Applies to: HPCF-SFI — catalog numbers HPCF-SFI-0004, HPCF-SFI-0110, and HPCF-SFI-0130
Does NOT apply to: HPCF Series — see HPCF Series Filter & Preventive Maintenance
The HPCF-SFI PLC automatically tracks system run hours and alerts when maintenance is due. Following this schedule is essential for system performance, purity, and longevity. Accessory manuals for the compressor, dryer, and booster are available by model number at southteksystems911.zendesk.com.
🛑 Safety Before Any Maintenance: Stop the system and disconnect all electrical power before beginning any maintenance task. Flip the internal breakers to the OFF position or unplug the system from its power source. Fully depressurize the affected section — confirm all gauges read 0 PSIG — before opening any component. Wear appropriate PPE throughout.
Maintenance Kit System
The HPCF-SFI uses a tiered FRP (Filter Replacement Parts) kit system. Each kit contains all components required for that service interval. Order kits using the part number for your catalog number — confirm your model number on the unit nameplate before ordering.
| Catalog Number | Model Numbers | 1K Kit | 2K Kit | 5K Kit |
|---|---|---|---|---|
| HPCF-SFI-0004 | 800258, 800347 | FRP-800347-1K | FRP-800347-2K | FRP-800347-5K |
| HPCF-SFI-0110 | 800345, 800346 | FRP-800345-1K | FRP-800345-2K | FRP-800345-5K |
| HPCF-SFI-0130 | 800343, 800344 | FRP-800343-1K | FRP-800343-2K | FRP-800343-5K |
| Kit | Contains | Due at Run Hours |
|---|---|---|
| 1,000 Hour (1K) | Filter replacement kit | 1,000 / 3,000 / 7,000 / 9,000 |
| 2,000 Hour (2K) | 1K kit contents + booster oil and valve kit | 2,000 / 4,000 / 6,000 / 8,000 / 10,000 |
| 5,000 Hour (5K) | 1K kit contents + compressor and generator valve kit | 5,000 / 10,000 |
ℹ Resetting Kit Timers: After completing any kit service, reset the corresponding timer in the PLC: Menu → Alarms / Filter Parameters → FRP Frequency, then press Reset next to the completed kit. This clears the alert and restarts the run-hour counter.
Full Maintenance Schedule Reference
| Component | Task | Interval | Part Number |
|---|---|---|---|
| Booster | Check oil level | Daily (before each use) | — |
| Air Compressor | Inspect inlet filters (F0) | 500 hours or 6 months | — |
| Refrigerant Dryer | Clean water separator | 500 hours or 6 months | — |
| N2 Generator | Inspect filters F1–F4 | 500 hours or 6 months | — |
| Booster | Re-tension V-belt | Every 125 hours | — |
| Booster | Replace purification cartridge (F5) | 500 hours or 6 months | 434508 |
| Air Compressor | Replace inlet filters (F0) | 1,000 hours (1K kit) | 301402 |
| N2 Generator | Replace F1 (particulate) | 1,000 hours or 6 months (1K kit) | E5102-P5 |
| N2 Generator | Replace F2 (coalescing) | 1,000 hours or 6 months (1K kit) | E5102-C01 |
| N2 Generator | Replace F3 (adsorber) | 1,000 hours or 6 months (1K kit) | E5102-AC |
| N2 Generator | Replace F4 (particulate) | 1,000 hours or 6 months (1K kit) | E5102-P5 |
| Booster | Inspect valve heads | 1,000 hours | — |
| N2 Generator | Calibrate O2 analyzer | 2,000 hours | Model dependent |
| N2 Generator | Top off CMS in PSA beds | 2,000 hours | 100004 |
| Booster | Change oil | 2,000 hours or 2 years (2K kit) | 400455 |
| Booster | Replace valve heads | 2,000 hours (2K kit) | 434507 |
| Air Compressor | Replace compressor valve heads | 2,000 hours (2K kit) | Included in 2K kit |
| N2 Generator | Process valve rebuild | 5,000 hours (5K kit) | Model dependent |
| Air Compressor | Rebuild/replace seals | 6,000 hours | 301403 |
| Air Compressor | Replace capacitor | 5 years | 301404 |
| High Pressure Hose | Replace hose to manifold | 5 years | 103029 (CGA 580) / 111829 (CGA 680) |
| High Pressure Leads | Replace leads to cylinders | 5 years | 103040 (CGA 580) / contact South-Tek (CGA 680) |
Air Compressor — Inlet Filter (F0)
Inspect at 500 hours or 6 months; replace at 1,000 hours. In high-dust or high-contaminant environments, inspect and replace more frequently.
- Disconnect electrical power by flipping the internal breakers to OFF or unplugging the system.
- Unscrew the cap on the compressed air inlet by turning counterclockwise. Take care — filter enclosures may be warm.
- Visually inspect the element. Replace if dirty or at the required interval.
- Install the replacement element and reinstall the cap.
