer (higher pressure capability
A double-ended unit that provides even higher ows
Double ended 64:1 ratio pump w/ air Double Ended S64P4S64 1 2 2 than double diaphragm pumps)
Safe operation in hazardous environments
and high pressure controls ...............S64P4S64CP
Double Ended w/ Air S64PS64C 1 2 2 1 Automatic shut-off at set pressure
Double Ended w/ Air & Pressure Stainless steel wetted parts
Controls S64P4S64CP 1 2 2 1 1
Easy assembly and service for air motor and high pressure
modules (eld assembly requires careful alignment; see
Assembly & Operating Instructions)
HOW TO ORDER Nominal liquid module displacements are as follows:
To order a hydraulic pump, the ratio of the pump must 5:1 2.4 cu in
be selected. 10:1 1.2 cu in
21:1 .6 cu in
P4-( ) ( )-P4-( )
Dene the liquid pressure and ow requirements for the applica-
34:1 .37 cu in
tion as well as the available air pressure and volume; then refer to
the Pump Performance Charts on pages 4 & 5. 64:1 .2 cu in
114:1 .11 cu in
From the chart, select a pump that exceeds the requirements. 203:1 .06 cu in
Drive air may be throttled if ow must be reduced.
333:1 .04 cu in
Use this pump liquid module ratio number and add it to the end
of the pump air motor module number. Example: P45.

PUMP NUMBERING SYSTEM Separation Kits

(Required on both sides of Double ended Pumps)

Ratio Model Number Kit Number

Typical Models Model Number 5:1 4SK5
Standard 64:1 Ratio Pump ........ P464 10:1 4SK10
21:1 4SK21
w/ separator kit ......................... P4S64 Pump Modules 34:1 S 4SK34 Pump Modules
w/ air controls ........................... P464C 5:1 Ratio
64:1 4SK64
5:1 Ratio
Model: 5; P/N 4F5 114:1 4SK114 Model: 5; P/N 4F5
w/ pressure & air controls ........ P464CP 203:1 4SK203
10:1 Ratio 333:1 4SK333 10:1 Ratio SINGLE ENDED DOUBLE ENDED
Double ended Model: 10; P/N 4F10
Separation Kits do not change pump dimensions.
Model: 10; P/N 4F10
64:1 Ratio Pump* ..................... S64P4S64
21:1 Ratio 21:1 Ratio
* Double ended pumps require separation Model: 21; P/N 4F21 Air Motor Model: 21; P/N 4F21
Module
* on both sides
34:1 Ratio Model: P4 34:1 Ratio The PowerStar 4 System is suitable for most water applications
P/N P4
Model: 34; P/N 4F34 Model: 34; P/N 4F34 Cleanliness and lubricity of liquid being pumped will affect pump seal life.
Nitrile is the standard elastomer. 64:1 Ratio Component Kits 64:1 Ratio A ve-micron inlet lter is recommended.
The pumps can be furnished with other Model: 64; P/N 4F64 Description Model Number Kit Number Model: 64; P/N 4F64
For applications that contain highly contaminated air and/or liquids, contact the Factory.
o-rings: Viton, EPR, Neoprene. 114:1 Ratio
Air Control Kit C 4ACKit
114:1 Ratio
(includes regulator
regulator, filter
Model: 114; P/N 4F114 gauge, & shut-off valve) Model: 114; P/N 4F114
4PC5
203:1 Ratio 203:1 Ratio
4PC10
Model: 203; P/N 4F203 Model: 203; P/N 4F203
Pressure Control Kit P 4PC21
(includes manifold, 4PC34
333:1 Ratio gauge, and bleed valve) 333:1 Ratio
Model: 333; P/N 4F333 4PC64 Model: 333; P/N 4F333
4PC114
4PC203
4PC333

6 3
 PERFORMANCE

P45 Pump P410 Pump P421 Pump

Air Consumption Standard Cubic Feet Per Min. SCFM Air Consumption Standard
Standar Cubic Feet Per Min. SCFM Air Consumption Standard
Standar Cubic Feet Per Min. SCFM
SAMPLE PERFORMANCE CHART (Air Consumption Normal Cubic Meters Per Min. NM3)
20 30 40 50
(Air Consumption Normal Cubic Meters Per Min. NM3)
20 30 40 50
(Air Consumption Normal Cubic Meters Per Min. NM3)
20 30 40 50
(.57) (.84) (1.12) (1.41) (.57) (.84) (1.12) (1.41) (.57) (.84) (1.12) (1.41)

