Series ‘N’ Hydro Pneumatic Press Cylinders

5.1 Hydro Pneumatic Press Cylinder

REGULATOR AIR
OIL FILL / AIR VENT PORT PRESSURE GAUGE

W
OIL LEVEL
NE SENSOR SUB-BASE MOUNTED
SOLENOID VALVES FOR
QUICK REPLACEMENT WITHOUT
DISTURBING ORIGINAL PIPING

PARKING VALVE (OPTIONAL)

FOR HIGH SPEED
APPLICATIONS HEAVY DUTY PISTON
TYPE AIR PRESSURE
W AUTO LUBE
NE REGULATOR WITH

OUTPUT OIL PRESSURE

LOCKABLE KNOB TO
ADJUST TONNAGE 5
GAUGE CALIBRATED BLEED VENTS FOR
TO INDICATE FORCE DETECT SEAL FAILURE
PRESSURE GAUGE
ISOLATOR VALVE TO
ENHANCE GAUGE LIFE

PRECISION HONED & FLOW CONTROL VALVE

HARD CHROME PLATED FOR FORWARD SPEED
BARRELS CONTROL

PRECISION GROUND &

HARD CHROME PLATED
PISTON ROD

5.2 Typical Applications

“MERCURY” Hydro Pneumatic Presses are ideal machines for any application requiring pressing
force from 0.4 tonnes to 30 tonnes.

Rivetting Blanking Straightening Forming Clamping Stamping

5.01/2
 5.3 General Description

“MERCURY” series “N” range of Hydro-Pneumatic Presses, combines the advantages of

efficient, low cost pneumatics, to achieve the large output forces associated with hydraulics. The system
operates on normal compressed air pressure of 5 bar, using standard pneumatic controls, thus
completely eliminating the use of expensive hydraulic power pack and associated control equipment.

The SALIENT features of Series “N” Hydro-Pneumatic Presses are :-

(i) Very low air consumption, resulting in energy saving of up to 80% over equivalent pneumatic
cylinders and 50% over equivalent hydraulic systems. The Speed of Operation is also much
higher than an equivalent standard pneumatic or hydraulic System.

(ii) Compact Cylinder design, which can be mounted in any position.

(iii) Compact, Lightweight Press Frames, which can be mounted on a light work bench.

(iv) Simple Design for easy maintenance.

(v) High stroke frequency because of shorter oil path between the oil reservoir and the output
hydraulic cylinder.

(vi) Force and Speed can be infinitely adjusted.

(vii) Rapid, pneumatically operated approach stroke and return stroke. In the Series “N” the
return force is larger than the approach force, resulting in the loading of heavier tools for respective
5 tonnages.

(viii) Absolute separation of air and oil chambers. This has been achieved by providing bleed holes
between the pneumatic and hydraulic seals. In the event of failure of pneumatic seals, the air
escapes to atmosphere through a bleed hole and does not mix with the hydraulic oil. If the
hydraulic seals fail, oil escapes from its bleed hole, indicating deterioration of the seal, which can
be procured and replaced well before total breakdown occurs.

(ix) New Automatic Lubrication. Our new Auto lubrication feature has greatly enhanced the
reliability of our presses. After a set (with jumper on PCB)number of cycles, the auto lube solenoid
comes on for a short time. This actuates a built-in pump which injects, under high pressure, about
2 drops of oil from the reservoir. This high pressure injection ensures complete lubrication of the
entire pneumatic components.
The advantage of this system is that lubrication is positive and not dependent on air flow
volume as in a standard lubricator of a FRL set. Also the quantity of lubrication is positive and
not dependent on any arbitrary setting by machine operator.

(x) New low oil level sensing system ensures that the machine comes to a stop when oil level
reaches minimum. This eliminates product rejections due to reduction in tonnage caused by
low/ insufficient oil in the reservoir.

