HG7/210AD

Air compressor

Operation Manual
Part Manual

A
20150205

PREFACE
Preface5

WARRANTY AND ASSISTANCE

1.1 Warranty8
1.2 Assistance9

SYSTEM INTRODUCTION
2.1 system specification 10
2.1.1 system technology parameters 11
2.1.2 instrument the value of setting
12
2.2 principle and structure
14
2.2.1 working principle 14
2.2.2 appearance 17
2.3 Bump configuration
19
2.3.1 crankshaft-rod kit 20
2.3.2 crankshaft-rod lubricating 21
2.3.3 cylinder kit
22
2.3.4 cylinder lubrication
23
2.4 driving and transmission
24
2.4.1 driving configuration
24
2.4.2 transmission
24
2.4.3 mechanism tensioning 24
2.5 safety and control kit
25
2.5.1 safety

25
2.5.2 emergency stop switch 26
2.5.3 oil pressure monitoring
26
2.5.4 oil pressure monitoring 26
2.5.5 temperature monitoring 26
2.5.6 check valve
26
2.5.7 D4 control valve
27
2.6 other device
27
2.6.1 gas and water separator
27
2.6.2 air inlet filter 28
2.6.3 automatic sewage system 28
2.6.4 inter stage cooler 29
2.6.5 cylinder group 29
2

2.7 Safety signs and danger zone30

2.7.1 Safety signs 30
2.7.2 Safety signs 31

INSTALLATION

AND

OPERATIO N

3.1 Unpacking32
3.2 Installation
32
3.3 Ready to use 33
3.2.1 Check before use 33
3.2.2 Lubricating oil filling
34
3.2.3 Pipe connection
35
3.2.4 Electrical connection
35
3.4 Compressor operation 36
3.4.1 Electric system operation 36
3.4.2 The control logic 44
3.4.3 Equipment safety operation regulation 46

M A I N T E N A N C E
4.1 Maintenance schedule 48
4.2 Lubrication system maintenance 49
4.3 Transmission parts maintenance 51
4.4 Filtering device
53
4.5 Lubrication and maintenance of Diesel 59
4.6 coolers
60
4.7 Removal of oil carbon 61

T R O U B L E

S H O T I N G

5.1 Compressor
unit
62
5.2 piston compressor
64
5.3 Valve troubles
68

CIRCUIRY
6.1 Circuitry

69

S P A R E

P A R T S

7.1 Compressor
spare parts
7.1.1 crankcase assembly
7.1.2 crank shaft assembly
7.1.3 rod assembly
7.1.4 oil-bump assembly
7.1.5 cylinder assembly8.125
7.1.6 cylinder assembly6.125
7.1.7 cylinder assembly3.25

7.1.8 cylinder assembly1.875

7.1.9 cylinder assembly1.25

7.1.10 guide-cylinder assembly

7.1.11 NO.1 cylinder-head assembly
7.1.12 NO.3cylinder-head assembly
7.1.13 NO.4cylinder-head assembly
7.1.14 NO.5cylinder-head assembly
7.1.15 piston assembly 8.125

7.1.16 balanced piston assembly6.125

7.1.17 piston assembly 3.25

7.1.18 piston assembly 1.875

7.1.19 piston assembly 1.25

7.1.20 Fan & wheel assembly

7.2 packing spare-parts

7.2.1 The separator assembly

7.2.2 Sewage assembly
7.2.3 mount assembly

7.2.4 Drive assembly

7.2.5 Diesel assembly
7.2.6 Transmission tighten assembly

7.2.7 Diesel fuel pipe assembly

7.2.8 pressure meter assembly
7.2.9 air-Cooler assembly

7.2.10 lubricating pipe assembly

7.2.11 Exhausting pipe assembly

77
79
81
82
83
84
85
86
87
88
89
90
92
93
94
95
96
97
98
99
100
101
107
105
107
109
115
123
124
125
128
130
132

PREFACE

1, please read and follow this manual provides all the user operation, operation
process, preventive measures and manual that appears all danger, warning statement,
otherwise there will be likely to lead to serious safety accidents.
2, please read carefully and correctly understand the contents of the manual and the
following

DANGER

Risk mark used when the misuse or failure may cause personal injury.
WARNING
Warning signs used when misoperation or fault may cause damage to units or
components.

WARNING LABLE
1

Table 0-1 Label content

NO.
1
2
3
4

Warning label content

Hand clamp
Mechanical movement parts
electric shock
Prohibit to remove the protective
structure

NO.
5
6
7

Warning label content

Prohibit to work in the movement
Please wear protective glasses
Please wear a helmet

Please wear protective gloves

This manual should be kept!

For the protection of personnel and property safety, please strictly observe safety
rules in this manual and safety regulations of local government.
7

WARRANTY AND ASSISTANCE

1.1

WARRANTY
High Air Machinery (Shang Hai) Co., Ltd. The machine warranty finished in
12 months after the deliveryError is to be reported within 8 days, if the customer
found it.
The warranty regulations apply only to the machine running environment in the
warranty period under normal operation, and after refer to manual for proper
operation, use and maintenance, still engender fault or damage.
The warranty explicitly ruled out the consequences due to error using. The
warranty does not include the consumption of materials and periodic maintenance
costs, the costs will be borne by the customer. Any changes without the High Air
Machinery authorization for the structure and control mode of the machine, the
warranty lapsed automatically.
High Air Machinery promised all fault or damage due to design , production,
and materials etc. ,can be Free repair or replacement .
If the Machine has been delivered, the customer found that damaged parts need
to be replacement , shall declare in advance, otherwise the warranty does not produce
any effect.
High Air Machinery has the right to repair and replacement parts, more than the
warranty period does not give change.
The unidentified warranty regulations, High Air Machinery does not provide
any parts of the compensation.
High Air Machinery don't assume for human injury and property damage directly
or indirectly (stop production, loss of interests etc.).