40:1 PUMP (SAMPLE ONLY)

137.9
Air Consumption Standard Cubic Feet per Min. SCFM 500 10
0
34.5 1,000 68.9 2,000

100

100
PS
I(
(Air Consumption Normal Cubic Meters Per Min. NM 3)

PSI

PSI
6.
9
B

(6 .
(6.9
OUTLET PRESSURE BAR

OUTLET PRESSURE BAR

OUTLET PRESSURE PSI

OUTLET PRESSURE PSI

OUTLET PRESSURE BAR

OUTLET PRESSURE PSI
110.3

AR
400 27.6 1,600

9B
800 55.2

BA
)A

AR
80

80
IR

80
PS

)A
)A
P
I(

PS
SI

IR
IR
20 30 40 50 5.
5B

(5.

I (5
AR
(.57) (.84) (1.12) (1.41)

.5
)A

BA
300 20.7 600 41.4 1,200 82.7

BA
IR

60

R)

60

R
60

A
P

)A
PS
IR
PS

SI
Outlet Pressure BAR

I(

IR
I (4

(4

4.
.13

.1
Outlet Pressure PSI

13
BA

3
R)

BA
BA
AIR )A 40
200 13.8 800 55.2

R)
400 IR 27.6 PS
40 P PS

40
I(

AI
SI ( I( 2.

R
2.7 2.7 75
100 PSI (6. 5 BA 5 BAR BA
4,000 8) B A R 276 R)
A IR )A
R)
AI
) IR R
100 6.9 200 13.8 400 27.6
80 PS
SI (5.4
4) BAR)
3,000 207
60 PSI (4.08
) BAR) FLOW ~ GPM 1 2 3 4 5 FLOW ~ CU. IN./MIN. 100 200 300 400 500
FLOW ~ CU. IN./MIN. 200 400 600 800
2,000 138 FLOW ~ LPM 3.8 7.6 11.4 14.1 18.9
40
0 PS
SI (2.7 1 FLOW ~ LPM 3.28 6.55 9.83 13.11
2 BAR
)
1,000
2 69
P434 Pump P464 Pump S64 P4S64 Double Ended Pump
Air Consumption Standard Cubic Feet Per Min. SCFM Air Consumption Standard Cubic Feet Per Min. SCFM Air Consumption Standard Cubic Feet Per Min. SCFM
Flow - Cu. In./Min. > 100 200 300 400 (Air Consumption Normal Cubic Meters Per Min. NM3) (Air Consumption Normal Cubic Meters Per Min. NM3) (Air Consumption Normal Cubic Meters Per Min. NM3)
Flow - (Liters/Min.) > (1.6) (3.28) (4.92) (6.55) 20 30 40 50 20 30 40 50 20 30 40 50
(.57) (.84) (1.12) (1.41) (.57) (.84) (1.12) (1.41) (.57) (.84) (1.12) (1.41)
3,600 6,400 441
100 10
6,000 PSI 413.7 6,000 0P 413.7
(6. SI
Solid lines indicate approximate ows at various driving air 9 B
(6

.9
10
pressures. Dotted lines indicate air consumption.

AR

BA
0
5,000 80 344.7

)A
3,000 206.8 5,000 344.7

PS

R
80 P S PS

)A
IR
I(
I (5 I(

6.

IR
.5 5.

