3-in-1 Heat Exchanger 10.5m³/min 370 CFM Refrigeration Air Dryer

This refrigerated compressed air dryerhas 3-in-1 heat exchanger. It integrates the three parts into one. That is, evaporator, heat exchanger and air-water separator. The pressure dew point of thisrefrigerant compressed air dryeris 2~8℃. The air pressure can be up to 16 bar. Sorefrigerated air dryer for compressoris suitable for laser cutting. The dryer design is beautiful. Besides, the structure is compact. The size is smaller than the traditional refrigeration air dryer. We can customize your special needs.

Refrigerant air dryer for compressor is a water removal machine. The refrigerant is eco-friendly R410a or R407c. They absorb heat when evaporate. So it can lower the temperature of the compressed air. During this process, moisture and oil will condense. A separator then separates them from the air. Finally, refrigerated compressed air dryer will discharge dry air.

1. Technical data sheet of the refrigerant compressed air dryer

2. Why choose our 3-in-1 refrigerated air dryer for compressor? (1) More energy saving

It uses a 3-in-1 plate heat exchanger. The heat exchange area is larger. So the efficiency is higher than the shell-tube type. It can fully recycle the waste cooling. The inlet/outlet temperature difference is only less than 10℃. The compressed air entering the evaporator is cooler. So it needs less refrigerant. That is, the required compressor power is smaller.

The former has less power. So it’s more energy efficient.It can save 20~30% energy consumption.In addition, the pressure loss is only 0.15 bar. That is far below the national standard. It can also reflect energy saving.

(2) Cleaner and hygienic

Conventional shell-tube heat exchangers uses carbon steel casing. Rust is unavoidable. Impurities can cause internal leakage in the evaporator. It will also clog the drain. But this refrigerated compressed air dryer is different in materials. It’s aluminum alloy or stainless steel. Not easy to rust. There will be no secondary pollution.

This refrigerated air dryer for compressor adopts eco-friendly refrigerant. That is, R134a, R410a and R407c.So it has wide application in medical food industry.

(3) Precise digital control

The refrigeration system is with electronic expansion valve and electronic pressure switch. So the system runs more stable. And it can avoid ice blockage.

The expansion valve can adjust the flow of refrigerant. Traditional refrigerant compressed air dryer uses thermal expansion valves. It takes 10 minutes from self-regulation to stabilization.

But the electronic expansion valve only takes 10 seconds. So the response is faster. And its adjustment accuracy is higher. Finally, it can ensure the precise operation of refrigerated air dryer for compressor.

(4) Higher compressed air quality

The pressure dew point of this refrigerated compressed air dryer is 2~8℃. Besides, it can withstand third-party test. The pressure dew point is very stable. Because it uses a three-in-one heat exchanger, the heat exchange efficiency is high. So the water removal effect is very good. Therefore, it can obtain such high compressed air quality.

(5) Suitable for laser cutting industry

The standard pressure of this refrigerated air dryer for compressor is 1.6MPa. So it’s applied to the demanding laser cutting industry. Compressed air has wide application in laser cutting. And its quality has a direct impact on the quality of laser cutting. Because there are water mist and oil, they are very harmful. If not purified, they can be ejected onto the laser protection mirror surface. So it can seriously affect the transmission of the laser beam. Finally, it will distract the focus and affect processing results. So we must need a refrigerated compressed air dryer. Sometimes, the dew point requirement is higher. Then it also needs a desiccant air dryer.

(6) Strong customization ability

Firstly, we can manufacture large refrigerated air dryer for compressor. The max air capacity can reach 350m³/min. Of course, it will be water-cooled refrigerant compressed air dryer. Many manufacturer can’t make such a big dryer. Moreover, We can add the compressed air filters onto the dryer. There are 4-stage coalescing filters. And it can be either external or built-in.

In addition, we can also customzie a pre-cooler on to the refrigerated compressed air dryer. So this air dryer can suit for high inlet temperature. Then it will has wider application. Besides,We can also add a digital controller. It can display the evaporation temperature of refrigerant air dryer.

