HYDROSTATIC TEST SYSTEM MANUAL

PDQC HYDROSTATIC TEST SYSTEM MANUAL Technical Specification Operating Instructions Part List Revised 12-2016 Manual # PDQC- 6,000 And PDQC-10,000 1

PDQC PERFORMANCE DATA Model Number Maximum Pressure Volume at 100CPM Pressure Ratio *Maximum C F M Required Maximum Air Required 1 Stage PDQC-1000 1000 PSI 8.60 G P M 10 TO 1 56 C F M 100 PSI PDQC-3600 3600 PSI 2.60 G P M 36 TO 1 56 C F M 100 PSI PDQC- 10000 9700 PSI 1.00 G P M 97 TO 1 56 C F M 100 PSI 2 Stage PDQC-1000-2 1000 PSI 25.60 G P M 10 TO 1 112 C F M 100 PSI PDQC-3600-2 3600 PSI 19.60 G P M 36 TO 1 112 C F M 100 PSI PDQC-10000-2 9700 PSI 18.00 G P M 97 TO 1 112 C F M 100 PSI * Total required CFM to produce rated at maximum pump pressure. This is relevant only when the system is used for continuous injection at the maximum rated pressure. Normal testing applications require much less CFM to begin with and fall to 0 at stall pressure. DIMENSIONS / WEIGHT Stage Length Width Height Weight 1 19 21 44 85 Lbs. 2 19 36 44 170 Lbs. 3

PDQC OPERATING INSTRUCTIONS 1.00 BEGINNING OPERATION 1.01 Attach a 100 psi maximum air supply 1.02 Rotate air regulator control knob anti-clockwise until handle becomes free and air gauge reads 0 psi and connect an air supply 100 PSI maximum. 1.03 Open air supply isolation valve (if fitted) 1.04 Rotate air regulator control knob slowly clockwise until pump begins to reciprocate (pump should start at 10 to 15 PSI under normal conditions) 1.05 Rotate air regulator control knob clockwise until 25 to 30 PSI is reached on the air gauge and run pump until all air is purged out of the circuit. When pressure testing, bleed all air out of the item being tested before pressurizing by fitting a bleed valve or vent plug at the highest point in the circuit. Care should be taken to take account of any internal cavities that may trap air inside the circuit. 1.06 Rotate air regulator control knob anti-clockwise until zero pressure is reached on air gauge 1.07 Close any vent valves once all air is purged from the system 1.08 Rotate air regulator control knob slowly clockwise until required hydraulic pressure is reached on the high pressure gauge Note - If the object being tested is large it will take a while before the pressure builds up in the system and registers on the pressure gauge. Do not set the air driving pressure too high if unattended as this may lead to the object under test being over pressurised. Approximate hydraulic output pressure can be preset by air drive pressure. See pump specification sheet. Air drive pressure can be preset by closing an air line isolation valve fitted between the regulator and pump closing air stop valve and rotating air regulator valve clockwise until the required pressure is registered on air pressure gauge. Air pressure should be set slightly below the required setting so that it can be raised to the correct setting once hydraulic pressure has built up and the pump has stalled out. The pump can then be started and stopped by using an air stop valve as it will go to the preset output pressure each time it is started. Once set the pump will maintain the set pressure indefinitely and make up any fluid losses within the hydraulic system automatically. 4