1.2

ASSISTANCE

High Air Machinery (Shang Hai) Co.,Ltd and our agents are always ready
to provide technical support and service for you. !

please contact with High-Air Machinery (Shang Hai) Co.,Ltd and our agents.

High Air Machinery (Shang Hai) Co.,Ltd

NO.155 Tinghua road Jin shan district Shang Hai.
TEL+86 021 60892089
FAX+86 021 60892120
http://www.highair.cn
sale@highair.cn
Service Phone +8621 60892116 18017133181 18017133182 400-8581-078
E-mailserver@highair.cn

SYSTEM INTRODUCTION

*The picture is for reference only, please make the object as the standard
High Air Compressor
W type, 6 cylinder 5 stage single action piston compression, the maximum discharge
pressure 210Bar. The precise balance of piston, single connecting rod design. Large
displacement, low speed, air - cooled and no foundation design , multiple V belt
drive, splash lubrication with forced lubrication. The complete equipment, open
architecture design, is the ideal choice for industrial users.

10

2.1

The system parameters

2.1.1

Technical Data

The system consists of five stage high-pressure compression :diesel engine, high
pressure cylinder group system, pressure control valves and electrical. control system. All the
parts are mounted on a cabinet control system. All the parts are mounted on a cabinet.
Table 2-1 The working environment of the unit
Ambient Temp.

-10~45

Elevation
Power
Working medium
Suction Temp.
Suction Pressure.

1000m
Diesel-driven
Air
Ambient Temp.
Atm. pressure

Table 2-2 compressor The main technical parameters

model
HG7/210AD
cylinder num. /
6/5
compression stage
Working medium
Air
air flow
6.5Nm3/min
Suction Pressure.

0.1 MPaAabs.

exhaust Pressure.
Cooling style
Drive style
shaft power
stroke
speed
Lubricating style
lubricating oil pressure
oil tank volume

21MPaG
Air-cooled
Diesel-driven
122KW
133.6mm
982RPM
Oil-bump + splash lubrication
1.5-3Bar(hot)
22L
SH150
183KW@1800rpm
~8000Kg

Lubricant model
Diesel-driven power
weight
Table 2-3 technical data of the cylinder :
stage
Cyl.No.
Dia(inch)
style
1
2
3
4
5
*)

2
1
1
1
1

8.125
6.125
3.25
1.875
1.25

Operating press.

*)

ingle action piston

2.9Bar
11 Bar
Single action piston with 33 Bar
a guide cylinder
80 Bar
210 Bar

The actual operating pressure in the test report shall prevail, this parameter is for reference only .

11

2.1.2

Instrument set points

The normal operation of the following monitoring and protection device used to
protect the compressor. If you run the value is out of range of the set value, the
compressor controller will automatically alarm and shutdown, and show the cause of
the problem.
At each compression stage, when there is problem for the automatic control and
monitoring system, the safety valve is to prevent overpressure as the last safety line. In
case of necessity, the safety valve will open, gas emptying out of the compressor.
The safety valve in the factory has been set up based on the release of pressure
at all stages of the required, and playing with the lead sealing. The working pressure
shall be at least 5% lower than the safety valve set pressure, the visible under the table.
Operation display instrument can indicate operation status of compressor. Operation data given in the table below are the loading condition based on normal environmental conditions.
During the running process of the compressor, some running parameters have
large deviation from the conventional numerical. Once this happens, it should immediately stop the compressor, and troubleshooting.

2-4

BV01

ball valve

Oil draining ,
bump

local

normally close

BV02

ball valve

Oil drain, Diesel

local

normally close

BV03

ball valve

Oil out, fuel tank

local

normally open

BV04

ball valve

Oil back-flow,
fuel tank

local

normally open

BV02

ball valve

Oil out, fuel tank

local

normally close

BV03

ball valve

Water out, tank

local

normally close

local

normally close

BV04

ball valve

PRV02 relief
valve, suction
port

ILV01

sluice valve

Exhaust, cylinder

local

normally close

ILV02

sluice valve

Exhaust, exhaust
port

local

normally close

10

ILV03

sluice valve

Air-Exhaust
Truncation

local

normally open

12

Table 2-5 Instrument set points

NO.

code

Instrument

Monitoring type

Installation

Figure*)

DCA01

Current gauge

Generation current;

Dash board

0-55A

DCV01

Voltage gauge

Charge voltage

Dash board

28V

20V alarm

FG01

Fuel gauge

oil level

Dash board

1/4 alarm

OLT01

oil level sensor

oil level

local

PI01

Press. gauge

1st suc. press.

local

0 bar

PI02

Press. gauge

1st Exh. press.

Dash board

2.9 Bar

PI03

Press. gauge

2st Exh. press.

Dash board

11 Bar

PI04

Press. gauge

3st Exh. press.

Dash board

33 Bar

PI05

Press. gauge

4st Exh. press.

Dash board

80 Bar

10

PI06

Press. gauge

5st Exh. press.

Dash board

210 Bar

11

PI07

Press. gauge

Lubricant press.

Dash board

1.5-3 Bar

12

PI08

Press. gauge

Regulated press.

local

8 Bar

13

PI09

Press. gauge

Exh. Press.

Dash board

210 Bar

14

PI10

Press. gauge

Exh. Press.

Dash board

210 Bar

15

PI11

Press. gauge

Regulated press.

local

2-3 bar

16

PRV01

Relief valve

Instrument air

Dash board

8 Bar

adjustable

17

PRV02

Relief valve

Instrument air

Dash board

3 Bar

adjustable

18

PS01

Press. switch

Exh. Press.

local

215 Bar

Adjust ban

19

PS01

Press. switch

Bump Press.

local

1.5 Bar

Adjust ban

20

PT01

Press. Temp.