Refrigerant Dryer — Water Separator
Clean every 500 hours or 6 months. The water separator removes bulk condensate before the drying process.
- Disconnect all electrical power from the unit.
- Locate the two screws on either side of the dryer, at the bottom corners nearest the front. Remove these screws to detach the front panel.
- The water separator is located in the lower right front corner once the cover is removed.
- Relieve any trapped pressure or condensate by turning the drain valve at the bottom of the separator counterclockwise.
- Remove the bowl by pulling down the tab and turning the bowl counterclockwise.
- Clean all components with a mild natural detergent. Replace components that are too dirty to clean adequately.
- Reinstall in reverse order.
N2 Generator — Compressed Air / Nitrogen Filters (F1, F2, F3, F4)
Inspect at 500 hours or 6 months; replace at 1,000 hours or 6 months (whichever comes first). All four filters are replaced as part of the 1K hour kit. In high-contaminant environments, replace more frequently.
| Filter | Type | Part Number |
|---|---|---|
| F1 | Particulate | E5102-P5 |
| F2 | Coalescing | E5102-C01 |
| F3 | Adsorber (activated carbon) | E5102-AC |
| F4 | Particulate | E5102-P5 |
- Disconnect electrical power by flipping the internal breakers to OFF or unplugging the system.
- Isolate inlet ball valve A0 and turn the drain on the bottom of the filter housing counterclockwise to relieve any trapped pressure.
- Remove the filter bowl by turning it counterclockwise. Unscrew the element from the housing.
- Clean the filter bowl with warm water and a clean cloth.
- Install the new element from the FRP kit. Reinstall the bowl, turning clockwise until fully seated.
- Slowly open ball valve A0. Check for leaks before returning the system to service.
Booster — Daily Oil Check
Check the booster oil level before each use, every day. Do not operate the booster with low oil.
- Stop the system. Remove the dipstick and wipe it clean with a dry cloth. Note: if any pressure remains on the inlet nitrogen line, it will vent when the dipstick is removed — this is normal.
- Fully re-insert the dipstick and seat it completely, then remove it again.
- Confirm the oil level is between the minimum and maximum marks indicated by the indent near the bottom of the dipstick.
- If oil is at or below the minimum mark, add the correct booster oil before operating. If uncertain about oil type, contact South-Tek Systems.
⚠ Oil Change — 2,000 Hours or 2 Years: The booster oil must be changed every 2,000 run hours or 2 years (part 400455). Detailed oil change instructions are included in the booster accessory manual — search by model number at southteksystems911.zendesk.com. It is recommended to schedule a service technician for this task along with a physical inspection.
Booster — V-Belt Tensioning (Every 125 Hours)
- Stop the system and disconnect all electrical power.
- Remove the belt shroud by unscrewing the 4 screws on the left and right sides of the shroud.
- On dual-compressor configurations, it may be necessary to remove the compressor closest to the booster. Remove the bolts securing the compressor feet to access the shroud.
- Loosen the motor from the frame by untightening all 4 bolts holding the motor — do not remove the nuts from the bolts.
- Pull the motor taut until the belt deflects no more than 3/8 inch with firm thumb pressure applied midway between the two pulleys.
- Verify pulley alignment by holding a straight edge across the front face of both pulleys.
- Retighten all motor mounting bolts. Reinstall the shroud and any compressor that was moved.
- Run the system for 5 minutes, then recheck belt tension and confirm no change.
Booster — Outlet Purification Cartridge F5 (Every 500 Hours or 6 Months)
The F5 purification cartridge (part 434508) is located on the high-pressure nitrogen outlet downstream of the booster. A missing or expired cartridge will prevent the system from reaching cylinder fill pressure.
- Disconnect all electrical power by flipping internal breakers to OFF or unplugging the system.
- Close the ball valves connected to any high-pressure storage.
- Open the service valve on the cylinder manifold to relieve high-pressure from the outlet line.
- Using the provided rod (stored inside the electrical cabinet), unscrew the F5 filter housing.
- Remove the old cartridge and install the replacement element.
- Reinstall the housing, reopen ball valves, and check for leaks before returning to service.
Booster Valve Heads and Compressor Valve Heads (2,000 Hours)
Both the booster valve heads (part 434507) and the compressor valve heads require replacement at 2,000 hours as part of the 2K hour kit service. Detailed rebuild instructions are included in the booster and compressor accessory manuals. It is strongly recommended to schedule a South-Tek Systems service technician for this task, combined with a full physical inspection of the unit.
Related Articles
- HPCF-SFI — Overview & Specifications
- HPCF-SFI — Installation & Startup
- HPCF-SFI — Controls & Operation
- HPCF-SFI — Alarms & Troubleshooting
- HPCF-SFI — Safety Guidelines
- HPCF Series — Overview & Specifications
Contact South-Tek Systems
Phone: (910) 415-1880
Email / Ticket: support@southteksystems911.zendesk.com