Atlas Copco FD90 - User Manual

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Summary

Leading Particulars

General Description

Concise summary of the dryer's function, removing moisture by cooling compressed air.

Air Circuit

Explains the path of compressed air through the dryer, including cooling and condensate separation.

Refrigeration Circuit

Details the refrigerant flow and components within the dryer, from compressor to evaporator.

Automatic Regulation System

Describes how the dryer's pressure and operation are regulated automatically using switches and valves.

Electrical System

Overview of the electrical components, wiring diagrams, and power supply requirements for the dryers.

Installation

Dimension Drawings

Provides physical dimensions, connection points, and weight for various dryer models.

Installation Proposal

Suggests a typical installation layout including prefilters, air receivers, and drain connections.

Installation Instructions

Details the procedures and considerations for physically installing the dryer, including location and connections.

Pictographs

Explains the meaning of various symbols and pictographs used on the dryer control panel and body.

Operating Instructions

Operating Safety Precautions

Lists essential safety rules and precautions for operating the dryer safely.

Altitude Operation

Advises on considerations and potential adjustments for operating the dryer at high altitudes.

Initial Start

Step-by-step guide for the initial startup procedure, including pre-heating and connections.

Starting the Dryer

Instructions for starting the dryer, including pre-heating, valve operation, and waiting periods.

During Operation

Describes regular checks, monitoring of indicators, and manual draining during normal dryer operation.

Stopping the Dryer

Provides instructions on how to safely stop the dryer and the status of indicator lamps.

Maintenance

Maintenance Safety Precautions

Critical safety measures for handling refrigerants and performing maintenance to avoid injury.

Problem Solving

High Pressure Dewpoint Issues

Lists common causes and solutions for a high pressure dewpoint, such as high inlet temperature or low airflow.

Condenser Pressure Issues

Outlines checks and actions for incorrect condenser pressure, including fan/motor issues or cleaning.

Compressor Start;Stop Issues

Troubleshooting steps for issues with the compressor starting or stopping, checking power and thermal protection.

Inoperative Condensate Trap

Addresses problems with the automatic condensate drain system, often due to clogging.

Continuous Condensate Trap Discharge

Identifies potential causes for continuous air and water discharge from the condensate trap, indicating a system issue.

Evaporator Pressure Issues at Unload

Solutions for issues related to evaporator pressure during partial load, involving by-pass valves or refrigerant levels.

Principal Data

Limitations and Nominal Conditions

Specifies the operating limits and nominal conditions such as pressure, temperature, and dewpoint.

Specific Data for FD90, FD110, FD130

Provides technical specifications like volume flow, power input, and refrigerant charge for specific dryer models.

Specific Data for FD170, FD230

Lists technical specifications including volume flow, power input, and refrigerant charge for specific dryer models.

SI to British Unit Conversions

This document is an instruction book for Atlas Copco FD90, FD110, FD130, FD170, and FD230 air dryers. It provides comprehensive information on the device's function, technical specifications, usage, and maintenance.

Function Description

The Atlas Copco FD air dryers are designed to remove moisture from compressed air by cooling it to near freezing point, causing water to condense. The condensate is then automatically drained, and the dried air is warmed up before exiting the dryer.

The air circuit involves compressed air entering a heat exchanger (13) where it is pre-cooled by outgoing, cold, dried air, leading to initial water condensation. The air then flows through a heat exchanger/evaporator (11) where refrigerant evaporation further cools it to near the refrigerant's evaporating temperature, causing more water to condense. A separator (3) then removes all condensate, which collects in a condensate trap (4) and is automatically drained. The cold, dried air is finally warmed up by the incoming air in the heat exchanger (13) to approximately 10 degrees Celsius below the incoming air temperature, preventing condensation in the air net unless the air cools below the pressure dewpoint indicated by gauge (1).

The refrigeration circuit begins with the compressor (M1) delivering hot, high-pressure refrigerant gas to the condenser (9), where most of it condenses. The liquid refrigerant then passes through a liquid refrigerant dryer/filter (12) to a capillary tube (7), exiting at evaporating pressure. It enters the evaporator (11) to absorb heat from the compressed air through further evaporation at constant pressure. The heated refrigerant then returns to the compressor via an accumulator (14).

The dryer features an automatic regulation system to maintain stable operation. A fan control switch (S3) stops and starts the cooling fan to keep condenser pressure constant. If the evaporator pressure drops to 2.25 bar(e) under partial or no load, a by-pass regulator opens, feeding hot, high-pressure gas to the evaporator circuit to prevent further pressure drops.

The electrical system varies by model. FD170 60Hz and FD230 60Hz dryers are 3-phase units, while all other FD dryers are single-phase. FD170 and FD230 refrigerant compressors (M1) are equipped with a crankcase heater (Rs) that energizes when voltage is supplied, keeping the oil warm to prevent refrigerant condensation and potential compressor damage at start-up. A fan control switch (S3) manages the condenser fan motor (M2) based on condenser pressure. A high-pressure shut-down switch (S7) stops the compressor if refrigerant circuit pressure exceeds a set point and requires manual reset. Compressor motors also have built-in thermic protection, which may cause the compressor to stop and restart after up to 2 hours when windings cool down.

An optional electronic thermostat with a display (3) shows the pressure dewpoint. It allows checking and altering the set point value (L1) for the dewpoint alarm and the differential value (HY1) for alarm on/off temperature difference. An alarm indicator lamp lights up if the temperature exceeds the preset value.