Exh.Temp.

local

21

RV01

safety valve

1st Exh. press.

local

4 Bar

Adjust ban

22

RV02

safety valve

2st Exh. press.

local

12 Bar

Adjust ban

23

RV03

safety valve

3st Exh. press.

local

45 Bar

Adjust ban

24

RV04

safety valve

4st Exh. press.

local

132 Bar

Adjust ban

25

RV05

safety valve

5st Exh. press.

local

220 Bar

Adjust ban

26

RV06

safety valve

Cylinder press.

local

220 Bar

Adjust ban

27

TT01

Temp sensor

Exh.Temp.

local

28

TT02

Temp sensor

Water-tank Temp

local

29

TT03

Temp sensor

Crankcase Temp

local

*)

remarks

Actual operating pressure to test report shall prevail, this parameter is for reference only .

13

2.2

Principle and structure

2.2.1

Working principle

HG7/210AD compressor Is the reciprocating compressor 5 stage compression

Specifically for the air pressure below the 210bar applications. The actual air delivery
of 6.5Nm3/min, the compression ratio and intercooler efficiency, reasonable design,
high pressure air supply reliable.
The following basic operation principle:

In the 1st stage piston suction stroke, atmospheric pressure air enters the 1st
stage cylinder through the air inlet filter and the suction valve. The compression
stroke will compress the air to an intermediate pressure, and the air is
discharged to the intercooler piping through the 1st stage of the discharge valve.
in here, the compressed air at high temperature and high pressure have heat
exchange with the cold air sucked by the cooling fan, so that the temperature of
the compressed air is reduced to above 15-20 than environmental
temperature, ensure the 2nd stage compression without over temperature.

The discharge stroke of 1st stage is just the suction stroke of 2nd stage. cooling
air is sucked to cylinder through 2nd stage of suction valve, the air in the cylinder
is further compressed to a higher pressure. In the 2nd stage of the compression
stroke, high temperature and high pressure air enters the 2nd stage intercooler
through 2nd stage of discharge valve, in the cooler, high temperature of the
compressed air get heat exchange with the cold air, the temperature is reduced
to above 15-20 than environmental temperature, ensure that the third stage
compression without over temperature.

Such a cycle, until after the five stage compression, air pressure to meet user
requirements, At the same time in the unit operation process, as a result of the
compressed air in the inter stage cooler and cooler air to exchange heat, its
temperature decreases, the saturate vapor in the compressed air condense to
water due to decreasing temperature, separate with compressed air in the
separator, Then through the automatic control with the drain valve, timing drain
out from separator.

Compressor configuration has a full start unloading system. This will

automatically release the pressure of the cylinder, inter stage cooler, and drain
out water from the separator when the compressor stop working.

CATIONWhen the compressor shutdownat least should be unloaded for more

than 5 minutes, to exhaust heat air in compressorbecause after the
compressor stops, the vapor in the compressed air will be precipitated when the
temperature drops, the cylinder internal will be get rust; in cold weather
conditions will make the pipes freeze.
14

15

Rc1/2

:
1800RPM

Rc1/2

DPI
01

PP
01

25T-2

IF
01

60.3P-5

12H-5

23H-3.5

BV
01

20T-3.5

25T-2

DO

HEA
01

88.9P-5

6T-1

ABV
03

ABV
02

PI
01

DO

PRV
01

8T-1.5

RV
07

SPF
01

DO

ABV
01

12T-2.5

12T-2.5

12T-2.5

AI

TT
03

SPF
02

88.9P-5

6T-1

38T-1.5
BV
02

6T-1

6T-1

PS
02

PI
07
DI

IC
01

SR
01

DC24V

60.3P-5

DI

SR
02

RV
02

30T-1.5
DCV
01

IC
02

12T-2.5

PI
08

DO

38T-1.5

PI 6T-1
03

BV
06

DI

PI 6T-1
04

GE

DCA
01
RC
01

AI

IC
03

SR
03

RV
03

30T-1.5

RV
01

30T-1.5
38T-1.5

12T-2.5

PI 6T-1
02

30T-1.5
30T-1.5

SV
02

LSL
01

IC
06

RT
01

AI

IF
02

AI

56H-3

50H-3

PI 6T-1
05

25T-2
25T-2
TT
02

183KW@
1800rpm

IC
04

SR
04

RV
04

14H-3

14H-3

PT
02

PI 6T-1
06

IF
04

AI

PP
02

LS
01

DI

IC
05

PS
01

BV
04

CV
01

SR
06

20T-3.5

SR
05

RV
05

HS

DI

6T-1

DO

25T-2

12T-2.5

12T-2.5

:
960RPM

G2

BV
07

IF
03

VS
01

BV
03

PT
01

TT
01

DI

AI

AI

PRV
02

RV
06

OLM
01

OLT
01

FG
01

DI

OT
01

HPC
04

HPC
03

HPC
02

HPC
01

16T-3

SV
03

DO

16T-3

SV
01

12T-2.5

38T-1.5

12T-2.5

38T-1.5

16T-3

DO

20T-3.5
20T-3.5

12H-280

16T-3

12T-2.5
16T-3

PI
11

PI
10

20T-3.5

ILV
03

20T-3.5

BV
05

ILV
01

PI
09

COV
01

23H-3.5

20T-3.5

ILV
02

25T-2

Rc1/2

3/4UNF16
JIS swivel

210Bar

6.5m/min

1FNPT

Process indicator diagram

16
Electric

IF
01

Oil filter IF

Tachometer TM
Tachometer/time
display TMT

Silencer SL
H

SL
01

Manual

Fuel gauge FG

LS
01

Limit switch LS

Conical filter

Voltmeter

PS
01

HEA
01

HOP
01

LOP
01

HGT
01

FS
01

VS
01

OLS
01

IC
01

ACV
01

FS
01

TM
01

FG
01

DCV
01

SR
Vertical
01
vessel SR
BFA
Breathing
A
01
filter A
BFB
Breathing
B
01
filter B
BF
Breathing
01
filter
TT
Temperature
01
transmitter TT
PT
Pressure
01
transmitter PT
TI
Temperature
01
indicator TI
PI
Pressure
01
indicator PI
Differential pressure DPI
01
indicator PdR
ACA
DCA
Ammeter
01
01

water

Cooler IC air

Pressure switch

Temperature switch
Low oil pressure
switch LOP
High oil pressure
switch HOP
Oil heater HEA