NO OTHER PUMPS OFFER ALL THESE ADVANTAGES Simple operating principle Air operated hydraulic pumps operate on the simple but efficient principle of pressure intensification through the use of differential areas. Fulfilling Boyle s Law, a larger air- driven piston delivers pressure to a proportionally lesser diameter hydraulic piston, providing fluid flow at relatively higher pressures. High output capacity and outstanding performance provided at very low cost. Guaranteed performance All pumps will give years of low cost, trouble free service when properly installed and maintained to manufacturer s instruction. Wide range of operating pressures is provided by all models. Wide range of output capacities Only 100 psi air pressure is required for all models to attain maximum rate of flow (see performance charts for data). Complete flexibility All pumps adapt to a wide variety of applications, from simple manual controls to fully automatic operation. Automatic restart Whenever the pump is idle, the pilot valve is designed to re-position the pump on the power stroke for the next cycle of operation. Smooth operation The air piston actuating valve is precision fit to close tolerances for maximum efficiency and long service life. Both pressure and volume of flow are easily and accurately controlled by a pressure regulator installed in the air supply line. Fluid Compatibility Pumps can operate with almost any type fluid service (specify when ordering). Hydraulic cylinders are constructed from aluminum-bronze, stainless steel, or carbon steel. Hydraulic pistons are constructed from stainless steel, hard chrome-plated. Materials incorporated in the hydraulic assembly vary depending upon type of service and pump model. Designed for easy maintenance Costly down time is reduced to a minimum when service is required. Applications include static and burst testing, flow testing requiring relatively low flows at high pressures, operation of hydraulic presses, clamping, pressing, metal forming, piercing, blanking, staking, etc. Applications requiring extreme intermittent pressure and velocity commonly associated with water blasting and jetting. 5

Liquid Pump Cut-a-way AIR PISTON ACTUATING VALVE AIR OUT AIR CYLINDER HYDRAULIC PISTON HYDRAULIC CYLINDER 6

All pumps have a 7 diameter air piston and a 2 ½ stroke. When operating from 0 to rated hydraulic pressure, air consumption will be approximately 56 scfm of free air at 100 psi output. At lower air pressures and higher hydraulic pressures air consumption will be reduced proportionately to flow rates indicated. Mounting may be in any position, vertical preferred. When mounting in an inverted position, a drain cock should be provided to drain off any liquid that may accumulate in the pilot valve air chamber. Part Number L A B Mounting Dimensions in Inches NPT/HF4 (Std) C Thread D Thread E F G H PI7000-03 19.625 4.875 2.375 1 ¼" 1" 1.500 2.500 --- 4.000 PI7000-05 18.625 4.750 4.375 1" 1" 1.375 1.375 2.375 3.000 PI7000-02 17.063 3.000 4.000 1" 1/2" 1.000 1.000 1.750 2.500 PI7000-01 AND PI7000-04 15.750 3.000 3.375 1/2 1/2" 0.875 0.875 1.750 2.500 Part Number Hydraulic Piston Diameter (in) Hydraulic Piston Area (in2) Measurements & Approximate Air to Hydraulic Pressure Volume per Stroke (in3) Air Pressure (PSI) 10 20 30 40 50 60 70 80 90 100 PI7000-03 3.000 7.070 17.70 50 100 150 200 250 300 350 400 450 500 PI7000-05 2.125 3.560 8.900 85 185 285 390 490 590 690 795 900 1000 PI7000-20 1.125 0.994 2.490 250 625 1025 1400 1800 2150 2500 2850 3250 3600 PI7000-04 0.875 0.601 1.500 450 1050 1700 2275 2900 3500 4100 4650 5200 6000 PI7000-01 0.688 0.371 0.928 750 1750 2800 3700 4750 5900 6875 7700 8750 9700 7

4000 3200 PI7000-03 Outlet Pressure bar 0 5 10 15 20 25 30 003 5 PI7000-05 Outlet Pressure bar 0 10 20 30 40 50 60 70 60 1800 005 30 10 50 1500 25 Liquid Flow in 3 /min. Liquid Flow in 3 /min. 020 35 Liquid Flow litre/min. 2400 40 1200 20 1600 800 100 psig (6.89 bar) 30 20 Liquid Flow litre/min. Liquid Flow in 3 /min. Liquid Flow in 3 /min. 900 600 80 (5.12) 10 300 100 psig (6.89 bar) 80 5 (5.12) 5:1 Ratio 60 60 10:1 Ratio (4.14) (4.14) 0 0 0 0 100 200 300 400 500 0 200 400 600 800 1000 600 500 400 300 200 100 0 PI7000-02 Outlet Pressure bar 0 30 60 90 120 150 180 210 240 270 80 (5.12) 10 5 100 psig (6.89 bar) 4 9 8 7 6 3 2 400 350 300 PI7000-03 Outlet Pressure bar 0 50 100 150 200 250 300 350 400 60 50 35:1 Ratio 1 60 (4.14) 55:1 Ratio (4.14) 0 0 0 0 500 1000 1500 2000 2500 3000 3500 4000 0 600 1200 1800 2400 3000 3600 4200 4800 5400 6000 250 200 150 100 80 (5.12) 030 55 100 psig (6.89 bar) 15 10 0 3 6 5 4 2 1 Liquid Flow litre/min. Liquid Flow litre/min. 8

