Maintenance

The maintenance of Horizon compressors is minimal but important. The indicators

on the control panel of the compressor give warnings when servicing of the
suction filter or oil filter element is necessary.

Maintenance schedule

Daily: Prior to starting the machine, it is necessary to check the oil level in the
receiver tank (see Starting the compressor in the Operation section No.
10.1). Should the level be low, add the necessary amount. If the addition of oil
becomes very frequent, a problem has developed which is causing this
excessive loss. Refer to the section on excessive coolant consumption in the
Troubleshooting section for a probable cause and remedy.

After a routine start has been made, observe the instrument gauges and be
sure they monitor the correct readings for that particular phase of operation.
After the machine has warmed up it is recommended that a general check on
the overall machine and instruments be made to ensure that the compressor is
running properly.

After initial 100 h of running:

Do not remove caps, plugs or other components when the

compressor is running or pressurised. Stop the compressor and
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relieve all internal pressure before doing so.

A check-up is necessary to detect and clean the system of any foreign materials.
Carry out the following operations.

l Clean the return line orifice(By pressurised air)

l Change the oil filter element

13.0
Maintenance

After every 1000 h of running:

l Change the compressor oil depending on the type of oil.

l Change the oil filter element

After every 1500 h of running:

l Change air filter element.

After every 4000 h of running:

l Change separator element.
l Clean receiver tank.
l Grease the motor. Use only a lithium based high temperature grease
such as Esso Unirex N 3 or Servo GEM N 3.

Maintenance of individual components and systems:

Check all the accessories independently to verify that they are functioning as
required and replace their components as necessary.
NOTE

The number of hours of running after which the filter and separator elements
and oil are to be replaced are given as a guideline for normal operating
conditions. They may vary depending on actual operating conditions.

Oil filter

The oil filter is fitted between the oil cooler and the compressor unit. The
components of the oil filter are shown in the figure below.

13.1
Maintenance

This is a full flow filter with a replaceable pleated element. For servicing this
filter, use repair kit (Available with service personnel) The procedure for
complete servicing of this filter is as follows.

Disassembly

l Disassemble the filter element by rotating it counter-clockwise.

l The hex adapter should be in the filter head during disassembly.
l Drain the oil present in the filter element.
l Once the recommended life of the element is over, it has to be replaced
with a new element.

Assembly of new filter element

l Ensure that the seal on the filter element is not damaged.
l Clean the seating surfaces.
l Lubricate the filter element.
l Assemble the filter element by rotating the filter element in the clockwise
direction; tightening by hand is sufficient.

13.2
Maintenance

Separator element

The separator element must be changed (a) when an indication appears on

the controller screen. Order a separator element kit (Refer insurance kit).
Observe the following procedure for separator replacement.

l Relieve oil pressure from the receiver tank and all fluid lines.

l Disconnect all piping connected to the receiver tank cover to isolate the
receiver tank from the return lines, service line, etc.

l Loosen and remove the hex head bolt from the cover plate.

l Lift the cover plate from the receiver tank.

l Remove the separator element.

l Scrap the old gasket material from the cover and flange on the receiver
tank. While doing so, take care not to let the scraps fall into the receiver
tank.

l Inspect and clean the receiver tank for rust and dirt.

l Fix the new gaskets after ensuring that the staples are present in both
the gaskets.

l Place the new separator element into the receiver tank, taking care not
to dent it against the tank opening.

l Clean the underside of the receiver tank and remove any rust. Paint the
surface with an epoxy paint.

l Replace the cover plate and fasten the cover on the receiver tank.

l Reconnect all piping. Ensure that the return line tube has a clearance of
1/4” above the bottom of the separator element. This will ensure proper
oil return flow to the compressor.

l Clean the return oil strainer before restarting the machine.

13.3
Maintenance

Receiver tank cover

Return line tube

Min 1/4"

Separator element

Air inlet filter

Clean the air filter using moisture free compressed air at less
than 2.5 bar g. The direction of cleaning should be from inside
to outside.
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Do not forget to remove the air filter clog indicator from the old
air filter and fix it on the new air filter.