IF
01

SPF
01

PP
01

Pump

Air inlet
filter SPF

GE

132KW
380V,50HZ

Generator

AC motor

Cylinder

Flow switch FS

Vibration switch VS

Hose

1ST

Oil level switch

Waterway

Drain line

EO

DO

Digital output
Auto temperature
control
Variable symbol

The control line

Vent line

DI

Digital input

Oil pipeline

AI

Analog input

gas pipeline

Pneumatic
high-pressure
valve ABV

Pneumatic valve

Check valve CV

Needle valve
Manual drain
valve VH
Safety relief
valve RV
Safety relief
valve RV
Solenoid valve

Globe valve

Electric
M
butterfly valve
Throttle valve
Temperature
B
C
A
control valve
Control
valve PCV
Pressure relief
valve PRV
Ball valve BV

Legend/Air

ABV
01

UNV
01

CV
01

SV
01

RV
01

RV
01

VH
01

ILV
01

ILV
01

BV
01

PRV
01

PCV
01

TCV
01

FF
01

BFV
01

Differential
pressure
control valve
Back pressure
valve BPV

Gas detector GCT

Explosion
proof lamp LT
Oil tank OT
Steel
cylinder HPC
Electric
Tracing Band
lever valve TOV

Smoke detector SD

Speed controller RC
Oil level
transmitter OLT
Oil level meter OLM
Level maintenance
meter LM
Flow indicator FI

Speed sensor RT

BPV
01

SQV
01

TOV
01

LDV
01

HPC
01

OT
01

LT
01

GCT
01

SD
01

FI
01

OLM
01

OLT
01

RC
01

RT
01

Legend and instructions

2.2.2

Appearance

Table 2-5 main configuration and nozzles;

NO.

Description

NO.

Description

Compressor suction filter

Diesel suction filter

compressor

Diesel

Air-cooler

Drain-nozzle;/G2

Diesel water tank

Fisher D4 control valve

17

Due to continuous research and improvement ,graphic may differ, please understand.
18

2.3

Components of the compressor unit

1
2

3
4

Table2-6 Components of the compressor unit

NO.

Name

NO.

Name

1st stage cylinder

Oil filling plug

2nd stage cylinder

crankcase

3rd stage cylinder

Fan driven wheel

4th stage cylinder

Breath filter

NO.5 cylinder

19

2.3.1

Crank rod kit

*The drawing is only used for the reference structure, does not represent the set of

20

2.3.2

Crankshaft-rod lubricating

4.3.

21

2.3.3

Cylinder kit

22

2.3.4

Cylinder lubrication

23

2.4

Drive and transmission

2.4.1

Drive
Unit driven by Cuminns Dieselparameters as belowSpecial maintenance is
available for Diesel
Table 2-7 Diesel parameters

2.4.2

Manufacturer

Cummins

Type

QSB6.7-C260

discharge capacity

6.7L

Power

183KW@1800RPM

Speed

800~1800rpm

Torque

990Nm@1500RPM

Cool style
Net weight

water
629Kg

Discharge class

Europe III

Transmission

The system adopts the mechanical clutch (model: WTD SP211) + power transmission
belt, gear clutch applied by hand. Pls reference its maintenance

2.4.3

The tensioning mechanism

24

Using a large barrel type tensioner, 4 point

support, good rigidity, convenient adjustment.

2.5

Safety and control kit

2.5.1

Safety valve
Safety valve's role is to protect the compressor (and the
cylinder) and prevent overpressure. Once the failure of
all other automatic control and automatic system, safety
valve will release the pressure in all compressor.

NO.

NO.

NO.2 NO.

NO.

safety valve is set according to below

pressure before leave the plant
-NO.1 safety valve0.4 MPa
-NO.2safety valve1.2 MPa
-NO.3safety valve4.5MPa
-NO.4safety valve13.2 MPar
-NO.5safety valve22 MPa

WARNING

Each separator equip with safety valve. If the final safety valve occurred jet and
continuous jet more than a minute, the compressor should immediately stop.
This shows that the leakage of cylinder pressure, the next higher stage of
suction / discharge valve have been cracked or carbonization.

Under no circumstances can change these safety valve set pressure.

If the safety valve action, according to the manual examination of the causes of
overpressure.

Do not remove, replace, or replace safety valve. Safety valve can only use the
original HG parts replacement. Any due to the set pressure of safety valve
tamper, and cause serious injury, will be immediately automatically cancelled
quality assurance.

2.5.2

Emergency stop switch

Abnormal cases occur in the unit

work, emergency stop.

Emergency
stop

25

2.5.3

oil pressure monitor

2.5.4

Compressor oil pressure can be observed on

the panel, also through the pressure switches
to monitor the pressure , if the oil pressure
below 1.5bar, pressure switch act and stop the
system .

Pressure monitor

check valve

2.5.5

The pressure sensor is installed after the

check valve, used for collecting the final
pressure signal, when the signal reaches the
pressure setting, automatic shutdown and
automatic start.

pressure sensor

Temp. monitor

Temperature sensor installed at

compressor exhaust , the temperature
transfer into a continuous analog
signal, and displayed through the PLC.

Temp. sensor

2.5.6

Check valve

Check valve

26

Check valve installed after the NO.5 separator,

preventing rear gas reflux and cause damage.

2.5.7

D4 control valve
D4control

2.6

Fisher D4 control valve, installed at the exhaust

pipe of the unit, maintain the system pressure
through venting, avoid the system frequent
start and stop .

D4 control valve, normally closed type ,control

pressure is 2-3bar through instrument air . For
more details ,Pls see the corresponding
instructions.

Other device

2.6.1

gas water separator

NO.3

NO.4

NO.2

NO.5

NO.1

After each stage of compression, compressor are equipped with a separator,used

to separate the oil and water in the compression process.