Important Technical Specifications

Nominal Conditions (50 Hz / 60 Hz):

Compressed air inlet pressure: 7 bar(e) / 7 bar(e)
Compressed air inlet temperature: 35 Celsius / 38 Celsius
Ambient temperature: 25 Celsius / 38 Celsius
Inlet relative vapour pressure: 1 / 1
Pressure dewpoint: 3 Celsius / 4 Celsius
Cooling air inlet temperature: 25 Celsius / 38 Celsius

Limitations:

Maximum compressed air inlet pressure: 13 bar(e)
Min.-max. ambient air temperature: 0-45 Celsius
Min.-max. compressed air inlet temperature: 0-55 Celsius

Specific Data (FD90, FD110, FD130 - 50 Hz / 60 Hz):

FD90:
- Volume flow: 90 l/s / 92 l/s
- Pressure drop: 0.16 bar
- Electric power input: 1.30 kW / 1.80 kW
- Refrigerant: R404a
- Total charge: 0.80 kg / 1.00 kg
FD110:
- Volume flow: 110 l/s / 113 l/s
- Pressure drop: 0.15 bar
- Electric power input: 1.40 kW / 2.30 kW
- Refrigerant: R404a
- Total charge: 1.00 kg / 1.10 kg
FD130:
- Volume flow: 130 l/s / 135 l/s
- Pressure drop: 0.21 bar
- Electric power input: 1.90 kW / 2.30 kW
- Refrigerant: R404a
- Total charge: 1.10 kg / 1.10 kg

Specific Data (FD170, FD230 - 50 Hz / 60 Hz):

FD170:
- Volume flow: 170 l/s / 175 l/s
- Pressure drop: 0.22 bar / 0.25 bar
- Electric power input: 1.90 kW / 3.60 kW
- Refrigerant: R404a
- Total charge: 1.80 kg / 1.60 kg
FD230:
- Volume flow: 230 l/s / 235 l/s
- Pressure drop: 0.22 bar / 0.22 bar
- Electric power input: 2.40 kW / 3.60 kW
- Refrigerant: R404a
- Total charge: 1.80 kg / 1.70 kg

Usage Features

Installation:

Install the dryer in an area with clean ambient air, ensuring the temperature remains within specified limits (0-45 Celsius ambient, 0-55 Celsius inlet).
Keep ventilation gratings clear and avoid external influences like wind or draughts that could disturb cooling airflow.
Connect compressed air lines to marked inlet and outlet pipes, providing inlet and outlet valves. A by-pass pipe and valve are recommended for servicing.
Install a manual condensate drain valve and route condensate drain hoses via a funnel to a drain collector for visual inspection. Hoses must slope downwards and be insulated if exposed to freezing temperatures.
For single-phase dryers, plug the electric plug into the supply cable.
For 3-phase dryers, verify transformer connections match supply voltage, ensure proper earthing, and protect against short circuits with inert type fuses in all phases. An isolating switch must be installed near the dryer.

Initial Start:

At least 4 hours before starting, switch on the mains supply to energize the crankcase heater of the refrigerant compressor (for FD170 and FD230).
For 3-phase dryers, press the ON-OFF button (S1) and check the rotation sense of the fan motor (M2); cooling air should be drawn in through the condenser and blown over the compressor. If incorrect, reverse two of the three phase connections at the mains terminals.

Starting:

Ensure voltage is on for 4 hours before starting FD170 and FD230.
If installed, close the dryer by-pass valve.
Press the ON-OFF button (S1).
Open the dryer air inlet valve (customer's installation).
Approximately 5 minutes later, open the dryer air outlet valve (customer's installation).
The nominal dewpoint should be reached approximately 10 minutes later.

During Operation:

Regularly check the pressure dewpoint indicator.
Verify that condensate is being discharged.
Regularly open the manual drain valve for about 10 seconds to discharge condensate and impurities.

Stopping:

Close the dryer inlet and outlet valves (customer's installation).
Press the ON-OFF button (S1). The dryer stops, but the voltage on lamp (H1) remains alight.
For FD170 and FD230, the crankcase heater remains switched on. Leave the voltage on if the dryer is on standby.

Maintenance Features

General Maintenance:

Keep the dryer clean.
Regularly brush or blow off the finned surface of the condenser.
Every six months, inspect and clean the inner components of the condensate trap.

Safety Precautions (Refrigerant R404a):

Always observe all applicable safety precautions when handling refrigerant R404a.
Wear special gloves and safety glasses to prevent freezing contact with skin or eyes. In case of contact, rinse skin with water; do not remove clothing.
Avoid inhaling refrigerant vapours; ensure the working area is adequately ventilated.
Local legislation may require that work on the refrigerant circuit or any equipment influencing its function be performed by an authorized control body, and the installation be checked annually by an authorized control body.

Problem Solving (Common Issues):

Pressure dewpoint too high: Check and correct air inlet/ambient temperature, increase inlet pressure, reduce airflow, check for refrigerant shortage/leaks, ensure compressor is running, and verify evaporator/condenser pressure.
Condenser pressure too high or too low: Check/replace fan control switch (S3), check fan/fan motor, correct ambient temperature, and clean condenser.
Compressor stops or does not start: Check electric power supply, or wait for motor windings to cool down if thermic protection has tripped.
Condensate trap inoperative: Flush the automatic drain system by opening the manual drain valve and have the system inspected.
Condensate trap continuously discharges air and water: Have the automatic drain system checked.
Evaporator pressure too high or too low at unload: Adjust the hot gas by-pass valve, check condenser pressure, or check for refrigerant shortage/leaks.