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Atlas Copco Air Dryers: FD90, FD110, FD130, FD170 and FD230
Atlas Copco Air Dryers: FD90, FD110, FD130, FD170 and FD230
Instruction book
· This instruction book meets the requirements for instructions specified by the machinery
directive 98/37/EC and is valid for CE as well as non-CE labelled machines.
This instruction book describes how to handle and operate the subject machine(s) to ensure safe operation, optimum working
economy and long service life.
Read this book before putting the machine into operation to ensure correct handling, operation and proper maintenance from
the beginning. The maintenance schedule contains a summary of the measures for keeping the dryer in good repair. The
maintenance procedures are simple but must be carried out regularly.
Keep the book available for the operator(s) and make sure that the dryer is operated and that the maintenance actions are carried
out according to the instructions. Record all operating data, maintenance work effected, etc. in an operator's logbook available
from Atlas Copco. Follow all applicable safety precautions, amongst others those mentioned in this book.
Repair operations should be performed by trained personnel from Atlas Copco who can also be contacted if any further information
is desired.
In all correspondence always mention the dryer type and the complete serial number, shown on the data plate.
For all specific data not mentioned in the text, consult sections "Maintenance" and "Principal data".
The company reserves the right to make changes without prior notice.
Contents
Page Page
1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.3 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2 Air circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.4 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.3 Refrigeration circuit . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Automatic regulation system . . . . . . . . . . . . . . . . . 4 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.5 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
5 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1 Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . 9 6 Problem solving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Installation proposal . . . . . . . . . . . . . . . . . . . . . . . 11
2.3 Installation instructions . . . . . . . . . . . . . . . . . . . . 12 7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.4 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 7.1 Limitations/nominal conditions . . . . . . . . . . . . . . 15
7.2 Specific data of FD90, FD110 and FD130. . . . . . 15
3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . 13 7.3 Specific data of FD170 and FD230 . . . . . . . . . . . 16
3.1 Initial start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
8 Conversion list of SI units into British units . . . . . . 16
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1 LEADING PARTICULARS trap (4) and is automatically drained. The cold, dried air flows
through heat exchanger (13), where it is warmed up by the
incoming air to approx. 10 degrees Celsius below the incoming
air temperature. Condensation in the air net cannot occur unless
1.1 General description the air is cooled to below the pressure dewpoint indicated by
gauge (1).
The FD air dryers remove moisture from compressed air by
cooling the air to near freezing point. This causes water to
condense. The condensate is automatically drained. The air is
warmed up before leaving the dryer.
1.3 Refrigeration circuit (Fig. 1.2)
1
3
M1
50643F
2 4 S7 S3
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1.4 Automatic regulation system (Fig. 1.2) 1.5 Electrical system (Figs. 1.3 up to 1.6)
The condenser pressure must be kept as constant as possible FD170 60Hz and FD230 60Hz dryers are 3-phase units, all other
to obtain stable operation, therefore, fan control switch (S3) FD dryers are single-phase units.
stops and starts the cooling fan.
The refrigerant compressors (M1) of FD170 and FD230 dryers
When, at partial or no load, the evaporator pressure drops to are equipped with a crankcase heater (Rs). When voltage is
2.25 bar(e), the by-pass regulator opens and hot, high pressure supplied, the heater is energized. It keeps the oil in the crankcase
gas is fed to the evaporator circuit to prevent the evaporator warm to prevent condensing of refrigerant in the compressor
pressure from dropping any further. housing, which could result in serious damage of the compressor
at start (liquid knock).
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C1. Start capacitor M1. Compressor motor S3. Fan control switch
C3. Run capacitor M2. Condenser fan motor S4. Electronic thermostat with
F0. Main fuses, local installation R. Resistor display (optional)
(customer's installation) R1. Temperature sensor, dewpoint S7. High pressure shut down switch
H1. Indicator lamp, VOLTAGE ON (optional) T1. Transformer (optional)
H2. Indicator lamp, DEWPOINT S0. Main switch (customer's Y1. Solenoid valve, interval drain
ALARM (optional) installation) (optional)
K1. Timer (optional) S1. Button, ON-OFF
Fan control switch (S3) starts fan motor (M2) as soon as the The compressor motor has a built-in thermic protection. If the
condenser pressure reaches the upper set point of the switch compressor motor stops without apparent reason, it will
and will stop the fan motor when the condenser pressure probably be the thermic protection which has tripped. In such
decreases to its lower set point. case, the compressor will restart when the motor windings have
cooled down, which may take up to 2 hours.
High pressure shut-down switch (S7-Fig. 1.1) stops the
compressor motor when the pressure in the refrigerant circuit
reaches the upper set point of the switch. After tripping, it
must be reset manually by pressing its reset knob.