After each stage of compression of gas temperature rise, will be to re
cooling,temperature reaches the dew point of the gas, water condenses out from
compressed gas must be separated.
In a separator, due to the special design of separator, causing cyclone or object
offset effect, the condensed water will accumulate in the bottom of the separator,
waiting for the sewage system will discharge.
DANGER
If the condensed water to a certain moment without treatment, will lead to the
occurrence of danger. The condensed water will be sucked into the next stage of
cylinder, compressor will damage. This is called "water shock"!
27

2.6.2

Air inlet filter

80% dust particles in the air will be
filtered by inlet filter, filter need regular
maintenance,
please
see
the
maintenance section.
Under special condition, the rain hat
should be installed to protect the filter
element.

2.6.3

Automatic drain system

Automatic drain system consists of a

normally closed solenoid valve +
pneumatic valve.
Automatic drain time and interval time are
arranged on the PLC
Due to the existence of small sundries in
sewage, easy to plug the solenoid valve,
automatic drain valve please timing

cleaning

Solenoid valve

Discharge dirt collected in the drain

collection bucket, please timed sewage
collecting barrel

Pneumatic high-pressure ball-valve

28

Please dispose of sewage

2.6.4

Inter stage cooler

NO.1

NO.2

NO.3

NO.4

NO.5

2.6.5

Compressed gas in each stage, must pass through the inter stage cooler, to
cool the heat by compression

The cooler is air cooler

Cylinder group
Table 2-8 Cylinder group

29

Cylinder pressure spec.

440L

Cylinder pressure

250Bar

Cylinder connection

2+2parallel
connection

2.7

Safety signs and danger zone

2.7.1

Safety signs

Table 2-7 Label content

NO.
1
2
3
4

Warning label content

Hand clamp
Mechanical movement parts
electric shock
Prohibit to remove the protective
structure

30

NO.
5
6
7

Warning label content

Prohibit to work in the movement
Please wear protective glasses
Please wear a helmet

Please wear protective gloves

2.7.2

Danger zone
5

Table 2-8 Danger area description

Position

Description

1.Compressor

To avoid scalding, compressor work will produce high

temperature, any maintenance work please in the unit shut
down after 30 minutes!

2.Diesel engine

Avoid high temperature burn!

3.Belt area

Beware of broken belt, involved in debris. No close

contact when the unit works!

4.The last stage

separator lines
5.Fan area

of High pressure working area!

To prevent the impact and abrasion, twisted,
contact when the unit works!

31

No close

INSTALLATION AND OPERATION

3.1

Unpacking
This unit is a container type, non wooden packing shipping. Accessories are as
follows:

Table 3-1 parts list

NO.
1

iten

quantity
4

ManualChinese

ManualEnglish

Synthetic lubricating oil/ 4.5L

Compressor suction filter

Compressor oil filter

Diesel parts/3 sort filter,V-belt

4
2set

Valve set/NO.1-5 valve sets

1set

Piston ring/1-5

1set

Special tool

1set

10

Compressor bump gasket

2set

11

Solenoid valveG1/2,16BarDC24V

12

Solenoid valve10BarDC24V,NC

13

PLCCPU224XPSIEMENS

14

V-VeltSPC4500

1
2

15

Portable dry powder fire extinguisherMFZ/ABC3

16

Certificate

16barrel

RemarkActual shipping list shall prevail

3.2

Installation

Please put the unit is placed on a horizontal surface

Please ensure that the installation area can ensure the unit in good
ventilation, heat dissipation.
Please ensure that the installation area does not exist dust, explosion, corrosion
and fire risk.
When the unit is in 40 degrees Celsius above ambient
temperature operation, please use the air conditioning for the use
of space cooling.
Please make sure that the unit from the wall over 1.5M.
Please make sure that the unit and the ceiling a distance of more than 1.5M.
Please ensure that the regional good lighting installation, various parts
and indication label clearly visible.
Units on the ground without special foundation, ground leveling can be ok; if
the units used in the ship, before the use should be set a fixed.
32

3.3

Ready to use
If you are the first time to use this product, so the correct installation the unit is
crucial for reliable to operate the compressor .
A lot of problems appearance relate to the compressor is not properly
installed. Please refer to the installation guide correctly installed .
When you receive the compressor unit, please check whether there are damaged
parts, please also check the spare parts. Please according to the packing list
checking whether the goods are lost. If you find any damaged or
missing parts, please contact immediately with the shipping company, and inform
us.

WARNING
Please handle with care in lifting process!

Reciprocating compressor system should be installed in the flat level surface can bear on
the unit weight. When installation, maintenance and repair should ensure that there
is enough space around the unit, in order to facilitate maintenance and repair work.

High Air compressor dynamic balance is very good, does not need the special
foundation. However, based on years of experience, a solid foundation is very
necessary for continuous and reliable operation of compressor.
Sewage pipeline of compressor should be as short as possible, as far as
possible, and use straight pipe, in order to reduce the pollution of the back
pressure. Sewage pipe installation should be downward sloping, discharge is
convenient for condensed water, oil mixture.

WARNING
Don't block the drain line, do not install the valve in the drain pipeline.

WARNING

Only installation of the unit has been Finished (including inlet and outlet port,
water inlet and outlet port , and other pipe), Start the compressor when the
condition has been meet (for gas, water, electricity and other equipment),
Otherwise, forcibly start may result in damage to the equipment!

3.3.1

check before initial use

Before start compressorPlease check as the below
A. Turn compressor round by hand
B. Check the tightness of belt
C. Check the connector leakage, power wiring
D. Check the oil level of bump
E. Check the antifreeze water in water tank of Diesel
33

3.3.2

Lubricating oil filling

filling

Oil leveler

Compressor lubricating oil

Oil filler is positioned at the upper part of the crankcase, as shown in the figure
unscrew the respirator and injecting lubricating oil

The oil level mirror mounted on the front end lower part of cankcase

The oil leveler maximum level from the bottom of the crankcase is about 11cm,
the lowest level from the bottom of the crankcase is about 9cm; in any case, the
oil level can not be lower than the minimum level, check oil level. every day .
Note: the high pressure compressor synthetic oil viscosity, please slow filling. Or
filling lubricating oil before heated it with warm water.

