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1、Compressed Air Freeze DryerUsers ManualMaintenanceI. Foreword:This manual mainly instructs you on how to use the equipment properly. Its purpose is to prolong the service life and diminish operational failure, so as to guarantee the compressed air quality. It also gives relevant information on the e
2、quipment for reference. So please read the manual carefully before use, and take operation and maintenance according to the instructions for fear of equipment breakdown.II. Functions： The key function of the cooling-type compressed air freeze dryer is to remove the moisture of compressed air. With a
3、 cold media heat exchanger (evaporator), it can drop the compressed air temperature to 10 and condense the moisture or water drops in the compressed air. Then it separates the air from water drops with a separator. Then the water drops are discharged from the system by an automatic drainer, which pu
4、ts the pre-cooling process. Under normal situation, the water content of the precooled compressed air is about 0.59g/m3, and the dewatering rate is up to 93%. The user can select the right model or add filters according to the actual condition.III. High Efficiency from the Excellent Jiasheng Design：
5、The low energy consumption and low pressure drops enable the lowest operating cost, so it is energy-efficient. The large Gas-to-Gas heat exchanger can remove half of the heat load in the air, thus to narrow the cooling system and reduce the power consumption to the utmost, which guarantees sufficien
6、t cooling and frees the downstream pipeline from condensation; With large covering, the evaporator enables to cool down the compressed air evenly to dew point temperature. The multi-channel design of the coolant can make the best use of the available cooling capacity and free the evaporator from fro
7、st.IV. Cold Media System Flow： Compressed by the cold-media compressor, the cold media will turn into high-pressure and high-temperature gas. After radiated by the air-cooling condenser, it will be condensed to liquefaction. And then the moisture and impurity are removed from its pipeline with a dry
8、 filter. And then the high-pressure liquid cold media will go through the capillary throttle before turning into low-pressure and low-temperature liquid to enter the evaporator. Then it absorbs the heat from the compressed air, and is gasified into the low-temperature gaseous cold media, and flows b
9、ack to the compressor through the liquid-gas separator, which puts the refrigeration cycle to an end.V. Installation Instructions：Location5.1 Choose a cool and draughty place as the best location for installation.5.2 Installation of the machines the ambient temperature is limited to 355.3 Do not ins
10、tall it outdoors, in a damp and dusty place, or in a corrosive and polluted place. 5.4 The location shall be one meter away from the wall and two meters away from other machines, which facilitates cleaning and maintenance. 5.5 Install it horizontally to facilitate drainage. Wiring5.6 Install a dedic
11、ated switch beside the power supply of the dryer for protection. For more information please refer to relevant instruction manuals. 5.7 The supply voltage cannot exceed the rated voltage.（Label specification5%）5.8 The power cords specifications depend on the current and the length of wires. 5.9 Do n
12、ot share the protection switch with any other equipment. 5.10 Connect the ground wire properly. III. Operations：6.1 Verify that the power supply is under normal voltage (label specification5%).6.2 Verify that the environmental temperature is normal.6.3 Verify that the compressed air has not yet ente
13、red the dryer. (Stop the air compressor from running, or fasten the valves, and turn on the air bypass valve.)6.4 Verify that the cold media meter is under normal pressure. (Before running, the cold media pressure must be kept around 711kgf/cm2，and not less than 6.0kgf/cm2 in winters).6.5 Verify tha
14、t the cooling water intake is under normal pressure and humidity. (Hydraulic pressure: 24kgf/cm2, water temperature: max. 35C) 6.6 Verify that the exhaust rate of the air compressor matches the processing capacity of the freeze dryer. During Operation6.7 Turn on the power, and the dryer will begin t
15、o work. 6.8 Verify that the dryer is under normal working voltage.（See label.）6.9 Verify that the cooling water intake/outtake is under normal temperature difference.（510C）6.10 Verify that the coolers fan motor is running well. 6.11 After ten minutes of running, let the compressed air in the dryer.（
16、Start up the air compressor or open the valves slowly and close the air bypass valve.） 6.12 Check whether there is air leakage. 6.13 Verify that the intake compressed air temperature is normal.（High temperature: WCD80C，Low temperature: WAD40C） 6.14 Verify that the intake compressed air is under norm
17、al pressure.（See label.）6.15 Verify that the passageway of the dryer is under normal temperature difference.（Temperature difference:1030C）。6.16 Verify that the cold media is under normal high/low pressure. (High pressure under zero load：13.515.5kgf/cm2, Low pressure：3.64.0kgf/cm2)。6.17 If the water-
