Comprehensive Maintenance Guide for Refrigerated Air Dryer

Introduction

A Refrigerated Air Dryer is an essential piece of equipment used in compressed air systems to remove moisture, ensuring the efficiency and longevity of pneumatic machinery. Proper maintenance is crucial to ensure its stable operation and prevent malfunctions. This article outlines a detailed maintenance plan for six Refrigerated Air Dryers, covering monitoring, drainage, temperature control, refrigeration system checks, electrical system inspections, and external cleaning.

I. Monitoring and Recording Instrument Values (Four Times Per Shift)

To ensure the proper functioning of the Refrigerated Air Dryer, it is necessary to observe and document key instrument readings regularly:

1. The pressure difference between the inlet and outlet of compressed air should not exceed 0.035 MPa.

2. The evaporation pressure gauge should remain between 0.4 MPa – 0.5 MPa.

3. The high-pressure gauge should be within the range of 1.2 MPa – 1.6 MPa.

II. Frequent Observation of Drainage and Sewage System

Maintaining an effective drainage system is essential to avoid water accumulation that could impact performance.

1. Float Drainer Cleaning – Clean approximately once a week.

2. Sewage Pipe Drainage – Drain once a week.

Electronic Drainer Cleaning Procedure:

a. Close the ball valve in front of the automatic drainer.
b. Loosen the upper fixing nut and remove the timing coil (avoid contact with water to prevent coil burnout).
c. Detach the hose and loosen the drain valve body to release compressed air.
d. Remove and wipe the valve core clean.
e. Reassemble the valve body, open the front ball valve slightly, and use compressed air to expel impurities, water, and oil.
f. Reinstall the valve core, timing coil, and hose, then fully open the front ball valve.

III. Regular Observation of Cooling Water and Compressed Air System

Proper cooling is critical for the efficiency of a Refrigerated Air Dryer.

1. Cooling water temperature should be maintained between 2°C – 32°C.

2. Water pressure should be within 0.15 MPa – 0.3 MPa.

3. Compressed air inlet temperature should generally not exceed 45°C.

Cooling System Maintenance:

• Ensure the cooling water remains clean.

• Y-type filter: Clean every two weeks (once a month if water quality is good).

• Water-cooled condenser: Clean once a year (depending on water quality).

• Air-cooled condenser: Clean once a month.

Cleaning Instructions:

• When cleaning the air-cooled condenser, avoid damaging the fin surface.

• Ensure proper ventilation around the condenser, avoiding direct sunlight.

• Use compressed air at a moderate pressure to remove dust accumulation.

Shell and Tube Water-Cooled Condenser Cleaning:

1. Close the cooling water inlet and outlet.

2. Open the end cap that is not connected to the water pipe.

3. Wash the gasket and end cap with water.

4. Use compressed air, water, or a cloth-covered rod to clean the inside of the copper tubes carefully.

5. Avoid excessive force to prevent internal tube breakage.

IV. Frequent Inspection of Refrigeration System

The refrigeration system is the core of a Refrigerated Air Dryer. Regular checks ensure efficient operation.

1. Compressor Condition – Touch it by hand at least once a day. It should be cold and frosted under normal conditions.

2. Dry Filter Temperature Difference – Check manually once a week.

   • If the inlet is hot and the outlet is cold, the filter needs to be replaced.

3. Compressor Abnormalities – If there are unusual noises or excessive heat, contact after-sales service immediately.

V. Electrical Control System Inspection

• Regularly remove dust and tighten terminal connections (only perform when the system is powered off).

• Prevent loose connections that may cause overheating or electrical failure.

VI. External Maintenance

• Wipe off dust and oil from the surface of the Refrigerated Air Dryer with a clean towel.

• Keep the installation area clean by removing accumulated dust and oil.

• Ensure a well-ventilated, contamination-free working environment.

Conclusion

Regular maintenance of a Refrigerated Air Dryer is essential to its long-term functionality and efficiency. By following the above steps—monitoring key parameters, maintaining drainage systems, ensuring cooling efficiency, inspecting the refrigeration and electrical systems, and keeping the equipment clean—you can prevent failures and extend the lifespan of the dryer. A well-maintained Refrigerated Air Dryer ensures a steady supply of dry compressed air, improving overall production efficiency.

Sollant Refrigerated Air Dryer