Diesel lubricating oil

Diesel factory has been filling lubricating oil, Its necessary to check the oil
leveler before the start, the oil level should be between the the groove ,as
shown below.

Lubricating oil brandCG-415W-4025-28LFor details, refer to Diesel

manual

WARNING

Please check the oil level before the start, please filling after driving, otherwise may
cause the compressor scuffing of cylinder bore or other serious accident

34

3.3.3

P i p e

c o n n e c t i o n

The unit needs material and energy exchange with the external , so the
corresponding connection port is reserved for use, as shown in the following table .
Table 3-2 table of pipe
NO.

Des.

Specification

Function

Qua.

Discharge

3/4-16UNF

Customer gun hose

Drain outlet G2 inner

Drain outlet 1-11.5NPT inner

The sewage for system

D4control valvecylinder group

1
1

Rc1/2

Diesel lubricant-draining

Rc1/2

Diesel fuel-draining

compressor oil-draining

DieselOil
outlet
Oil tank
drain

Bump drain Rc1/2

Note: the vent and discharge nozzle shall not be installed other valves, prevent blocking

3.3.4

Electrical connection

The unit driven by DieselNo additional electrical connections

Check the wiring terminal connection whether firm and Completely covered.

WARNING
Electrical must be operated by Professional, otherwise cause serious accidents!

35

3.4

Compressor operation

3.4.1

Electric system operation

3.4.1.1 N o t i c e
General requirements for safety:
This set of electrical control system specially used for air compressor automatic
control, please carefully read all instructions and descriptions of this manual. System
can endanger people life due to there have high voltage, moving parts, high
pressure fluid. part of the equipment surface injure people as a result of high
temperature, in the installation, wiring, start, run or do any adjustment before, please
use the manual as a guide. Improper operation will likely result in personal injury
or property significant losses, so the operation and repair personnel should be
strictly in accordance with the provisions of the manual to operation and
maintenance.
Warning signs and significance:
Danger
Said that if you do not take corresponding care measures, will cause death or
Warning
Said that if you do not take corresponding care measures, can lead to death
Caution
A warning triangle, said that if you do not take the corresponding care measures, may
NOTE
Said if you don't pay attention to the corresponding prompt, may appear undesirable
key point
Said that if the note corresponding prompt, may be relatively easy to master the
Remarks
The records of the supplemental content reference, relevance and other functions.
Qualified professionals

Only allow installation and drive attached devices or systems associated with the file.
Commissioning and operation of equipment or systems allow only by qualified
professionals. This document security technology of qualified professional personnel
refers to technical safety standards has engaged in equipment, system and the
According to the provisions to use
The device only allows the use of prescribed in the manual, and only allow the use
of High Air company recommended or designated other manufacturer of equipment
and components. The normal and safe operation of equipment must be dependent on
the appropriate transportation, proper storage, placement and installation and careful
36

3.4.1.2 device power on

Warning

Produced by equipment operation noise can cause hearing damage, please

wear earplugs or earmuffs protection;

When the equipment works, please pay attention to ventilation;

Don't run the machine under the condition of no secure isolation, set a
soundproof cover can effectively isolate the noise, and also play a protective

After electrical preparation of chapter, 3.3.4, supply equipment power by .turn on battery
switch by clockwise rotation of

The battery switch

Remarks
If the emergency stop button is pressed, please press the button pop
up to reset, otherwise the system will not startup!

37

3.4.1.3 Device Operations

A-Electrical control panel

HG7/210AD compressor The operation interface as above

Button introduction
S1power switch
S2Automatic / manual selection button manual selection butto must be
supportec by Diesel Controller by plant service personal
EP1Emergency stop for Emergency
PB3button for Sewage from stage1 to stage 5
PB7The ignition switch.
Each position definition is preheating, stop, run, start as Clockwise
direction
PB6The Diesel accelerator .This feature has been disabled load Diesel by
button switch
P1Fault indicating lamp
PB4Running lamp
PB5stop lamp
1# S3Toggle switch
Upward: load from rpm to 1800,
Middle:maintain the idle for Diesel
2# S4Toggle switch
when Diesel idle ,move upword ,Increase RPM50 every action.

38

B-The exhaust control panel

Gas-exhaust, Hose

Hose pressure

Needle valve, exhaust

Cylinder pressure

Gas-exhaust, cylinder

When compressor running, exhausting Needle valve open completely, in

contrast for others
,when air is unavailable ,Pls operate as below:
1shut down hose and exhausting
valve until pressure is 0

Needle valve, don't

close

relief

2if want to exhaust the pressure of cylinder pressure ,Pls open relief
valve on the cylinder or
exhausting Needle valve pls ensure personnel
safety
3if want to exhaust the pressure of the unit,pls press the manual drain
button on the front panel.

39

1. C-Operation steps instruction

1The battery switch is allocated to "/"power selection switch dial exactly right on the electrical
panelpower is available for System
2 SelectAutomatic functionPLC are shown in the following picture After initialization

Alarm inquiry
reset

Ch/En

Inquiry

setting

Maintenance setting

3Check the settings of the

parameters

Parameter setting for reference table 3-3

4Ensure breaking off Clutch and after each checking ,then start Diesel
by ignition switch Diesel idling runs with RPM800
5Diesel speed is regulated by Toggle switch 2# Increase RPM50 every
action along direction upward till to rpm 1200mthen load the clucth
after stable running, when Diesel idle ,stir switch 1# along direction
upward till max 1800rpm

40

6complete all parameter record for compressor runningsuch ascompressor

lubricant pressurestage pressureexhausting pressureexhausting
temperature water temperature of Dieselspeed
7PLC records the compressor fault with compressor runningas follow