18、cooling model is under abnormal high pressure, please adjust the water-regulating valve at the cooling water entrance. （Clockwise to decrease the pressure, and vice versa.） 6.18 After 30 minutes of operation, check whether the drainage system is under control.（Generally speaking, the high-pressure d
19、rainer will drain automatically.）When all the above items are normal, the operation is under control. Caution：1、Idling should be not more than 30 minutes. 2、Restart the machine 5 minutes after shutdown for fear of damaging the compressor. IV. Routine Maintenance：7.1 Check the high-pressure drainer e
20、very day for fear that it might be jammed to stop draining；clean it once it is jammed；clean it once a week（depending on the actual situation）.7.2 Check whether the cooling water is under normal condition every day (Standard hydraulic pressure: 24kgf/cm2，intake water temperature: below 35C.7.3 For th
21、e water-cooling model，please clean the water filter every three months or when the high pressure of the cold media is over 17kgf/cm2. If the pressure of the cold media is still off standard, please clean the condenser and the front cooler. 7.4 Open the drainage valve at least twice a day. 7.5 For la
22、rge models, please coordinate with our company on a thorough maintenance.VI. Multiple Protection System： Overcurrent protection；Compressor overheat protection. The multiple protection system ensures normal operation of the equipment and rest you assured. IX. Failure and Solutions：StateCauseSolutions
23、Abnormal power supply Master power supply protection switch damaged or jumped offMake sure whether the power supply is lack of phase, in short circuit or unconnected to ground wire, and check whether the power switch is damaged. Abnormal voltageRated voltage allowance on label 5%Offline Find and rep
24、air the offline part Electric organ breakdown Bad power switch, electromagnetic switch or fuse Replace it.Overload protector, high-pressure protection switch jumped off or in bad condition Reset or replace it.Poor operating capacitanceReplace it.Bad compressorReplace it.Bad pressure switch Replace i
25、t.Bad fan motorReplace it.Bad overload protectorReplace it.Poor capacitance of blowerReplace it.Service condition not matched or wrong operation Continuous startupRestart at an interval of over 5 minutes.Overload throughput Precooler overloadPrecoolers inlet temperature or environmental temperature
26、too high Add cooling or improve ventilation. Fin of condenser or cooler jammed Cleanse it.StateCauseSolutionsAbnormal piping systemPiping valve not fully open Open the valve fully.Small caliberEnlarge the caliber.Too long piping, too many elbows and jointsRedesign the piping system.Over two air comp
27、ressors in parallel operation, not matched wellRedesign the piping systemBypass valve not fastened Fasten the bypass valve.Air not past dryerFully open the intake valve of the precooler. Precooler not horizontalPut it horizontally.Air handling capacity exceeds rated value. Piping filter jammedCleans
28、e the filter or replace the filter element. Too much air leakage on piping joint Check the piping. Evaporators end plate frozenBad pressure switchReplace it, check the circuit, and revise the switch.Capillary jammedCheck or replace the capillary. Abnormal cooling systemCold media leakageFill the lea
29、kage or fill cold media.Compressor valve wear and tearReplace it. Cold media piping jammedChange the desiccant，vacuumize it again, and fill the cold media. Pressure switch failure Replace it.Breakdown of fan motor of condenser or cooler Replace it.Abnormal dewatering effect Condenser fin jammed Clea
30、nse it. Drainage valve failure or not fully openReplace it or open the valve.Abnormal operating pressure Consider to change or update the model.Automatic drainer inclined Put it horizontally.Drainer filter screen jammedCleanse it.Drainpipe jammedCleanse it.Drainpipe higher than automatic drainerRein
31、stall the drainpipe. Drainage floating ball troubleReplace it.X. Working Condition：Specification Sheet：ModelWCD-5SGWCD-10SGWCD-20SGWCD-30SGWCD-50GFWCD-60GFWCD-75GFWCD-100GFWCD-120GFAir throughputNm3/min0.851.52.53.56.56.58.513.513.8Power supply（A）1220V 50HZ1220V 50HZ1220V 50HZ1220V50HZ1220V 50HZ1220
32、V50HZ1220V 50HZ1220V 50HZ1220V 50HZCompressor power（kw）0.20.430.730.921.381.381.782.572.57Working current（A）1.52.93.64.06.86.88.61010Cold media filling capacity（g）25065070095011001200140018001800Air passageway caliberR3/4R1R1R1-1/2R1-1/2R1-1/2R2R2-1/2R2-1/2Net weight23.5 KG94.5 KG99 KG103 KG123 KG17
33、0 KG210 KG238KG350KGPlace type size(mm)530350 450730 380 910730 380 910740 430 940900 500 12901020 610 9901010 610 12901200 620 12001260 610 1350Cold media：口R22 口R407 口R410Working pressure：Standard: 0.7Mpa，Max:1.0Mpa Allowable inlet temperature：80C。Environmental temperature：below 35C Dew point temperature：210C。Installation environment：draughty and dust-free place Extra specifications available upon demand