250 PI7000-01 Outlet Pressure bar 0 100 200 300 400 500 600 4.0 Liquid Flow in 3 /min. 200 150 2.5 100 100 psig (6.89 bar) 1.0 50 95:1 Ratio 60 (4.14) 80 (5.12) 0.5 0 0.0 0 2000 4000 6000 8000 10000 3.5 3.0 2.0 1.5 Liquid Flow litre/min. 9

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Item Part Code DESCRIPTION 1 PI044 WASHER LOCK 2 PI003 END 3 PI006 CYLINDER AIR 4 PI004 PISTON AIR 5 PI012 O RING 6 PI010 O RING 7 PI007 BEARING ASSEMBLY 8 PI009 O RING 9 PI001 APA VALVE ASSEMBLY 10 PI019 O RING 11 PI015 BUMPER 12 PI005 SPRING 13 PI020 PILOT VALVE ASSEMBLY 14 PI022 HEAD 15 PI002 BUMPER 16 PI011 O RING 17 PI021 O RING 18 PI014 RETAINING RING 19 PI043 WASHER FLAT 20 PI008 O RING 21 PI013 RETAINING RING 22 PI017 BOLT HEX 23 PI041 PLUG 24 PI016 NUT HEX 25 PI018 SET SCREW HEX SOCKET 11

PILOT VALUE ASSEMBLY PI020 PILOT VALUE ASSEMBLY PI020 Item Part Number Description 1 PI030 SPIROLOK RING 2 PI029 O RING 3 PI011 O RING 4 PI026 SPRING 5 PI023 PILOT VALVE BODY 6 PI025 CHECK VALVE ASSEMBLY 7 PI027 SEAT 12

CHECK VALVE ASSEMBLY PI025 CHECK VALVE ASSEMBLY PI025 Item Part Number Description 1 PI038 CENTRE SCREW 2 PI036 O RING 3 PI033 WASHER 4 PI035 POPPET BODY 5 PI031 NUT 6 PI032 WASHER 7 PI034 SPRING 8 PI037 WASHER 13

PDQC AIR MOTOR REPAIR KIT PI6100 18

PDQC AIR MOTOR REPAIR KIT 19

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PDQC10,000 HYDRAULIC END ITEM NO QTY PART NO DESCRIPTION 1 2 PI5051 RETAINING RING 2 2 PI5053 SPRING 3 2 PI5056 O-RING EPR 4 2 PI2037 CHECK BALL 5 1 PI5032 SEAT-INLET 6 2 PI5054 BALL GUIDE 7 2 PI5052 SPRING GUIDE 8 1 PI5043 GASKET 9 2 PI5026 BACK UP 10 1 PI5020 PISTON BUMPER 11 1 PI5039 FENDER WASHER 12 1 BUTTON HEAD CAP SCREW 13 1 PI5030 HELICAL SPRING LOCK WASHER 14 1 PI5042 HYDRAULIC PISTON 15 1 PI5025 O-RING 16 1 PI5047 HYDRAULIC CYLINDER 17 1 PI5031 SEAT-OUTLET Note PI5039 includes items 11, 12, and 13 15

PDQC10,000 HYDRAULIC END REPAIR KIT PI6099 20

PDQC 10,000 COMPLETE REDRESS KIT PI5050 (NITRILE) QTYPART NO DESCRIPTION 1 PI012 O-RING 2 PI010 O-RING 1 PI009 O-RING 1 PI019 O-RING 1 PI015 BUMPER 2 PI011 O-RING 1 PI008 O-RING 1 PI013 RETAINING RING 1 PI026 SPRING 1 PI029 O-RING 1 PI030 RETAINING RING 1 PI025 AIR CHECK ASSEMBLY 2 PI5051 RETAINING RING 2 PI5056 O-RING EPR 1 PI5043 GASKET 2 PI5026 BACK UP 1 PI5020 PISTON BUMPER 1 PI5030 HELICAL SPRING LOCK 1 PI5025 O-RING 21