41

9Under normal circumstances, the system automatically stop when meet the
stop terms, Before stopping the machine, the system will automatically
drain and unload a few minutes, for exhausting the heat in the pipe.
If meet system fault, unit will stop without draining until
the clutch
10Unit maintenance queries on PLC as follows

42

disconnect

3.4.1.4 Parameter setting

Table 3-3 Parameter setting table

Parameter

Original value

Setting range

Remarks

Exhaust pressure

210bar

50-250bar

PLC setting

Exhaust pressure
min. value

180bar

20-250bar

PLC setting

Exhaust temperature 215bar

100-250bar

PLC setting

high exhaust

60

40-65

PLC setting

Lubricant heating

-35-40

PLC setting

Load delay time

10s

5-30s

Unload delay time

5min

2-300min

Sewage Interval

15min

5-60min

Each stage Sewage

10s

2-30s

The parameter setting value recommended numerical select provided by our

company, these values are all our years of experience and, more conducive to
the protection of the compressor and the normal operation of the unit.

Tip: automatic operation system, the parameter value must

be accurately set page. Parameter is not set or not set the correct value causes
the system operation instability, even trouble!

The PLC control unit, set the system parameters stored

in PLC memory. PLC data in memory in case of power off, the general can only
maintain 100 hours of data memory, if the configuration of a battery, PLC can
keep 1 months of data memory. Therefore, if the system after a long time
of power off, need to recheck the parameter value. Necessary, need to do re
input.

43

3.4.2

Control logic
Running condition.
When the system is in the automatic control mode exhausting-pressure up to
210barexhausting regulating valve open and the system idling.
When the system is in the manual control modeexhausting-pressure is over ,compressor
unload and unit stop.
If test by automatic control mode start the unit by Diesel key switch once unit run
normally
If supply pressureauto draining pressurepressure regulator closeexhausting pressure
increase.
If supply pressureauto draining pressurepressure regulator openexhausting pressure
decrease
When the system is in the automatic control modesupply pressure up to 210 bar, unit
stop with delay modedelay time rang from5-30minduring delaypressure regulator
open and system unload ,if supply pressure <auto draining pressuresetting
pressurefor example200barpressure regulator closeDuring delay time, if
supply pressure decrease and lower than auto draining pressuresystem will suspend stop
programotherwise, continue to execute the stop program.
Whether the system is in the automatic / manual operation state, the Diesels idle and loading
depend on manual operation to complete.
System startup conditions
Following terms is necessary for start the compressor
Exhausting pressure210barexhausting term.50lubricant
tem.5lubricant pressure1.5bar
Unit startup in the low temperature , lube oil need preheating, the process is controlled by
PLC, oil heater in the crankcase with thermocouple temperature transmitter, pass the infor.
To PLC through the transmission ;
During the start-up of the unit, all the drain valve will open, and unit unloaded for start, after
successful start-up, the drain valve closed.
When the system is in the automatic control mode
During running with load situationThe drain valve drain once every 15minlast 10sact
sequence13452.
When the system is in the automatic control situationif exhausting pressurealarm high
pressureDiesel Maintain running situationcompressor regulating valve open and
drainon the other hand ,exhausting pressure over-high, unit stop immediately.
Diesel dont restart automatic after stop unless manual styleDiesel dont restart
automatic due to supply pressurelower alarm pressure.
If exhausting pressure>215barunusual Vibrationunit will stop immediatelydrain valve
and pressure control valve open.
If exhausting tem.>50unit will stop with delay.
the Unit point stop or alarm fault, pls see Appendix 1.

44

Table 3-4 unit shutdown or alarm fault

Protection
point

normal value

Display Alarm

Stop

unload

Exhaust
pressure

210barg

Exhaust MAX.
pressure

215barg

exhaust
temperature
high

ambient
temperature+10~15

60

60

water tank
temperature
high

Online

104

111

Low battery
voltage

DC24V

Power current

Diesel oil
pressure Low

2332psig

16psig

Compressor oil
Normal 1.8~2.0bar
pressure Low

1.5bar

1.5bar

Fuel level low

1/4
Range

11

Emergency stop

12

water level of
local
the water tank

13

Speed
protection

1850rpm 1850rpm

14

crankcase oil
temperature

NO.

15

Normal 35~70psig

full load /
1800rpm
approximate
60

set back Semi

Unit Vibration circle after
working point

45

3.4.3

Equipment safety operation regulation

Warning: compression Air is dangerous, only trained and authorized person may operate
compressor, don't change internal structure and control method of units, except authorized by
Highair company.
1. the items must be Checked before start

Check all fasteners, pipe whether loose or damaged, ensure that no debris around the
compressor

Check the compressor oil level, replace oil every 2000 hours or 1 years

Check the water tank liquid level, the oil and fuel level of diesel

Check the belt tightness , disconnect the clutch

Check the compressor parameter setting according to the instruction check

2.Start compressor

turn on the power switch on cylinder bracket, and put the control switch on the panel in
the "automatic" location

Diesel is not allowed to start with load, it is suggested to disconnect clutch before restart
Diesel

Start Diesel turn the key switch with Clockwise rotation , Diesel is in the idle state
(800rpm), increase speed to 1200rpm by the 2# toggle switch , then push on the clutch,
and then use the 1# toggle switch loading (till to 1800rpm), if emergency parking, press
emergency button

Under condition with Automatic mode, compressor will load and unload automatically
based on the pressure sensor

Compressor unload through the control valve Fisher D4 , once supply electromagnetic

valve power ,D4control valve open by instrument air .excess gas drain away through the
control valve ; once the pressure decreased to a value point, the electromagnetic valve
loss electricity power, Instrument air drain and control valve cut off.
3.stop compressor

When does not need to use compression Air , close valves, then press manual drainingbutton on panel, the unit unload, and then close the throttle gradually, and Diesel is idle ,
then disconnect the clutch, the Diesel to continue running 5 minutes with idle mode, then
stop the unit by Diesel Ignition switch along counterclockwise

Avoid loading and unloading frequently t, its not conducive for Reliability of unit

It is available to stop the unit by pressing emergency button on the control panel in
emergency situation

Compressor should at least be unloaded more than 5 minutes before stop running, to
ensure the heat Air drained completely, otherwise cause rust on internal cylinder due
to vapor will precipitate.

if let unit unused for longtime after stop, pls. shutdown the battery switch on cylinder
bracket. Otherwise cause unable to restart the unit due to battery leakage.