When the air filter clog indicator indicates a blocked condition, remove the air
filter and replace it with a new one.

l Shine a bright light from inside the element to inspect for damage or holes
that will cause leaks. The light will emerge from the holes, indicating their
location.

l Inspect all gaskets and gasket contact surfaces of the housing. Should
faulty gaskets be evident, replace the element immediately.

l After the element has been installed, inspect and tighten if necessary all
air inlet connections prior to resuming operation.

13.4
Maintenance

If a clean element is to be stored for later use, it must be stored in a clean

container.

Hub

Element

Hub

Drive coupling

l The unit has been provided with a flexible coupling, which has the following
advantages:

l There is no relative movement between connected parts and hence there

is no wear and tear.

l The coupling needs no lubrication and maintenance.

l The flexible element has a very long life and is the only part which needs
replacement.

l The coupling has torsional flexibility and dampening properties that allow
it to absorb torsional vibrations and shock loads.

If the flexible member undergoes failure, a loud noise is heard, indicating a

problem.

No alignment check is required. The intermediate housing between the airend

and the motor is designed and fabricated to ensure correct alignment of shafts
when fitted.

Disconnect all power at the source before attempting

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maintenance or adjustments.

13.5
Maintenance

If you need to reduce the operating pressure to save energy,

contact ELGI’s Service Engineer.
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Minimum pressure valve

Maintenance of the minimum pressure valve is minimal. The only part which
normally requires replacement is the O ring on the piston.

Housing

Cap
Plunger

Spacer
Valve seat

Teflon seat Spring

Washer
'O' ring

Allen screw

Piston

Housing

13.6
Maintenance

The minimum pressure valve cover is under heavy spring tension. Loosen the
cover bolts one turn at a time alternatively to relieve the spring tension.

Extreme caution should be taken when removing the cap or cover

from the body because of the spring tension.
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l Remove the cap evenly to relieve the spring tension.

l Remove the spring.
l Remove the piston.
l Remove the O ring and discard it.
l Clean the piston.
l Replace the O ring.
l Coat the piston and O ring with grease.
l Replace the piston.
l Replace the spring and cap.

Inlet valve
Screw

Stopper

Gasket

Screw

Housing
Spring washer

Spring outer Washer

piston

Cup seal 'O' ring

Pressing pad
Piston

'O' ring Sliding pin

Spring
Cylinder cover Inner piston

13.7
Maintenance

Inlet valve maintenance usually involves replacement of the piston spring,

piston O ring, seal ring and check valve spring. Follow the procedure below
for proper installation:

l Remove the control lines from the fittings on the intake valve.

l Remove the four cap screws that attach the valve body to the airend and
remove the valve.

l Remove the snap ring and the Teflon O ring inside the valve body.

l Lift and remove the check valve assembly and spring from the inlet body
flange.

l Remove the piston cap, piston spring and piston.

l Clean the valve body as needed, making sure all the air passages are
clear and the old seal ring is removed from the inlet body flange.

l Reassemble the inlet valve using the new parts supplied in the repair kit.

l Install the cup seal on the piston, lightly oil the piston and install it in the
valve body.

l Install the new piston spring and replace the piston cap.

l Place the new check valve spring into the piston and install the check
valve assembly.

l Position the Teflon O ring in the valve body and install the snap ring.

l Clean the airend/intake valve flanges before installing the new flange
seal ring.

l Install the valve on the airend and apply a torque of 45–50 ft lb.

l Install the control lines and air inlet elbow.

l Start the compressor and check for proper operation of the intake valve.

