Comprehensive Analysis of Precautions for Using Air Suspension Blowers

Air suspension blowers are widely used in wastewater treatment, industrial pneumatic conveying, and other fields due to their non-contact suspension bearings, high efficiency, energy saving, low noise, and other characteristics. To ensure safe and efficient operation and extend the service life of the equipment, the following key precautions are summarized from four dimensions: installation, operation, maintenance, and safety.

I. Selection and Preparation of Installation Environment

1.Site Selection Requirements

1. Choose an open area away from obstacles such as tall buildings and trees to ensure unobstructed air intake and avoid performance degradation due to insufficient wind.

2. Avoid densely populated areas and main traffic routes to reduce the impact of noise on the surrounding environment. For example, a wastewater treatment plant reduced noise complaints by 60% by installing the equipment at the edge of the plant.

3. For indoor installation, ensure good ventilation. In cases of excessively high temperatures in summer, it is recommended to install air conditioning or industrial fans to prevent motor overheating and shutdown.

2. Foundation Stability

1. The equipment must be installed on a concrete base and secured with anchor bolts to prevent tipping due to vibration. A chemical plant experienced impeller damage due to equipment displacement during strong winds because the base was not secured.

2. Regularly check for loose base screws, especially in earthquake-prone areas where shock-absorbing pads should be added.

3. Pipeline System Compatibility

1. Before starting, ensure all exhaust valves are fully open to avoid damage to the equipment due to excessive pipeline pressure. A steel plant burned out its motor due to direct startup without opening the valves.

2. Pipeline design should account for thermal expansion and contraction, with expansion joints reserved to prevent leaks caused by freezing in winter or expansion in summer.

II. Operation Standards and Parameter Settings

1. Startup and Shutdown Procedures

1. Power-On Sequence: First close the main circuit switch, then close the control circuit breaker to avoid damaging the frequency converter by directly cutting off the power.

2. Startup Method: Press and hold the "Run" button for 3 seconds, and confirm startup after the touchscreen displays "Ready." Avoid short presses or frequent starts and stops. A printing and dyeing plant experienced a threefold increase in bearing wear due to 20 daily starts and stops.

3. Shutdown Steps: Press the "Stop" button first, and cut off the power only after the speed drops below 500 rpm to prevent back electromotive force from impacting the circuit.

2. Operating Parameter Monitoring

1. Monitor data such as pressure, flow rate, and temperature in real time. If the intake temperature consistently exceeds 40°C, shut down the equipment and check the cooling system.

2. Set alarm thresholds via PLC, such as automatic shutdown and alarm when vibration values exceed 8 mm/s or filter pressure difference exceeds 2.5 kPa. A food factory experienced motor burnout due to a clogged filter because no pressure difference alarm was set.

3. Mode Selection and Adjustment

1. Select constant speed, constant pressure, or proportional control mode based on process requirements to avoid parameter conflicts caused by frequent mode switching.

2. Adjust the speed step by step, with each increase or decrease not exceeding 10%, to prevent airflow sudden changes from causing surging.

III. Maintenance and Troubleshooting

1. Daily Cleaning and Inspection

1. Filter Maintenance: Clean the primary filter every 2 weeks (using compressed air blowdown) and replace it monthly; replace the high-efficiency filter every 3 months. An electronics factory experienced a 40% reduction in air volume and a 25% increase in energy consumption due to a clogged filter.

2. Impeller Cleaning: Clean accumulated dust with a soft brush every six months. Do not use water washing or high-pressure air guns to avoid disrupting the impeller's dynamic balance.

3. Cooling System Check: Check the coolant level monthly. In winter, add antifreeze to prevent pipe damage due to freezing and expansion.

2. Regular Deep Maintenance

1. Every 2 years, commission the manufacturer to inspect the bearing clearance. If the suspension height deviation exceeds 0.1 mm, adjust the electromagnetic coil current.

2. Every 5 years, replace the permanent magnet motor bearing grease using the manufacturer's specified model (e.g., Shell Gadus S2 V100 3).

3.Rapid Response to Faults

1. Alarm Handling: Record error codes (e.g., E-102 indicates overcurrent protection) and upload data via the manufacturer's APP to obtain solutions.

2. Emergency Shutdown: In case of abnormal vibration or smoke, immediately press the red emergency stop button and maintain the site conditions for technical analysis.

IV. Safety Protection and Personnel Training

1. Operation Safety Standards

1. Do not open the protective cover while the equipment is running. The impeller speed can reach 20,000 rpm, and contact may cause amputation risks.

2. Before maintenance, cut off the power and hang a "Do Not Close" sign. A maintenance worker died from electric shock due to failure to hang the sign.

2. Personnel Qualification Requirements

1. Operators must pass manufacturer-certified training to master touchscreen operation, parameter interpretation, and simple troubleshooting.

2. Conduct quarterly safety drills to simulate scenarios such as electric leakage and fires to improve emergency response efficiency.

Spare Parts Management

Stock key spare parts (e.g., suspension bearings, frequency converter modules) to ensure resumption of operation within 4 hours after a failure. A pharmaceutical factory incurred losses exceeding one million yuan due to insufficient spare parts.

V. Handling Special Working Conditions

1.Extreme Weather Protection

1. Before heavy rain, check the waterproofing of the equipment room to prevent motor short circuits from water ingress. After sandstorms, clean the filter immediately to avoid particle intrusion into the bearings.

2. During winter shutdowns, drain accumulated water from pipes to prevent freezing and cracking (electric heating tapes can be installed).

2.Process Change Adaptation

1. If air volume needs to be increased, prioritize using frequency conversion speed regulation. Do not modify the impeller diameter without authorization, as this may disrupt aerodynamic balance.

2. When changing process media, recalculate pressure parameters. For example, when switching from air to nitrogen, reduce the outlet pressure by 10% to prevent overload.

By strictly adhering to the above standards, air suspension blowers can achieve over 98% operational reliability, reduce maintenance costs by 40%, and extend service life to over 15 years. Users are advised to maintain equipment records, documenting each maintenance activity to provide a basis for long-term optimization.