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5.4 Sequence of Operation
The sequence of operation is outlined in Fig. 1 & Fig. 2
There are three stages of operation :-
(a) Initial Low force, Large travel, Rapid Approach.
(b) High Force, Short travel, Power Stroke.
(c) Low Force, Rapid Retraction.
(i) In the retracted position air is admitted to ports ‘B’ and ‘D’ and exhausted from port ‘C’ through
5/2 Approach Solenoid Valve. Port ‘A’ is also exhausted through 3/2 Power Stroke Solenoid
Valve.
(ii) When the Electrical Two Hand Safety push buttons are actuated simultaneously, the Approach
Solenoid Valve is switched “ON”. This causes air to be admitted to port ‘C’, and ports ‘B’ and ‘D’
are exhausted. The output shaft extends rapidly, with a low force due to the air pressure acting on
top of the approach piston through port ‘C’. The speed of extension can be varied infinitely by
adjusting the Flow Control Valve ‘F’. The Hydraulic Shaft, which is attached to the output shaft,
also moves down, causing oil from the spring loaded reservoir to fill the Hydraulic Chamber.
(iii) When the output shaft touches the workpiece, the Power Stroke Solenoid Valve is switched “ON”.
The change over from approach to power stroke depends on the setting of the “APPROACH TIME”
knob on control panel. This causes air to be admitted to port ‘A’. The Intensifier Piston extends and
moves the Intensifier plunger into the Hydraulic Chamber, causing the pressure of the oil in this
chamber to rise. The intensified oil pressure acts on the Hydraulic Shaft, generating the high force
“Power-Stroke”. The output force can be varied by adjusting the Air Pressure Regulator ‘R’. The
change over from “APPROACH” to “POWER-STROKE” can be varied by adjusting the

(iv)
“APPROACH TIME” knob on the Control Panel.
The duration of application of high force on the workpiece can be varied by adjusting the “CYCLE
5
TIME” knob on the Control Panel. When this time has elapsed, both the Approach and Power
Stroke Solenoid Valves are switched “OFF”. This causes air to be admitted to ports ‘B’ and ‘D’ and
exhausted from Ports ‘A’ and ‘C’. The Approach and Intensifier Pistons retract rapidly and oil is
transferred back to the reservoir.
(v) The cylinder is now ready for the next cycle.

Pneumatic Circuit Diagram (Standard)

LOW OIL LEVEL SENSOR 3/2 HAND SLIDE VALVE TO
SHUT/OPEN AIR SUPPLY

OIL RESERVOIR

PRESS CYLINDER

REGULATOR ‘R’ FOR

AIR IN

TONNAGE ADJUSTMENT
3/2 SOLENOID-SPRING
B WITH EXTERNAL PILOT
FILTER & REGULATOR SET
(NOT SUPPLIED BY US)
FOR POWER STROKE

AUTOLUBE
SOLENOID
C
OUTPUT
OIL OUT

GAUGE WITH
ISOLATOR VALVE EXHAUST SILENCERS

5/2 SOLENOID-SPRING VALVE FOR APPROACH STROKE

D
FLOW CONTROL VALVE ‘F’
FOR FORWARD SPEED CONTROL

FIG. 1
5.01/4
 Standard Features

Standard Control Panel

1) True, 2 hand “Non Tie Down” controls. If the 2 push buttons are not actuated within 1 sec., The press
will not start.
2) Compact, yet easy to service.
3) Hinged and locable cover to avoid tempering of timer settings.
4) Status LED indicators for each stage of sequence.

FAST APPROACH “ON” INDICATOR

POWER “ON” POWER STROKE “ON” INDICATOR

INDICATOR OIL LEVEL LOW INDICATION
POWER “ON” AUTO/MANUAL SWITCH
SWITCH
FUSE

EMERGENCY STOP BUTTON

DWELL TIMER
APPROACH TIMER
PUSH BUTTON SWITCH FOR MANUAL
OPERATION OF POWER STROKE
PUSH BUTTON SWITCH FOR MANUAL
OPERATION OF FAST APPROACH
HEAVY DUTY, TWO HAND SAFETY, SHROUDED PUSH BUTTONS
5
(CAN BE MOUNTED AT ANY CONVENIENT LOCATION)

Low Oil Level Sensing LOW OIL LEVEL

LIMIT SWITCH
When oil level becomes low (5% reserve capacity) the
limit switch is actuated. This stops operation of the press
and “OIL LEVEL LOW” indicator glows. The press can
be operated temporarily by pressing 2 hand safety
buttons for forward & emergency stop button for return

Programmed Automatic Lubrication

A pneumatically actuated pump is installed below the oil
reservoir. This pump injects oil under high pressure
directly into cylinder. The no. of strokes after which oil
should be injected can be programmed by changing a
jumper on the PCB of the panel. Unlike a FRL in which
oil flow depends on the flow of air, the direct injection
of oil at the top & bottom of the cylinder guarantees
proper lubrication.
AUTOLUBE PUMP
MODEL : ALS2

