Schulz ADS 35 Refrigerated Air Dryer Instruction Manual

1. Introduction

This manual provides essential information for the safe and efficient installation, operation, and maintenance of your EDGE_INDUSTRIAL Schulz ADS 35 Refrigerated Air Dryer. This unit is designed to remove moisture and oil from compressed air systems, ensuring dry air for various applications. Please read this manual thoroughly before operating the equipment.

2. Safety Information

• Proposition 65 Warning: This product may expose you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
• Always disconnect power before performing any maintenance or service.
• Ensure proper electrical grounding. The unit requires 1-phase 115V power and 10 AWG wire.
• The maximum inlet pressure for the dryer is 200 PSI. However, the Stage 1 and Stage 2 filters have a maximum input of 175 PSI. Ensure your compressor output does not exceed 175 PSI to prevent damage to the filters.
• Liquid water and oil from your compressor can damage the interior components of the dryer. It is vital that these are removed from your compressed air lines before entering the refrigerated air dryer.
• Do not operate the unit if any components are damaged or missing.

3. Product Overview

The Schulz ADS 35 Refrigerated Air Dryer system is a comprehensive solution for achieving moisture and oil-free compressed air. It consists of three primary components:

1. Refrigerated Air Dryer Unit: This non-cycling dryer continuously circulates refrigerant to cool compressed air, causing moisture to condense and be removed. A hot gas bypass valve regulates the refrigerant temperature to prevent freezing.
2. Stage 1 Water Separator with Regulator: This component features a 5-micron element that removes approximately 95% of moisture from compressed air lines. It includes an adjustable pressure regulator (7-175 PSI) with a gauge and an internal float drain for automatic moisture release.
3. Stage 2 Coalescing Filter: Also known as an oil-removing filter, this unit contains a 0.01-micron element to remove remaining moisture vapor and residual oil from the compressed air. It also includes a metal bowl and an internal float drain.

Figure 3.1: This image displays the complete system: the blue Schulz ADS 35 refrigerated air dryer unit on the left, and the silver Stage 1 water separator with pressure regulator and Stage 2 coalescing filter assembly on the right. This combination ensures dry and oil-free compressed air.

Figure 3.2: A detailed view of the pre-filtration system. On the left is the Stage 1 water separator with an adjustable pressure regulator and gauge, designed to remove bulk moisture. On the right is the Stage 2 coalescing filter, which removes remaining moisture vapor and oil particles. Both units feature clear bowls for visual inspection and automatic float drains.

Figure 3.3: A close-up of the dryer's control panel, featuring an ON/OFF switch, indicator lights, and a digital display for monitoring operational parameters. Schematic diagrams illustrate the internal air and refrigerant flow.

4. Setup and Installation

Proper installation is crucial for the performance and longevity of your air dryer system.

4.1 Pre-Installation Requirements

• Ensure that liquid water and oil are effectively removed from your compressed air lines before they enter the refrigerated air dryer. Failure to do so can damage the dryer's internal components.
• The maximum output pressure from your air compressor should not exceed 175 PSI to protect the Stage 1 and Stage 2 filters.

4.2 Piping Connections

The dryer unit features 1/2" Female NPT inlet and outlet ports. Use appropriate piping and fittings for connection to your compressed air system.

Figure 4.1: A close-up view of one of the 1/2 inch Female NPT ports on the dryer, indicating where compressed air lines connect for inlet or outlet.

4.3 Electrical Connection

The unit requires a 1-phase 115V electrical supply. A 10 AWG wire is required for proper and safe operation. Ensure all electrical connections comply with local codes and safety standards.

4.4 System Layout

Refer to the diagram below for a common compressed air piping system setup. A bypass line is highly recommended for maintenance and system flexibility.

Figure 4.2: This diagram illustrates a typical compressed air system setup, showing the compressor, main disconnect, flexible air-line, and the recommended placement of the air dryer and pre-filters. It also depicts a bypass line, quick couplers, lubricator, and drain legs, emphasizing the importance of a bypass for maintenance and system flexibility.

5. Operation

The Schulz ADS 35 is a non-cycling refrigerated air dryer. This means the refrigerant circulates continuously throughout the system to maintain a consistent cooling temperature. The unit is designed to achieve a dew point of 41 degrees Fahrenheit at 100 PSI, effectively removing moisture from the compressed air.

5.1 Initial Startup

1. Ensure all piping and electrical connections are secure and correct.
2. Turn on the main power supply to the dryer.
3. The dryer will begin its cooling cycle. Allow sufficient time for the unit to reach its optimal operating temperature before introducing compressed air.
4. Adjust the pressure regulator on the Stage 1 filter to your desired output pressure, ensuring it does not exceed 175 PSI.

5.2 Continuous Operation

During operation, the hot gas bypass valve automatically regulates the refrigerant temperature, preventing freezing within the system even with varying compressed air flow and ambient temperatures. Monitor the control panel for operational status and any error indicators.

6. Maintenance

Regular maintenance ensures the longevity and efficiency of your air dryer system.

6.1 Filter Maintenance

• Automatic Drains: Both the Stage 1 water separator and Stage 2 coalescing filter are equipped with internal float drains that automatically release accumulated moisture and oil. Periodically verify that these drains are functioning correctly.
• Bowl Inspection: Regularly inspect the metal bowls of both filters for any significant accumulation of moisture or oil. While the Stage 2 bowl is unlikely to have much buildup, visual checks are important.
• Element Replacement: The filter elements (5-micron in Stage 1, 0.01-micron in Stage 2) will require periodic replacement depending on usage and air quality. Refer to the filter manufacturer's guidelines for replacement intervals.

6.2 Dryer Unit Maintenance

• Keep the ventilation grilles on the dryer unit clean and free from obstructions to ensure proper airflow and cooling.
• Periodically check all connections for leaks.
• If the unit exhibits unusual noise or performance issues, consult the troubleshooting section or contact support.

7. Troubleshooting

This section addresses common issues you might encounter with your air dryer system.

8. Specifications

Key technical specifications for the Schulz ADS 35 Refrigerated Air Dryer.

Figure 8.1: This image shows the product's specification label, detailing technical data.

9. Warranty and Support

For warranty information or technical support, please contact EDGE_INDUSTRIAL directly. Keep your purchase receipt and product serial number (found on the specification label) readily available when contacting support.