Hi-lo pump circuit

Often a cylinder needs very little force to stroke to and from the work -- and only a short high-force stroke to perform the work. When this is the case, the hi-lo circuit in Figure
9-10 works well and costs less.

For example: if a single-pump circuit needs 60 gpm to make the required cycle time and 3000 psi to perform the operation, the circuit would require a 110-hp electric motor to
drive it. (60 X 3000 X 0.000583 = 104 hp)

The circuit in Figure 9-10 is a typical hi-lo pump circuit that consumes less horsepower while maintaining fast cycle times. It uses a 25-hp motor and supporting equipment for
less expense up front, as well as during its useful life. The motor drives a 50-gpm low-pressure pump and a 15-gpm high-pressure pump -- for a total of 65 gpm. The extra flow is
required to maintain cycle time because the work stroke is slower. The tank, valves, and line sizes are still rated for 65-gpm flow and 3000 psi, but the electric motor and
controls are much smaller.

Fig. 9-10. Typical hi-lo circuit using two pumps.

As shown in Figure 9-10, the hi-lo circuit also has a relief valve, an unloading valve, and a check valve. The relief valve protects the low-volume/high-pressure pump from
pressure above 3000 psi. The unloading valve is set at 500 psi to divert flow from the high-volume/low-pressure pump to tank when system pressure climbs above this setting. A
check valve after the high-volume/low-pressure pump isolates system pressure from the unloading valve circuit while performing work at maximum pressure.

A 4-way, 3-position, solenoid pilot-operated, spring-centered, all-ports-open directional control valve sends all pump flow to tank while the system is idle. This power unit and
valve arrangement send a double-acting cylinder through a fast-approach, high-force work stroke and fast return driven by a 25-hp electric motor. The unloading valve
cutaway view shows the pipe connections to this in-line mounted valve.

Energizing solenoid A1 on the directional valve sends flow from both pumps to the cap end of the double-acting cylinder. The cylinder advances rapidly at low pressure until it
contacts work. At this point, contact pressure builds quickly and when it passes 500 psi, the unloading valve is forced open. Now, all high-volume pump flow is diverted to tank
at very low pressure (and horsepower). Up to this point, the highest horsepower draw would be: (65 gpm)(500 psi)(0.000583) = 19 hp.

With the high-volume pump unloaded, there is plenty of horsepower to raise the high-pressure pump to the 3000-psi pressure required to do the work. The work requires (15
gpm)(3000 psi)(0.000583) = 26 hp. This is well within the capability of the 25-hp motor specified.

A hi-lo circuit makes it possible to replace a high-horsepower motor and its control components with a much smaller less-expensive setup.

Other applications for relief valves

Relief valves are used in circuits to protect components from excess pressure due to heat or external forces where pressure buildup in a blocked flow circuit could damage an
actuator or be a safety hazard.

In hydraulic motor circuits, relief valves can eliminate shock when the motor must be decelerated quickly. In this function, fluid is ported from the high-pressure outlet port of
the motor to the low-pressure inlet port, while holding ample backpressure to stop the motor without damage.

Fig. 9-11. Symbols for modular relief valves. (Note that these symbols do not show X and Y ports for solenoid pilot-operated valves.)

Most relief valve functions are available as modular or sandwich valves that mount between the directional control valve and sub-plate. Figure 9-11 shows most of the common
configurations presently offered by fluid power suppliers. These modules are usually available in all valve sizes up to D08 (3/4 in.) ports.