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PDQC6,000 HYDRAULIC END ITEM QTY PART NO DESCRIPTION 1 2 PI5051 RETAINING RING 2 2 PI5053 SPRING 3 2 PI5056 O-RING EPR 4 2 PI2037 CHECK BALL 5 1 PI5032 SEAT-INLET 6 2 PI5054 BALL GUIDE 7 2 PI5052 SPRING GUIDE 8 1 PI5043 GASKET 9 2 PI3026 BACK UP 10 1 PI5020 PISTON BUMPER 11 1 PI5039 FENDER WASHER 12 1 BUTTON HEAD CAP 13 1 HELICAL SPRING 14 1 PI3042 HYDRAULIC PISTON 15 1 PI3020 O-RING 16 1 PI3047 HYDRAULIC 17 1 PI5031 SEAT-OUTLET Note PI5039 includes items 11, 12, and 13 17

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PDQC 6,000 COMPLETE REDRESS KIT PI3050 (NITRILE) QTY PART NO DESCRIPTION 1 PI012 O-RING 2 PI010 O-RING 1 PI009 O-RING 1 PI019 O-RING 1 PI015 BUMPER 2 PI011 O-RING 1 PI008 O-RING 1 PI013 RETAINING RING 1 PI026 SPRING 1 PI029 O-RING 1 PI030 RETAINING RING 1 PI025 AIR CHECK ASSEMBLY 2 PI5051 RETAINING RING 2 PI5056 O-RING EPR 1 PI5043 GASKET 2 PI3026 BACK UP 1 PI5020 PISTON BUMPER 1 PI5030 HELICAL SPRING LOCK 1 PI3020 O-RING 23

PDQC 739 24

PDQC PARTS OF FRONT VIEW BREAKDOWN Item # Part # Description 701 PI7000-01 10,000 PSI PUMP 702 PI7000-02 3600 PSI PUMP 703 PI7000-03 1000 PSI PUMP 706 PI7000-06 GAUGE 0-15,000 707 PI7000-07 GAUGE 0-5000# 708 PI7000-07 GAUGE 0-5000# 711 PI7000-11 GAUGE 0-160# 716 PI7000-16 REGULATOR 1/2 721 PI7000-21 WHEELS 729 PI7000-29 WHEEL COLLAR 730 PI7000-30 FLAT WASHER 732 PI7000-32 AXLE SHAFT 736 PI7000-36 BLEED VALVE 1/4 738 PI7000-38 CABINET 741 PI7000-41 BOLTS (4REQUIRED) 742 PI7000-27 LOCK NUT 788 PI7000-88 MERCHANT COUPLING 790 PI7000-90 1/2 MALE CROWSFOOT 25

PDQC PARTS OF BACK PANEL Item # Part # Description 712 PI7000-12 BRACKET KIT 713 PI7000-13 N PIPE PORT KIT 1/2 714 PI7000-14 VALVE BRASS BALL 1/2 723 PI7000-23 BOLT (4) 725 PI7000-25 LOCK WASHER (4) 726 PI7000-26 FLAT WASHER (4) 727 PI7000-27 NUT (4) 731 PI7000-31N HANDLE T-TYPE 739 PI7000-39 CABINET BACK 790 PI7000-90 1/2 MALE CROWSFOOT 796 PI7000-96 M X F ADAPTER 90 799 PI7000-18 LUBRICATOR 26