5.01/6
 POWER STROKE
PORT ‘A’ SOLENOID VALVE PORT ‘A’

REGULATOR
‘R’

INTENSIFIER PISTON
INTENSIFIER PLUNGER
PORT ‘B’ PORT ‘B’

BLEED HOLE 1
HYDRAULIC CHAMBER
HYDRAULIC SHAFT
BLEED
OIL HOLE 2
RESERVOIR
AIR INLET
OUTPUT 6 Kg/cm2
PRESSURE
PORT MAX. PORT
GAUGE
‘C’ ‘C’

APPROACH
SOLENOID VALVE APPROACH
STROKE
APPROACH PISTON
TOTAL
STROKE PORT ‘D’ FLOW CONTROL PORT ‘D’
VALVE ‘F’

5 OUTPUT SHAFT

START POSITION LOW FORCE FAST APPROACH

PORT ‘A’ PORT ‘A’

PORT ‘B’ PORT ‘B’

PORT PORT
‘C’ ‘C’

APPROACH
+
POWER
STROKE TOTAL
PORT ‘D’ STROKE PORT ‘D’

HIGH FORCE POWER STROKE FIG. 2 LOW FORCE RAPID RETRACTION

5.01/5
 Optional Special Features

FAST APPROACH “ON” INDICATOR

Automatic Cycling of Power Stroke (Optional)
POWER STROKE “ON” INDICATOR
OIL LEVEL LOW INDICATION
UNIVERSAL MOUNTING
ARRANGEMENT AUTO/MANUAL SWITCH

FUSE

RAPID 1st POWER 2nd POWER 3rd POWER

APPROACH STROKE STROKE STROKE COUNTER TO SET NO. OF
POWER STROKES (1 TO 9)
APPLICATION :- Bearing and bush pressing. On DWELL TIME BETWEEN POWER
actuation of 2 hand safety buttons, the ram comes STROKES
DWELL TIME FOR EACH POWER STROKES
down rapidly and applies power stroke. After an
HINGED COVER WITH SCREW LOCK TO
adjustable delay, power stroke is automatically applied PREVENT TAMPERING OF TIMER SETTINGS
a second time. This repeats for the no. of times set HEAVY DUTY, TWO HAND SAFETY, SHROUDED PUSH BUTTONS
(CAN BE MOUNTED AT ANY CONVENIENT LOCATION)
(1 to 9) on the counter.

Power Stroke Depth Control

STROKE ADJUSTMENT
POWER NUT WITH LOCK WASHER
STROKE

5
ADJUSTMENT

APPLICATION :- Useful for toolings in which it is not

possible to control the stroke with a mechanical stopper
in the tool.

Pressure Switch Sensing

PRESSURE
The press retracts automatically when the set (adjustable) SWITCH

pressure is reached. If for any reason the set pressure is

not reached (e.g. oil level low, input air pressure low), the PRESSURE
press does not retract. It has to be retracted by pressing SENSING
ADJUSTMENT
emergency stop. This feature ensures on line quality
ADJUSTMENT
control. REGULATOR
KNOB

Stroke Counter
(a) An electromagnetic stroke counter registers the number of power
strokes applied.
(b) Reset is by manual push button.

Continuous Cycling
(a) This features integrates the press to feeding devices. The return
position of the press gives a signal for the feeder to start and the
end stroke of the feeder gives a signal for the press to start.
(b) Can be made to stroke continuously as in mechanical power
presses.

5.01/7
Foot Switch Operation

A momentary press of the foot pedal initiates the press PLUG IN CONNECTOR
FOR QUICK CONNECT/
cycle. The return is automatic after the set time. DISCONNECT OF FOOT
SWITCH
IMPORTANT NOTE :- There is no safety in foot operation
mode. The foot switch is connected to the control panel
through a Plug-In connector for easy removal. It is the
responsibility of the management to ensure that the foot
switch is unplugged whenever the press is operated in 2
hand safety mode and foot operation is not required.

OPTIONAL
ELECTRICAL
FOOT SWITCH
ELECTRICAL WITH GUARD
FOOT SWITCH

Ejection Cylinder

APPLICATION :- For ejecting components out of the die

when press is retracting. The control panel has as
standard 2 terminals for switching a solenoid valve with
off delay timer to operate the ejection cylinder.
The size of the cylinder can be ordered as per customer
requirement of the ejection force.
5
EJECTION CYLINDER

Low Energy System

This is useful for saving compressed air in 8T, 15T & 30T
presses operated at more than 15 strokes/min. The return
REGULATOR
of the cylinder force can be adjusted to the minimum FOR TONNAGE
pressure required to retract the cylinder and connected ADJUSTMENT
tooling.

