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This article explains the technical procedure for repairing and recharging refrigerated air dryers, ensuring optimal drying performance, energy efficiency, and extended equipment lifespan. It covers detailed inspection steps, troubleshooting methods, refrigerant charge calculations, and essential maintenance guidelines for industrial compressed air systems.
TECHNICAL SERVICE & REFRIGERANT CHARGING FOR REFRIGERATED AIR DRYERS
1. Overview of Refrigerated Air Dryers
A Refrigerated Air Dryer is an essential component in any compressed air system.
Its main function is to remove moisture from compressed air by cooling it down so that water vapor condenses and can be drained away.
Dry, clean compressed air helps protect pneumatic tools, valves, cylinders, and production lines from corrosion and damage.
To maintain stable operation and high efficiency, proper maintenance and refrigerant charging are critical during repair and servicing.
2. Standard Repair Procedure for Refrigerated Air Dryers
Step 1: Overall Inspection
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Check the electrical system and control panel.
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Inspect temperature and pressure sensors.
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Evaluate the condition of the refrigeration compressor (block), condenser fan, condenser coil, and evaporator coil.
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Inspect copper piping and detect any refrigerant leakage.
Step 2: Troubleshooting Common Problems
| Problem |
Cause |
Solution |
| Refrigerant leakage |
Cracked copper tube, weak solder joints |
Repair or replace damaged parts |
| Weak compressor (block) |
Mechanical wear or electrical fault |
Replace with the proper capacity compressor |
| Evaporator icing |
Defrost system malfunction or gas shortage |
Check defrost system, recharge refrigerant |
| Insufficient or excessive gas |
Incorrect gas charging |
Discharge and recharge with correct amount |
3. Proper Vacuuming and Gas Charging Process
After repairing leakage or replacing parts, it is necessary to vacuum the system for at least 30 minutes to remove moisture and air.
Then, charge the refrigerant accurately according to the compressor’s capacity and the cooling type (air-cooled or water-cooled).
4. Calculating the Correct Refrigerant Charge
| Cooling Type |
With After Cooler |
Without After Cooler |
| Air-cooled |
HP × 0.7 = kg of refrigerant |
HP × 0.8 = kg of refrigerant |
| Water-cooled |
HP × 0.6 = kg of refrigerant |
HP × 0.7 = kg of refrigerant |
Example Calculations:
5. Important Notes for Refrigerant Charging
✅ Always use the correct refrigerant type specified by the manufacturer (R134a, R22, R407C, etc.)
✅ Check suction and discharge pressures after charging
✅ Measure the outlet air temperature to ensure it meets design conditions
✅ Use an electronic weighing scale for precise refrigerant measurement
6. Conclusion
Refrigerant charging for refrigerated air dryers must follow strict technical standards and accurate calculation formulas.
Proper service ensures stable performance, lower energy consumption, longer equipment life, and optimal air-drying efficiency for your compressed air system.
7. Professional Repair & Maintenance Service
HOP NHAT HCM TECHNICAL CO., LTD
Industrial Compressed Air Solutions – Energy Saving & Performance Optimization
📍 Office: 99 Dien Bien Phu, Da Kao Ward, District 1, Ho Chi Minh City, Vietnam
🏭 Workshop: No. 19, N3 Street, Dong An Residential Area, Di An City, Binh Duong Province
🌐 Website: www.hopnhatvn.com
📞 Hotline: +84 989 508 177 (Mr. Nguyen Van Luu)
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