Industrial System Routine Maintenance

Minimum Routine Maintenance Requirements (where applicable)

Daily Tasks:

Compressor:

• Check Oil Levels on booster and compressor by checking sight glass. 
  • It is recommended to check sight glass while unit is running loaded. 
  • Add additional oil if at, or below the minimum level indicated on the sight glass. 
  • If there is no indicator on the sight glass, ensure oil level is filling the sight glass approximately halfway.  Do not overfill. 
  • If oil loss is frequent, open a support ticket ([e-mail]).
• Visually inspect for oil leaks inside the compressor cabinet.
• Ensure the compressor discharge temperature is no higher than 110° above ambient temperature on the Elgi compressor.
  • If the temp is above this level, blow out the compressor cooler and monitor.  
• Check for any errors or alarms in the compressor and booster logs. If alarms are frequent, open a support ticket ([e-mail]).
• Listen for obvious air leaks and unusual noises (knocking, grinding, etc.) when the booster or compressor is running.
• Turning off the compressor daily may cause additional wear and tear. 

Dryer:

• Check operations of desiccant dryers and ensure back pressure is not over 4psi.
• Ensure that refrigerant dryers are powered on and confirm fan and compressor are running.

Nitrogen Generator:

• Check the inlet pressure of the generator and ensure that it matches your system design.  Some pressure recovery time during cycling is expected.

Booster:

• Visually inspect for oil leaks inside the booster cabinet.
• Listen for obvious air leaks and unusual noises (knocking, grinding, etc.) when the booster or compressor is running.
• Check for any errors or alarms in the compressor and booster logs. If alarms are frequent, open a support ticket ([e-mail]).

 Weekly Tasks:

Compressor:

• Clean all pre-filters (inlet screens) on the Elgi compressors with compressed air (not to exceed 40psi).
  • Do not use any solvents.

Nitrogen Generator:

• Observe towers cycle properly on the N2 generator and ensure back pressure is not excessive on the regenerating tower.
• Ensure that each sieve bed reaches the same max pressure during cycling +-5psi. 

Booster:

• Inspect the final filter housing on the booster for excessive condensate. 
  • Replace element if necessary. 
  • Clean air filter element on the Ozen booster with compressed air (not to exceed 40psi.)
  • Do not use any solvents.
• Inspect intercooler, aftercooler, and flywheel on Ozen boosters.

System:

• Inspect condensate lines for leaks and ensure condensate can move freely.
• Test timer/zero loss tank drains by pressing the “test button.” For timer drains, monitor system while running and wait for drain to open. This will happen every 1-5 minutes for a few seconds, depending on the model.
• Inspect float drains on all filtration for oil or water buildup.
  • Ensure float moves freely. 

Monthly Tasks:

Compressor:

• Blow out compressor air oil cooler. 
• Blow out the air-intake filter from inside out on Elgi compressors (to prevent damage, use no more than 40psi to blow out filter).
• Check the Elgi compressor air inlet filter for damage or holes with a flashlight. If oil or particulate is excessive, replace it and reset the service timer on the panel.
• Visually inspect any belts for damage and tightness.
• Power down and check oil levels. 
  • Top off, if necessary, do not overfill!
• Check current to compressor.

Dryer:

• Blow out the dryer cooler on the refrigerant dryer. 

Nitrogen Generator:

• Check final filter housing and element for oil or contamination.
  • If contamination is excessive, replace elements.

Booster:

• Visually inspect for oil leaks inside the booster cabinet.
• Visually inspect any belts for damage and tightness.
• Power down and check oil levels. 
  • Top off, if necessary, do not overfill!
• Check current to booster.

System:

• Check final filter housing and element for oil or contamination.
  • If contamination is excessive, replace elements.
• Inspect the oil water separator and empty if necessary, according to local guidelines.
• Check tightness of cable connections.
• Check tightness of fasteners and retorque where applicable.
• Test safety relief valves, while the system is running, check for leaks.
• Visually inspect all hoses for air/oil leaks.

 Sauer boosters require an oil change and retorque of all connections at 50hrs after initial startup. 

All connections on the Sauer booster must be retorqued 50 run hours after any service.  Torque specs can be found in the Maintenance/Operation Manual

At startup and following any media replacement, desiccant dryer mufflers should be removed to blow any desiccant dust out for the first 4-6 Regen cycles longer if dust is excessive. 

The purpose of this document is to summarize the regular maintenance checks and is in no way all inclusive.  Each manufacturer (Elgi, Sauer, Bauer, Ozen) will come with its own operating/maintenance manual.  It is recommended that these manuals be used in conjunction with this document to ensure proper maintenance is performed.  Please open a support ticket on our website with any questions or concerns. www.southteksystems.com