REGULATOR FOR RETURN UNDER

VERY LOW PRESSURE

Dual Force Systems for Online Quality Control

APPLICATION :- For critical pressing such as press fitting

of bearing, shear pins etc., under close tolerance.
The machine can be set for “LOW” & “HIGH” level LOW
pressing forces, the difference of which can be as low as FORCE
REGULATOR
1000N (100 kgf.)
The Press first applies the “LOW” force. If the job is
pressed then it is looze and machine stops.
If pressing force is within the set limit, then the press HIGH
FORCE
operates normally. REGULATOR

If job is not pressed when “HIGH” force is applied then

it is tight and machine stops.

5.01/8
 Double Action Press

APPLICATION :- For jobs which need pressing from top

and bottom such as powder compacting, deep drawing
etc.
These special purpose presses are designed as per
customer requirement.

BOTTOM
PRESSING
CYLINDER

Parking Feature

5 1 2

CYLINDER FULLY CYLINDER IN

RETRACTED PARKED POSITION PARKING
NOTE : TRAVEL ‘X’ SCREW
SHOULD BE LESS
THAN TOTAL POWER
STROKE TRAVEL

3 4 5

CYLINDER OPERATES CYLINDER RETRACTS CYLINDER OPERATES

ONLY WITHIN POWER TO PARKED POSITION AGAIN WITHIN POWER
STROKE STROKE

APPLICATION :- This feature is useful for applications

where the job is automatically fed into the die by
press feeders etc. The cylinder is not required to
retract/travel fully. This saves cycle time and air
consumption considerably.
5.01/9
Series ‘N’ Press Cylinder Dimensions
OIL RESERVOIR

D E
‘N’ B.S.P. PORTS ‘F’ THDS.
4Nos. C

ØG ØH ‘J’ SQ. ‘K’ SQ.

FOR MOUNTING
B A
‘L’ 4Nos. FOR 2 & 4 TONNES
‘L’ 6Nos. ON ‘M’ P.C.D. FOR 8, 15 & 30 TONNES

MODEL TON Total Power A B C D E F ØG ØH J L M N P Q (NL)

No. Stroke Stroke SQ. AIR. CONSU.

Output Forces (Kgf.) at Inlet Air

To Calculate Compressor Power Capacity Pressure of 5 Bars
1HP = 120 litres of Fee Air (NL) Per Minute at 5 Bars.
Tonnage 8T 14.75T 15T 30T 45T
N = Number of Cycles per minute
Approach 275 435 475 435 680
Q= Free Air Consumed Per Cycle (From Chart) in Normal Litres (NL)
QxN QxN Power 8585 14750 14800 29175 44950
Power Required = (H.P.) or x 0.746 (KW) Return 425 1050 825 1160 1300
120 120
To Calculate the cost of electricity
Example :- A 15 Tonne, 50mm stroke with 6mm power stroke press is used at 5 bars to cut Aluminium washers from a sheet at the rate of 10 pieces per minute.
1) From above chart model N151-50 cylinder consumes 33 NL of air per cycle.
2) @ 10 strokes/min air consumption = 33 x 10 = 330 NLPM
3) Electric Power used = 330 120 = 2.75 HP 2.05 KW/min
4) Power used per hour (KWH) = 2.05 x 60 = 123 KWH
5) Cost of electricity @ Rs 4.5 per KWH = 123 x 4.5 = Rs 553
6) Cost of electricity per cut piece (10 x 60 = 600/hr) = 553 600 = 0.92 i.e. Rs. 0.92 per piece