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B1. Electronic condensate drain H3. Indicator lamp, DEWPOINT RS. Crankcase heater
(optional) ALARM (optional) S1. Button, ON-OFF
C1. Run capacitor K1. Start relay S3. Fan control switch
C3. Start capacitor M1. Compressor motor S4. Electronic thermostat with
F0. Main fuses, local installation M2. Condenser fan motor display (optional)
(customer's installation) R1. Temperature sensor, dewpoint S7. High pressure shut down switch
H1. Indicator lamp, VOLTAGE ON (optional) T1. Transformer (optional)
H2. Indicator lamp, DRYER RUN
Fig. 1.4 Electrical diagram of FD170 50Hz and FD230 50Hz
F0. Main fuses, local installation K2. Contactor, fan motor S0. Main switch (customer's
(customer's installation) M1. Compressor motor installation)
F3/4. Fuses M2. Condenser fan motor S1. Button, ON-OFF
F8. Thermal overload, fan motor Q1. Circuit breaker S2. High pressure shut down switch
H1. Indicator lamp, VOLTAGE ON Q2. Circuit breaker S3. Fan control switch
H2. Indicator lamp, DRYER RUN R1. Temperature sensor, dewpoint S4. Electronic thermostat with
H3. Indicator lamp, DEWPOINT (optional) display (optional)
ALARM (optional) RS. Crankcase heater T1. Transformer (optional)
K1. Contactor, compressor motor 1x1. Terminal strip
1x2. Terminal strip
Figs. 1.5 and 1.6
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2 INSTALLATION
2.1 Dimension drawings (Figs. 2.1 and 2.2)
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4
1. Insulating block with heat exchangers
2. Condenser
3. Condensate separator 51533F
4. Condenser cooling fan
5. Accumulator 5
Fig. 2.4 Side view
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4
51534F
4 3 1
1. Pictograph, manual condensate drain
2. Manual condensate drain valve
3. Pictograph, automatic condensate drain
4. Automatic condensate drain
5
2.3 Installation instructions C3
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Altitude operation
Consult Atlas Copco if operating above 3000 m.
3 2
3 2
50642F
50647F S1/H2 H1 4 1
S1/H1 4 1
Fig. 3.1 Control panel of FD90 up to FD130 Fig. 3.2 Control panel of FD170 and
(typical example) FD230 (typical example)
H1. Indicator lamp, VOLTAGE ON 1. Pressure dewpoint indicator 4. Pictograph, dewpoint alarm
H2. Indicator lamp, DRYER RUN 2. Pictograph, pressure dewpoint 5. Pictograph, voltage on
S1. Button, ON-OFF 3. Pictograph, dryer on-off
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3.4 Stopping (Figs. 3.1 and 3.2) 6 PROBLEM SOLVING (Fig. 1.2)
1. Close the dryer inlet and outlet valves (customer's
installation). 1. Pressure dewpoint too high
2. Press on-off button (S1). The dryer stops. Voltage on lamp a. Air inlet temperature too high
(H1) remains alight. On FD170 and FD230, the crankcase a. Check and correct; if necessary, install a pre-cooler
heater remains switched on. Leave the voltage on if the b. Ambient temperature too high
dryer has to remain stand-by. b. Check and correct; if necessary, draw cooling air via a duct
from a cooler place or relocate dryer
c. Air inlet pressure too low
c. Increase inlet pressure
d. Dryer capacity exceeded
4 MAINTENANCE d. Reduce air flow
e. Shortage of refrigerant
Cooling dryers of FD type contain refrigerant HFC. e. Have circuit checked for leaks and recharged
f. Refrigerant compressor (M1) does not run
Safety precautions f. See 3
When handling refrigerant R404a, all applicable safety g. Evaporator pressure too high
precautions must be observed. The following points are g. See 6
stressed: h. Condenser pressure too high
- Contact of refrigerant with the skin will cause freezing. h. See 2
Special gloves must be worn and in case of contact, the
skin should be rinsed with water. On no account may 2. Condenser pressure too high or too low
clothing be removed. a. Fan control switch (S3) out of order
- Fluid refrigerant will also cause freezing of the eyes; a. Replace
therefore, safety glasses are a must. b. Fan or fan motor out of order
- Refrigerant R404a is poisonous. Do not inhale refrigerant b. Check fan/fan motor
vapours. Check that the working area is adequately c. Ambient temperature too high
ventilated. c. Check and correct; if necessary, draw cooling air via a duct
from a cooler place or relocate dryer
Local legislation may impose that: d. Condenser externally clogged
- work in the refrigerant circuit of the cooling dryer or on d. Clean condenser
any equipment which influences its function should
according to the law be executed by an authorized control 3. Compressor stops or does not start
body. a. Electric power supply to compressor is interrupted
- the installation should according to the law be checked once a. Check and correct as necessary
a year by an authorized control body. b. Thermic protection of refrigerant compressor motor (M1)
has tripped
General b. Motor will restart when motor windings have cooled down
- Keep the dryer clean.
- Brush or blow off the finned surface of condenser (2-Fig. 4. Condensate trap remains inoperative
1.1) regularly. a. Automatic drain system clogged
- Once every six months inspect and clean the inner a. Flush the assembly by opening manual drain valve. Have
components of condensate trap (3-Fig. 2.6). system inspected
Footnote chapter 3
1) The pressure dewpoint will deviate from nominal if the air inlet conditions or volume flow differ from nominal.
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7 PRINCIPAL DATA
50 Hz 60 Hz
Nominal conditions
Compressed air inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7 7
Compressed air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . Celsius 35 38
Ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Celsius 25 38
Inlet relative vapour pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1
Pressure dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Celsius 3 4
Cooling air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . Celsius 25 38
Limitations
Maximum compressed air inlet pressure . . . . . . . . . . . . . . . . . bar(e) 13 13
Min.-max. ambient air temperature . . . . . . . . . . . . . . . . . . . . . Celsius 0-45 0-45
Min.-max. compressed air inlet temperature . . . . . . . . . . . . . . Celsius 0-55 0-55
Refrigerant
Tetrafluoroethane CH2FCF3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R404a R404a R404a
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FD170 FD230
Pressure drop through dryer at nominal conditions, approx. . . . . . . . . 50 Hz bar 0.22 0.22
60 Hz bar 0.25 0.22
Refrigerant
Tetrafluoroethane CH2FCF3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R404a R404a
Total charge, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Hz kg 1.80 1.80
60 Hz kg 1.60 1.70
Footnote chapter 7
1) At nominal conditions.
Footnote chapter 8
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