Hi-P Sprague Troubleshooting guide
Installation:
The Sprague Products gas boosters, with or without accessories, require the following plumbing connection lines:
1) From driving air source to booster air inlet.
10m filtration
2) From a pre-charge gas source to the booster
pre-charge inlet. 40m filtration
3) From the booster outlet port to the
working system.
Quick Start Up Guide – Boosters
Operation:
Start Up Procedure:
1) Adjust drive air regulator to zero.
2) Close outlet bleed valve.
3) Slowly open pre-charge shut-off valve
(or drive air supply valve if single source).
4) Adjust pre-charge pressure regulator
to desired pre-charge pressure.
5) Lock pre-charge pressure regulator.
6) Open drive air shut-off valve if not
already open.
7) Slowly adjust drive air pressure regulator
until booster starts operating.
8) Check all connections for leaks.
9) Continue increasing drive air pressure
until desired output pressure is reached.
Shut Down Procedure:
1) Close drive air shut-off valve.
2) Close pre-charge shut-off valve.
3) Open outlet bleed valve. For safety
leave open.
4) Disconnect from work.
Written authorization
is required prior to
disassembly of any
Sprague Product. Failure
to do so may void
warranty.
NOTICE
DANGER
No lubricator is needed.
Do not run high-pressure
boosters with lubricated
air. Oil leaking into the
compression chamber
could cause an explosion.
DANGER
Remove oil from pre-
charge air (gas) going to
high-pressure boosters.
(If shop air is used in a
high-pressure system an
explosion could occur.)
DANGER
Pressurized Air or Gas
can cause severe injury
or death if misused.
Failure to use Sprague
OEM parts can create
dangerous operating
conditions, poor pump
performance and will
void the warranty.
NOTICE
Single source drive and pre-charge
– applies to all boosters
Dual ratio PowerStar booster shown
Separate source drive and
pre-charge – applies to all boosters
Single ended PowerStar booster
shown
While this information is presented in good faith and believed to be accurate, Sprague Products, division of High Pressure Equipment Company , does not guarantee satisfactory results
from reliance on such information. Nothing contained herein is to be construed as a warranty or guarantee, expressed or implied, regarding the performance, merchantability, fitness or
any other matter with respect to the products, nor as a recommendation to use any product or process in conflict with any patent. Sprague Products, division of High Pressure Equipment
Company, reserves the right, without notice, to alter or improve the designs or specifications of the products described herein.
Trouble Shooting Guide
Problem Cause Remedy
Booster is not delivering Gas
(booster running)
A. Pre-charge gas to booster not connected
or line is blocked.
B. Outlet check clogged or faulty.
C. Leakage in high pressure system.
A. Connect pre-charge gas line to booster. Remove
and clean line.
B. Check O-ring & seat.
C. Repair or replace.
Booster fails to generate flow
or pressure
A. Leakage or blockage at inlet or outlet check valves.
O-Ring blown off poppet.
B. Pre-charge pressure too low.
C. Drive piston seal worn.
D. Connecting rod shift nut not adjusted properly.
A. Remove & clean check valves. Look for foreign matter
lodged in seating areas. Replace poppet O-ring.
B. Replace source if necessary, or turn on supply.
Insufficient supply gas filtration is a leading cause
of seal and check valve failure.
C. Replace piston seal if necessary.
D. Adjust shift nut as required.
Booster is not delivering Gas
(booster not running)
A. Air valve sticking detent spring damaged.
B. Air valve sticking – shuttle is worn.
C. Connecting rod shift nut not adjusted properly.
D. Shift spring broken.
E. Confirm adequate pre-charge pressure –
refer to manual.
F. Driving air supply disconnected air shut off valve closed
or air filter clogged.
G. Air pressure regulator not adjusted.
H. Air directional valve sticking (PowerStar 4 Booster).
J. Air Pilot valve damaged or sticking (PowerStar 4 Booster).
A. Examine detent spring for damage. Replace if needed.
B. If shuttle is worn, it must be replaced. Excessive
wear can be seen if the plating has been worn away
from the air valve shuttle.
C. Readjust per booster assy. Check manual on our
website.
D. Replace if needed.
E. Adjust pre-charge regulator or acquire additional
pre-charge.
F. Reconnect line. Open valve. Clean air filter.
G. Adjust regulator.
H. Replace valve.
J. Remove and clean or replace as needed.
Booster running rapidly gas
flow is reduced (PowerStar 4
Gas booster)
A. Air pilot valves damaged or sticking.
B. Air pilot valve O-ring damaged.
C. Air pilot valve springs broken.
D. Air directional valve interface. Seals damaged or missing.
E. End plate air seals damaged or missing.
A. Remove and clean or replace.
B. Replace.
C. Replace.
D. Replace.
E. Replace.
Gas Leaking A. Damaged high pressure seals. A. Replace.
2955 W. 17th Street • Erie, Pennsylvania 16505 U.S.A. • Phone: (814) 838-2028 • 1-800-289-7447
Fax: (814) 838-6075 • E-Mail: sales@highpressure.com • www.HighPressure.com
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