(7) Work together with famous air compressor brands

Our refrigerated air dryer for compressor has good quality and reputation. They usually work with many big air compressor companies, such as Ingersoll Rand, Atlas Copco, Kaeser, Hitachi, Sullair, Kobelco, etc. So, you can rest assured of our quality. We are the top rated refrigerant compressed air dryer manufacturer in China.

3. How does refrigerated compressed air dryer work?

Compressed air enters the 3-in-1 aluminum alloy plate heat exchanger. After heat exchange and cooling, it comes to the built-in air-water separator. And it will remove the water by wire mesh separation. The working principle also includes two processes. That is, air system and refrigeration system.

At first the compressed air is hot and humid. They go into the refrigerant compressed air dryer. Then come to the heat exchanger. So heat exchange with low temperature drying air. The temperature will drop a part. Some moisture also condenses into liquid. Afterwards, comes the evaporator. They will be cooled by refrigerant to 2~8℃. Water vapor will condense deeply. Both air and liquid enter the separator. Because of the float type drainer, it can drain water automatically.

Panasonic compressor outputs gas refrigerant. Then enter the condenser to start cooling. Finally, it outputs liquid refrigerant. The filter drier removes the impurities inside. Then go into the capillary of refrigerated compressed air dryer. After throttling, the refrigerant enters the evaporator. Refrigerant will absorb heat from the compressed air. As a result, the liquid refrigerant evaporates into gas. Finally, the gas refrigerant is sucked back by the compressor. It will recompress. So start a new refrigeration cycle. That is the principle of refrigerated air dryer for compressor.

4. The functions of spare parts of refrigerated air compressor dryer (1) Refrigerant compressor

We generally use rotary compressors. It produces the refrigerant to cool the compressed air. Its cooling capacity is closely related to the working conditions. The lower the evaporating temperature, the less cooling capacity. And the higher the condensing temperature, the lower the unit cooling capacity. So sometimes we want to lower the evaporating temperature. In order to reduce the dew point of refrigerant compressed air dryer. But this is not economical.

We know it can compress air. But cannot compress liquids. Instead, the liquid will damage the compressor device. When refrigerated compressed air dryer working, the liquid refrigerant enters the evaporator. If too much, the compressed air cannot fully evaporate them. As a result, liquid refrigerant may be sucked into the compressor. Then it is very easy to damage the compressor valve plate.

So we need to prevent the compressor from producing “liquid hammer”. Generally take the following measures to protect the refrigeration dryer:

① Set the low pressure liquid tank. So ensure that only gaseous refrigerant enters the compressor;
② Install the hot gas bypass valve.

(2) 3-in-1 plate heat exchanger

It is a key component of refrigerant compressed air dryer. It contains 3 main spare parts. Namely heat exchanger, evaporator and separator. So it integrates the functions of these 3 components.

① Heat exchanger of refrigerated air dryer for compressor

It is also called pre-cooler. After evaporation, the compressed air is cold. They will come back here. Then they exchange heat with the hot air . Therefore, it can reduce the load of refrigerated compressed air dryer. Then it’s saving engergy. In addtion, the purified compressed air will warm up. So the temperature difference between the inlet and the outlet is very low. It’s about 5~8℃. At the same time, it can avoid condensation water droplets at the outlet.

② Evaporator of refrigeration air dryer

It is the main heat exchange part of refrigerant compressed air dryer. The refrigerant liquid will absorb the heat of the high temperature air. Eventually they evaporate into gas. During this process, the water vapor condenses into liquid. Then it will be discharged from the dryer by the separator.

③ Air-water separator

It’s very critical. If not, it can’t really achieve the purpose of drying. It is an inertial separator. The separation efficiency is greater than 99%. There is an electronic drain valve. So it can drain the water in time.

(3) Refrigeration system accessories

① Refrigerant filter drier

Our refrigerated compressed air dryer uses the famous brand. It’s EMERSON filter drier from USA. It plays two functions. i.e. filtering and drying.

There are moisture and solid impurities in refrigerant and refrigeration oil. In severe cases, the throttling structure will be dirty and blocked. So there must be a filter. In addition, moisture is very harmful to refrigeration systems. We must do drying treatment. So it’s important for refrigerated air dryer for compressor.