13.8
Maintenance

Blow-down valve
Hex. Screw

Spring washer

Top cover

Gasket

'O' ring

Plunger

Main body

Valve

Valve cone

Spring

'O' ring

Bottom cover

Spring washer

Hex. Screw

Maintenance of the blow down valve is limited to replacement of the gasket and
internal ring and seat. Using the spare kit, follow the instructions given below
for proper installation.

l Remove the four screws on the top cover which hold the assembly together.
l Pull the top cover away from the body.
l Remove the old gasket and replace it with the new one.
l Align the top cover with the body, replace the four screws and tighten.
l To replace the valve seat, loosen and remove the two socket head screws
in the bottom cover.

13.9
Maintenance

l Pull the bottom cover from the main body.

l Remove the cover ring, spring, seat cup and seat. Discard the seat and
ring and replace them with the new ones in the kit.
l Reassemble the bottom cover.

Moisture separator

The water separator will operate indefinitely under normal working conditions.
However, at some time, it may be necessary to replace the seals, should the
housing leak.

Housing

Housing 'O' ring

Auto drain assembly

Auto drain seal Bowl

'O' ring

Bowl

Auto drain assembly

Vent valve Auto drain seal

Sight glass
Seal
Sight glass
Seal

13.10
Maintenance

l Isolate the housing from the air supply.

l Depressurise fully using the vent valve at the bottom of the bowl.

l Unscrew the bowl and remove it. If the pressure has not been completely
released from the housing, air will escape from the warning hole, giving
an audible alarm. Screw back the bowl and repeat step 2 before beginning
again.

l Check the condition of the O ring and replace it if necessary. Clean the
screw threads.

l The auto drain assembly is not serviceable and must be replaced if it is

faulty.

l Check the auto drain seal and replace it if it is worn.

l Replace the vent valve if it is faulty or leaking.

l Refit the bowl with the O ring seal.

l A sight glass is provided to monitor the functioning of the automatic drain.

Under certain conditions it can become contaminated. When this happens,
dismantle it and clean it. A replacement kit (Refer insurance kit ) is
available.

l Repressurise and check for leaks. If leaks do occur they will most probably
be from the bowl O ring. Depressurise the housing and remove the O
ring as stated above. Inspect it and clean it. Ensure that the mating
surfaces are clean, refit the O ring and repressurise.
NOTE
Note: When replacing the auto drain , take the opportunity to clean the
inside of the bowl and the screw threads.

13.11
Maintenance

Procedure for cleaning the cooler

The following procedure is suitable for cleaning the internal surfaces of copper
oil coolers:

l Mix toluene and isopropanol (isopropyl alcohol) in a 50:50 ratio by volume

and circulate this through the cooler for a minimum of four hours.

Handle toluene and isopropanol with care. These solvents are

harmful and hazardous to humans.
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l For aluminium coolers, use a 5% by volume mixture of caustic soda in

water. Circulate this mixture at 60ºC in the cooler for five hours. The
duration of circulation may be increased if required.

l The exterior of both copper and aluminium coolers may be cleaned using
steam or mild caustic
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soda solution in water (5 %).

l Exteriors of coolers of compressors used in textile industries can be

cleaned at regular intervals using compressed air at less than 7 bar g to
avoid choking of the cooler fins with cotton.

Do not get rid of the cotton in the cooler fins by burning it. This
may lead to deformation of the cooler. It may also lead to expansion
of the cooler joints, resulting in leakage

13.12
Maintenance

Oil service procedure

l Drain the old oil from the separator tank.

l Drain the old oil from the oil cooler using an air jet. Direct the air jet from
the motor side and collect the oil from the moisture filter side. Open only
the inlet and outlet of the cooler. All other openings should be closed.

l Remove the oil filter element and drain the oil from the filter.

l Rotate the drive coupling manually and remove all the oil from the airend.

l Fill new oil as described in the manual in the Installation section

(Commissioning). Use only an oil recommended in this section.

l Replace the oil filter element.

l Refit all the plugs of the separator tank and the oil cooler.

l Run the compressor for a few minutes and stop it after closing the air
outlet line ball valve.

l Check the oil level in the separator tank again. It should be at the half
level of the oil sight glass after the foam has settled down. If it is less, add
oil till it reaches the half level.

13.13