PDQC NEW STYLE DESIGN 27

PDQC PARTS OF BACK VIEW BREAKDOWN (PANEL REMOVE) Item # Part # Description 723 PI7000-23 BOLT 728 PI7000-28 BULK HEAD PLATE 735 PI7000-35 STRAINER 744 PI7000-44 1 X 1/2 BUSHING GALV. 763 PI7000-63 ELBOW 764 PI7000-64 PUSH LOCK SWIVEL FEMALE 766 PI7000-66 PUSH LOCK HOSE FITTING 768 PI7000-68 PUSH LOCK HOSE FITTING 769 PI7000-69 STREET T MALE 770 PI7000-70 28 HOSE 771 PI7000-71 STRAIGHT FITTING 774 PI7000-74 MALE ELBOW 778 PI7000-78 N MALE CONNECTOR 1/2 780 PI7000-80 BUSHING 782 PI7000-82 1/4 SS TUBING X 7 LONG 783 PI7000-83 HOSE 1/4 X12 784 PI7000-84 HOSE 1/4 X16 785 PI7000-85 HOSE 1/2 X24 786 PI7000-86 HOSE 1/2 X25 787 PI7000-87 HOSE 1/2 X12 791 PI7000-47 19.5 HOSE 792 PI7000-46 23 HOSE 793 PI7000-93 ADAPTER: ¼ MJ X ½ MP 794 PI7000-94 TEE: MP X MJ (RUN) X MJ 795 PI7000-95 MALE X FEMALE 28

PDQC APPENDIX 1 PUMP INSTALLATION INSTRUCTIONS 1.10 MOUNTING THE PUMP 2-off 3/8-24 UNF tapped holes are located on the base of the hydraulic cylinder and supplied with ¾ long mounting bolts, washers and spring washers for panel mounting up to a max thickness of 1/4 (6mm). 1.20 FLUID SUPPLY CONNECTION Make a suitable flexible or hard piped connection to the threaded fluid inlet port, marked fluid in on check valve body. (Size of thread shown on page 8). Use PTFE tape or suitable anti-seize compound to prevent galling of the threads and ensure all connections are leak free. All connections to this port should be the same size or larger, as smaller size fittings, hoses, etc. can cause a restricted flow supply. The installation of a 100 mesh screen (140 micron) fluid filter, or finer is recommended, located between the fluid reservoir and fluid inlet port and that the location of the fluid reservoir be above or level with the pump to ensure a flooded condition at the fluid inlet port. Note. Standard pumps are supplied with NITRILE hydraulic seals suitable for oil, water, methanol and glycol service. Ensure that the fluid to be pumped is compatible with this material prior to use. For other process applications Viton and Chemraz hydraulic seal kits are available. 1.30 PRESSURE PORT CONNECTION Make a suitably rated flexible or hard piped connection to the threaded fluid outlet port, marked fluid out on check valve body. (Size of thread shown on page 8). Use PTFE tape or suitable anti-seize compound to prevent galling of the threads and ensure all connections are leak free. Connect a suitably rated gauge and a bleed valve or vent plug at the highest point in the circuit for purging air from the circuit. Note - hydraulic hoses or piping including adaptors or couplings must have a pressure rating equal to or more than the maximum output pressure of the pump. 1.40 AIR SUPPLY CONNECTION Make a suitable flexible or hard piped connection to the ½ NPT air supply port, marked air in. Use PTFE tape or suitable anti-seize compound to prevent galling of the threads and ensure all connections are leak free. To ensure maximum performance, ½ NPT air supply components are required as smaller sizes will reduce the flow. The pump is designed to operate on air pressure from 10 to 100 PSI, unless it is a low pressure start (LPS) model when it will operate from 5 to 100 PSI. To control the pump an air filter and regulator is required (not supplied) It is recommended an isolation valve (not supplied) is fitted between the air filter/regulator unit and the pump. NOTE - It is not necessary to fit an air line lubricator as the pump is a NON-LUBE version and internally lubricated with NL SUPERLUBE GREASE. 29

PDQC 1.50 MUFFLING THE EXHAUST It is recommended a muffler is fitted to the 1 NPT air out port to reduce the operating noise of the pump. The muffler can be screwed directly into the 1 NPT port or piped away. Do not fit a smaller muffler than 1 NPT as this can reduce the speed of the pump. Use PTFE tape or suitable anti-seize compound to prevent galling of the threads and ensure all connections are leak free. 30