5.01/10
 Tseries “AB”for
Spare Parts Air‘N’Boosters
Series Hydro Pneumatic Press

POWER STROKE SOLENOID VALVE FOR STANDARD PRESS

SEAL KIT
PART No. DESCRIPTION
No.
NS312EPR 1/4” 3/2 N.C. SOLENOID VALVE WITH EXTERNAL PILOT SKNS312EPR

NS314EPR 1/2” 3/2 N.C. SOLENOID VALVE WITH EXTERNAL PILOT SKNS314EPR

RAPID APPROACH SOLENOID VALVE

SEAL KIT
PART No. DESCRIPTION
No.
NS612PR 1/4” 5/2 SOLENOID VALVE SKNS612PR

NS614PR 1/2” 5/2 SOLENOID VALVE SKNS614PR

SOLENOID VALVE FOR AUTOMATIC CYCLING OF POWER STROKE

SEAL KIT
PART No. DESCRIPTION
No.
NS612EPR 1/4” 5/2 SOLENOID VALVE WITH EXTERNAL PILOT SKNS612EPR

NS614EPR 1/2” 5/2 SOLENOID VALVE WITH EXTERNAL PILOT SKNS614EPR

5 TONNAGE GAUGE WITH ISOLATOR VALVE

PART No. DESCRIPTION PART No. DESCRIPTION

88-009-2T FOR 2T ‘N’ SERIES CYLINDERS 88-009-4TP FOR 4T ‘P’ & ‘X’ SERIES CYLINDERS
88-009-4T FOR 4T ‘N’ SERIES CYLINDERS 88-009-8TP FOR 8T ‘P’ & ‘X’ SERIES CYLINDERS
88-009-8T FOR 8T ‘N’ SERIES CYLINDERS 88-009-15TP FOR 15T & 30T ‘P’ & ‘X’ SERIES CYLINDERS
88-009-15T FOR 15T ‘N’ SERIES CYLINDERS 88-077 FOR ‘Z’ SERIES CYLINDER, 210 bar
88-009-30T FOR 30T ‘N’ SERIES CYLINDERS 88-078 FOR ‘Z’ SERIES CYLINDER, 350 bar
88-009-2TP FOR 2T ‘P’ & ‘X’ SERIES CYLINDERS

AUTOLUBE REGULATED AIR PRESSURE GAUGE

PART
PART SEAL KIT DESCRIPTION
DESCRIPTION No.
No. No.
1/8”, Ø50, 0-10 bar PNEUMATIC
ALS2 AUTOLUBE SKALS2 20-940 GAUGE FOR ALL PRESS
CYLINDER MODELS

OIL FILL PLUG

PART No. DESCRIPTION

86-001 1/4” OIL PLUG WITH ‘O’ RING FOR ‘N’ SERIES 2T & 4T

105-036 1/2” OIL PLUG WITH ‘O’ RING FOR ‘N’ SERIES 8T, 15T & 30T

VALVE REGULATOR ASSEMBLY

PART No. DESCRIPTION

VRA2 1/4” VALVE-REGULATOR ASSEMBLY

VRA2T 1/4” VALVE-REGULATOR ASSEMBLY WITH TIMER
VRA4 1/2” VALVE-REGULATOR ASSEMBLY
VRA4T 1/2” VALVE-REGULATOR ASSEMBLY WITH TIMER

5.01/11
 LOW OIL LEVEL LIMIT SWITCH

PART No. DESCRIPTION

105-092 LOW OIL LEVEL SENSING LIMIT SWITCH

STANDARD 2 HAND SAFETY CONTROL PANEL

PART No. DESCRIPTION

86-545-1 STANDARD CONTROL PANEL

AUTO CYCLE 2 HAND SAFETY CONTROL PANEL

PART No. DESCRIPTION

86-547 AUTOMATIC CYCLING OF POWER STROKE PANEL

AIR SILENCERS

PART No.

SL2
DESCRIPTION

1/4” SILENCER
5
SL4 1/2

SOLENOID COILS

PART No. DESCRIPTION

M22L 230VAC COIL WITH ILLUMINATED CONNECTOR

M22P 24DC COIL WITH ILLUMINATED CONNECTOR

ELBOW FLOW CONTROL VALVE

SEAL KIT
PART No. DESCRIPTION
No.
UF2 1/4” SWIVEL ELBOW FLOW CONTROL VALVE FOR 2T & 4T SKUF2

UF4 1/2” SWIVEL ELBOW FLOW CONTROL VALVE FOR 8T, 15T & 30T SKUF4

SPARE SEAL KITS

PART No. DESCRIPTION

90-051 SEAL KIT FOR PRESS CYLINDER MODEL No. N151 & N154

90-052 SEAL KIT FOR PRESS CYLINDER MODEL No. N301 & N304

90-069 SEAL KIT FOR PRESS CYLINDER MODEL No. N086

90-070 SEAL KIT FOR PRESS CYLINDER MODEL No. N156

90-103 SEAL KIT FOR PRESS CYLINDER MODEL No. N451 & N454

5.01/12