② Hot gas bypass valve

Here we use the electronic bypass valve. Actually it is a safety device. It is located between the evaporator and the condenser. It is directly connected to the evaporation pressure. Sometimes, the evaporation pressure is too low. So the hot gas bypass valve opens automatically. The high temp refrigerant vapor enters the evaporator. Then it can raise the evaporation temperature. Thus, it avoids ice blockage in refrigerant compressed air dryer.

③ Refrigerant expansion device

There are mainly 2 types. Namely capillary and heat expansion valve. They are throttling devices. It uses the capillary in this refrigerated compressed air dryer. It has wide application in small air dryers.

Capillaries have self-compensating feature. When the evaporative pressure decreases, the pressure difference between the two ends will increase. Thereby increasing the amount of refrigerant flowing into the evaporator.

5. 3-in-1 Plate Exchanger Refrigeration Air Dryer VS Shell-Tube Type Refrigerated Air Dryer

(1) Heat exchange efficiency

The 3-in-1 heat exchanger is made of metal sheets. Its heat exchange area is large. Various plates form the thin rectangular channels. Heat exchange through the plates. Besides, it has a certain corrugated shape. So it can generate strong turbulence. Therefore, the heat transfer coefficient of the former refrigerated compressed air dryer is relatively high. Generally, it is 3~5 times that of latter.

(2) Corrosion resistance

3-in-1 heat exchanger is aluminum alloy or stainless steel. So the corrosion resistance is better. The latter is generally made of carbon steel. Contact with moisture can easily lead to corrosion. Then the refrigerant compressed air dryer inside will rust. Eventually it will pollute the compressed air. At the same time, it will cause the filter element to become clogged. So the air quality will decrease.

(3) Dimensions of of refrigerated air dryer for compressor

For the latter, the fluid will be blocked by the baffles. Heat exchange is not sufficient. Therefore, to achieve a good dew point, its size is often relatively large. Finally, the refrigerated compressed air dryer will also be bigger. And it is heavier and takes up a lot of space. For example, the volume of our shell-tube type LY-D75AH dryer is 0.934CBM. But the volume of PD-75A air dryer is only 0.398CBM.

6. Refrigerated Compressed Air Dryer Troubleshooting (1) Refrigeration system failure ① Expansion valve blockage

Ⅰ. Specific problem: the sight glass does not flow. The expansion valve outlet is frozen and frosted. The high pressure pipe is hot. Or the high pressure trips.
Ⅱ. Causes:Dirty blockage, ice blockage, or thermal capillary breakage.

Ⅲ. Processing steps:
Adjust the superheat degree of the expansion valve;
Add the superheat of the temperature sensor;
Increase the high pressure pressure (ie the fan pressure switch setting). Close the hot gas bypass valve of refrigerant compressed air dryer. Perform impact on blockage.

② Filter drier clogged

Ⅰ. Problem: its inlet/outlet temperature difference is large. Or there is frost on the outlet.
Ⅱ. Solution: replace the filter drier of refrigerated air dryer for compressor.

③ Refrigerant compressor failure

Ⅰ. Reasons: motor burnout, liquid shock, and other mechanical failures;
Ⅱ. Treatment steps:
1) Measure the resistance of the motor to determine;
Three-phase: ROA=ROB=ROC
Two-phase: ROA=ROB+ROC (ROB=ROA+ROC)
(ROC=ROA+ROB)

2) Check the condition of the capacitor of refrigerant compressor;

Capacitance detection method: Firstly, adjust the gear of the multimeter to the maximum. Then, connect the two probes across the capacitor. If it’s 0 or ∞, it shows that that the capacitor is leaking or breaking down.

3) Start the refrigerated compressed air dryer. Then observe whether the where compressor is running (or abnormal noise). Feel whether there is heat in the middle of the compressor by hand;

④ Refrigerant leaking

This is a common failure of refrigerated air dryer for compressor.

Ⅰ. Problem: the compressor and high-pressure pipe are hot. High and low pressures tend to be low. If there’s a serious leakage, it will cause a low pressure alarm.