9
5 BA

BA

BA
R)

R)
80

R)
AI

OUTLET PRESSURE BAR

PS

AI

OUTLET PRESSURE BAR

OUTLET PRESSURE BAR

OUTLET PRESSURE PSI

OUTLET PRESSURE PSI

OUTLET PRESSURE PSI

I (5 R

AI
R
2,400 .5 165.5 4,000 275.8 4,000 275.8

R
B AR 60 PS
60 P I (4.1

EXAMPLES:
)A SI 3B
(4 .13 AR
)A

IR
60 PSI BA IR
( 4 .1
3B 3,000 206.8

R)
1,800 AR 124 3,000 206.8

AI
40
1 With 100 PSI (6.8 BAR) driving air, the pump will consume )A PSI

R
IR
(2.7
5B
AR )
50 SCFM (1.41 NM 3/MIN) at an operating pressure of 1,000 PSI (68 40 PSI (2.75 B
AR) A
IR 2,000
40 PSI (2
2.75
BAR
)A 2,000
AIR
137.9
1,200 82.7 137.9
BAR) and will produce an outlet ow of 358 Cu. In./Min. (5.9 LPM). IR

2 If the volume of compressed air is reduced to 20 SCFM 600 41.3 1,000 68.9 1,000 68.9

(.57 NM3/MIN), the ow will be reduced to 225 Cu. In./Min.

(15.3 Liters). Shaded area indicated ow reduction.
FLOW ~ CU. IN./MIN. 50 100 150 200 250 FLOW ~ CU. IN/MIN. 25 50 75 100 150 FLOW ~ CU. IN./MIN. 40 80 120 160 200 240
FLOW ~ CC/MIN. 819 1638 2458 3277 4096 FLOW ~ CC/MIN 409 819 1229 1638 2458 FLOW ~ CC/MIN. 655 1311 1966 2621 3277 3932

NOTES:
Most air compressors will produce 4 to 5 SCFM of compressed air per P4114 Pump P4203 Pump P4333 Pump
Air Consumption Standard Cubic Feet Per Min. SCFM Air Consumption Standard Cubic Feet Per Min. SCFM Air Consumption Standar
Standard Cubic Feet Per Min. SCFM
horsepower at 100 PSI. (Air Consumption Normal Cubic Meters Per Min. NM3) (Air Consumption Normal Cubic Meters Per Min. NM3) (Air Consumption Normal Cubic Meters Per Min. NM3)
30
All air driven pumps will operate on low air volumes as long as the sup- 20 40 50 20 30 40 50 20 30 40 50
(.57) (.84) (1.12) (1.41) (.57) (.84) (1.12) (1.41) (.57) (.84) (1.12) (1.41)

ply of air is sufcient to operate the air selector valve. 30,000 2069

10
0P
SI
100 PS
Performance charts are based upon air supply stated, pumping oil I (6

(6
10,000 .9 689.5 20,000 10 0 P 1,378.9

.9
BA SI ( 25,000 80 PS 1723.6

BA
R) 6.9 I (5
(Mil-H-5606) with ooded suction. BA .5

R
BA

)A
R)
AI

IR
80
R

R)
AI

OUTLET PRESSURE BAR

PS R

OUTLET PRESSURE PSI

A

OUTLET PRESSURE BAR

OUTLET PRESSURE BAR

I (5

IR
OUTLET PRESSURE PSI
OUTLET PRESSURE PSI

.5 80 P
8,000 551.6 16,000 SI ( 1,103.1 20,000 1379
B AR 5.5 60 PSI (4.13
) BA B AR)
AI
R
AI

R)
R

AI
60 PS

R
6,000 I (4 413.7 60 P 827.3
.1 3 12,000 S 15,000 1034
BA I (4
R .1 3
BA
R)
)A

40 PS
A I (2.75
IR

BAR)
AIR

IR
40 PSI (2 8,000 551.6
4,000 .75
BAR
275.8 40 PSI (2.7 10,000 689.5
5B
)A AR
IR )A

IR
2,000 137.9 4,000 275.8 5,000 344.7

FLOW ~ CU IN./MIN. 20 40 60 80 100 FLOW ~ CU IN./MIN. 10 20 30 40 50 FLOW ~ CU IN./MIN. 5 10 15 20

FLOW ~ CC/MIN. 327.7 655.5 983.2 1310.9 1638.7 FLOW ~ CC/MIN. 163.8 327.7 491.6 655.5 819.3 FLOW ~ CC/MIN. 81.9 163.9 245.8 327.7

4 TYPICAL OR NOMINAL PERFORMANCE, DOUBLE ENDED PUMPS = 1.6 X SINGLE PUMP FLOW 5