46

MAINTENANCE

47

4.1

Maintenance schedule

Interval

Maintenance work

remarks

every day

1, Check the oil level before the start or each class , long-term
shutdown, must be manual turning before starting, and
check whether the oil deterioration.
2, you should observe the unit has no leakage, unusual sound
3, check whether the normal condensed water discharge.
4, check abnormal noise and vibration.
5, check the inter stage pressure, water pressure, water
temperature.

The first
100 h

1check screw connections and pipe couplings

2change crank gear oil and oil filter

User self inspection

weekly

1check maintenance indicator of air inlet filter

2check crank gear oil level

User self inspection

every 200
h

1check screw connections and pipe couplings

2check crank gear oil level

User self inspection

1, blow the cooler and the compressor cylinder head

every 1000
2, blow the motor heat sink
h
3, clean the crankcase breathing filter
1clean air inlet filter cartridge
2replace oil and oil filter
3clean and replace internal parts of compressor valves
every 2000 stages 1-5
4clean and inspect internal parts condensate drain valves
h
and replace, if necessary.
5clean and inspect internal parts of non return valve
6fill grease in motor

4.2.3
4.3

1replace complete compressor valves of stages 1-5

2replace filter cartridge of air inlet filter
every 4000
3clean coolers, separators and pipes
h
4check V-belt tension of fan drive, replace it if necessary
5replacement of complete non return valve

examined by profes
sional

every 6000
1replace needle bearings with gudgeon pin
h

examined by profes
sional

yearly

1change crank gear oil filter

2clean complete unit
3check safety valves by slightly lifting during compressor
operation

48

4.3

4.2

Lubrication system maintenance

49


compressorcrankcase

50

4.3

Transmission parts maintenance

4.3.1 V-belt

51

4.3.2 Mechanical clutch maintenance

Comply with 2# lithium grease based on America Petroleum Association

Fill grease by gun grease every 100 hours

More detailed maintenance requirements ,please refer to the instruction manual

of mechanical clutch

52

4.4

4.4.1

Filtering device

Safety

53

4.4.2

Design

4.4.3

Air cleaner maintenance

54

Changing the main element

55

56

57

58

4.5

Lubrication and maintenance of Diesel

According to the diesel of the user device, shall comply with the following
instructions.

Check the Diesel lubricant level and clean the oil tank regularly

use clean diesel

Please refer to the Diesel manual on Diesel maintenance;

59

4.6

Coolers

60

4.7

Removal of oil carbon

61

TROUBLE SHOOTING

WARNING

Before performing any repair, must cut off the power supply and switch on power
suspension warning signs, release the pressure, but also, for repair personnel must
be authorized!

5.1

Compressor unit

62

63

5.2

Piston compressor

64

65

66

67

5.3

Valve troubles

68

CIRCUIRY
Total 8 pageNO.1 page -Operation panel layout

69

Total 8 pageNO.2 page-Diesel Circuit 1

70

Total 8 pageNO.3 page-Diesel Circuit 2

71

CPU224XP

Siemens

Total 8 pageNO.4 page-CPU Wiring

72

EM231*4RTD

1 2 3 4 5 6 7 8

ON

Siemens

Total 8 pageNO.5 page-pressure The current module wiring1

73

Total 8 pageNO.6 page- The control circuit

74

Total 8 pageNO.8 page -Controller distribution diagram

75

Total 8 pageNO.8 page -Terminal diagram

76

SPARE PARTS

7.1

Compressor spare parts

spare parts for bump.

77

78

7.1.1

crankcase assembly

79

80

7.1.2

Crankshaft assembly

81

7.1.3

Rod assembly

82

7.1.4

Oil-bump assembly

83

7.1.5

cylinder assembly 8.125

84

7.1.6

cylinder assembly 6.125

85

7.1.7

cylinder assembly3.25

86

7.1.8

cylinder assembly1.875

87

7.1.9

cylinder assembly1.25

88

7.1.10

Guide-cylinder assembly 6.125

89

7.1.11

NO.1 cylinder head assembly

90

91

7.1.12

NO.3 cylinder head assembly

92

7.1.13

NO.4 cylinder head assembly

93

7.1.14

NO.5 cylinder head assembly

94

7.1.15

Piston assembly 8.125

95

7.1.16

Balanced piston assembly6.125

96

7.1.17

Piston assembly3.25

97

7.1.18

Piston assembly 1.875

98

7.1.19

Piston assembly1.25

99

7.1.20

Fan & wheel assembly

100

7.2

Packing spare-parts

101

102

7.2.1

Separator assembly

103

104

7.2.2

Sewage assembly

105

106

7.2.3

Mount assembly

107

108

7.2.4

Drive assembly

109

110

111

112

113

114

7.2.5

Diesel assembly

115

116

117

118

119

120

121

122

7.2.6

Transmission tighten assembly

123

7.2.7

Diesel fuel pipe assembly

124

125

7.2.8

Pressure meter assembly

126

127

7.2.9

Air-cooler assembly

128

129

7.2.10

Lubricating pipe assembly

130

131

7.2.11

Exhausting pipe assembly

132

133

134

135

136

137

138

139

140

High Air Machinery (Shang Hai) Co.,Ltd

NO.155 Tinghua road Jin shan district Shang Hai.
TEL+86 021 60892089
FAX+86 021 60892120
http://www.highair.cn

sale@highair.cn

Service Phone +8621 60892116 18017133181 18017133182 400-8581-078

E-mailserver@highair.cn

141