Ⅱ. Treatment steps: firstly must find the leakage points. Then fill new refrigerant into the refrigerated air dryer for compressor. Finally re-commission.

(2) Air system failure

① There is a pressure drop in the air system of refrigerant compressed air dryer

Solution steps:
Ⅰ. Ice blockage inside the dryer evaporator. So the evaporation pressure is low —— adjust the evaporation pressure above 0.4MPa;
Ⅱ. The filter element of the air-water separator fails —— replace;
Ⅲ. Compressed air pre-filter element failure —— exchange;
Ⅳ. The air pressure gauge is broken —— repair or replace it;
Ⅴ. Serious leakage in drainage system —— fix it.

② Poor water removal in the air system of refrigerated compressed air dryer

Processing steps:
Ⅰ. The compressed air inlet pressure is seriously low;
Ⅱ. The drainage system does not drain. The time setting of the electronic drain is short —— re-set the time.
Ⅲ. The float drain is dirty and blocked. Manual sewage discharge is not timely —— fix or replace.

7. FAQ (1) How to check refrigerant leakage in refrigerated air dryer for compressor?

Refrigerant leakage is one of common problems in refrigerated compressed air dryer. Especially we use refrigerant dryer for a period of time. At this time, its drying effect is obviously not good. The possible reason is refrigerant leakage. So we have to detect the leak point and deal with it. The most intuitive display is that the refrigerant pressure gauge is zero. Common methods for checking refrigerant leakage are as follows:

① Visual leak detection:

Directly observe the inside of refrigerant compressed air dryer. There is cooling oil mixed in the refrigerant. If there is a leak, the cooling oil will also flow out. So watch where there are oil stains. Then it approximate determin the leak location.

② Halogen lamp leak detection:

There must be some refrigerant in the refrigerated air dryer for compressor. If not, you need to refill the refrigerant. Let the refrigerant pressure reaches about 0.25MPa. Then pressurize to 1.23MPa with nitrogen. Start leak testing the refrigerated compressed air dryer.

Feed gas to the burner. Light a small fire. Put the probe of the suction hose is close to the leak. Then move slowly. At the same time, observe the change of flame color. If there is a leak, the refrigerant will be drawn into the hose. If the flame turns green or purple, that’s a leakage. Because the burner contains copper.

③ Soapy water leak detection:

The method is simple and convenient. Firstly, charged dry nitrogen into refrigerant compressed air dryer. The nitrogen pressure is 8 bar. Then use soapy water to wipe on each joint and welding points. Watch for bubbling. If there are, it proves that there is a leak here.

④ Pressurization & immersion leak detection:

This method is only suitable for the dryer spare parts. Inject spare parts to working pressure. They are usually the heat exchanger parts. Watch carefully after the water is calm. If there are bubbles escaping, it means there is a leak.

Of course, the above methods aim at external leakage. If you still can’t find the leak, it’s most likely internal leak. That is, the evaporator and heat exchanger leaking. At this time, it needs professional to repair the refrigerated compressed air dryer.

(2) How to control the dew point of refrigerant compressed air dryer?

The compressed air load is always changing. Therefore, we should also change the cooling capacity of refrigeration dryer accordingly. It’s to adapt to the load changes of compressed air. So it can ensure stable pressure dew point. In refrigerated compressed air dryer, there are several parts that adjust the cooling capacity.

① The expansion valve has a throttling effect. Firstly, it detects suction superheat degree of the compressor. Then, it can control the refrigerant supply amount. So it can fit compressed air load changes.

② The bypass valve can send the refrigerant directly after the expansion valve. Sometimes the compressed air load will reduce. The evaporator temperature may be below the freezing point of water. Condensed water in refrigerated air dryer for compressor will freeze. This will block the airflow path. But bypass valve can avoid this situation.

③ In addition, it also has requirements for the condensing capacity of condenser. It has to adapt to the load change of the evaporator. If a water-cooled refrigerant dryer, adjust it by the water volume control valve. If air-cooled refrigerant compressed air dryer, use a pressure switch to adjust.

We are the high quality manufacturer of refrigerated compressed air dryer. So if you have any inquiry for refrigeration dryer, just contact us.