Atlas Copco FD 40 Instruction Book
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Atlas Copco FD 40 Instruction Book

Refrigerant compressed air dryers
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Atlas Copco
Refrigerant compressed air dryers
FD 40, FD 50, FD 60, FD 70, FD 95
Instruction book

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Summary of Contents for Atlas Copco FD 40

  • Page 1 Atlas Copco Refrigerant compressed air dryers FD 40, FD 50, FD 60, FD 70, FD 95 Instruction book...
  • Page 2 Atlas Copco Refrigerant compressed air dryers FD 40, FD 50, FD 60, FD 70, FD 95 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations, part numbers and drawings.

  • Page 3: Table Of Contents

    aerocompressors.ru Instruction book Table of contents Safety precautions......................4 ...........................4 AFETY ICONS ......................4 AFETY PRECAUTIONS GENERAL ...................5 AFETY PRECAUTIONS DURING INSTALLATION ....................6 AFETY PRECAUTIONS DURING OPERATION ................7 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description......................9 ...........................9 NTRODUCTION ............................11 IR CIRCUIT ........................12 EFRIGERATION CIRCUIT ......................14 UTOMATIC REGULATION SYSTEM...
  • Page 4 aerocompressors.ru Instruction book Installation........................26 ........................26 IMENSION DRAWINGS ........................29 NSTALLATION PROPOSAL ........................32 LECTRICAL DIAGRAMS ..........................36 ICTOGRAPHS Operating instructions....................38 ............................38 ARNINGS ............................38 TARTING ..........................39 URING OPERATION ............................39 TOPPING Maintenance instructions....................41 Device settings......................43 Problem solving......................44 Technical data.......................46 ...........................46 USE RATING ....................46 EFERENCE CONDITIONS AND LIMITATIONS ..........................48 IR DRYER DATA Pressure equipment directives...................50...

  • Page 5: Safety Precautions

    aerocompressors.ru Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note Safety precautions, general General precautions All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer.

  • Page 6: Safety Precautions During Installation

    aerocompressors.ru Instruction book Safety precautions during installation Precautions during installation 1. The dryer must only be lifted using suitable equipment and in accordance with the applicable safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk zone under a lifted load.

  • Page 7: Safety Precautions During Operation

    aerocompressors.ru Instruction book Also consult following safety precautions: Safety precautions during operation Safety precautions during maintenance or repair. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein.

  • Page 8: Safety Precautions During Maintenance Or Repair

    aerocompressors.ru Instruction book Also consult following safety precautions: Safety precautions during installation Safety precautions during maintenance or repair. These precautions apply to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application which are not included herein.
  • Page 9 aerocompressors.ru Instruction book • Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical first aid.

  • Page 10: General Description

    The condensate is automatically drained. The air is warmed up before leaving the dryer. The dryers can be provided with the options as described in section Available options. General view FD 40 / FD 50 - general view Reference Name Air inlet Air outlet ®...
  • Page 11 Instruction book Side views FD 40 and FD 50 - back view FD 60 up to FD 95 - front view Reference Name Insulating block with heat exchangers Electronic condensate drain Pressure switch, fan control Condenser Condenser cooling fan...

  • Page 12: Air Circuit

    Instruction book Reference Name Filter dryer Capillary Manual condensate drain outlet Automatic drain outlet Air circuit Flow diagram Flow diagram FD 40 and FD 50 Flow diagram FD 60 up to FD 95 2920 7083 01...

  • Page 13: Refrigeration Circuit

    Condensation in the air net cannot occur unless the air is cooled to below the pressure dewpoint, indicated on ® the screen of the Elektronikon α regulator. Refrigeration circuit Refrigerant flow diagram Flow diagram FD 40 up to FD 50 2920 7083 01...
  • Page 14 aerocompressors.ru Instruction book Flow diagram FD 60 up to FD 95 Description Compressor (4) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where most of the refrigerant condenses. The liquid flows through liquid refrigerant dryer/filter (7) to capillary tube (8). The refrigerant leaves the capillary tube at evaporating pressure.

  • Page 15: Automatic Regulation System

    Instruction book Automatic regulation system Air and refrigerant flow diagram Flow diagram FD 40 up to FD 50 Flow diagram FD 60 up to FD 95 Description The condenser (6) pressure must be kept as constant as possible to obtain stable operation. Fan control switch (P) therefore stops and starts the condenser cooling fan (11).

  • Page 16: Condensate Drain System

    Following options are available : Filter option FD 40 and FD 50: This option comprises a DD filter, mounted at the dryer inlet and a PD filter, mounted at the dryer outlet. Both filters are equipped with a pressure drop indicator.
  • Page 17 PD filter at dryer outlet Pressure drop indicator 20 bar version FD 40 and FD 50 can be supplied in a special version, capable to work at compressed air inlet pressures up to 20 bar(e) (290 psi(g)). See Air dryer data for technical data.
  • Page 18 aerocompressors.ru Instruction book Dryer inlet and outlet connections on top FD 60 up to FD 95 can be supplied with the dryer inlet (1) and dryer outlet (2) connections on top (for standard dryers only). Inlet and outlet connections on top allows easy installation of the dryer against the wall. OSD option (In combination with filter option only) FD 60 up to FD 95: When the dryer is used after an oil injected compressor, oil containing condensate is leaving the drain system.

  • Page 19: Electrical System

    aerocompressors.ru Instruction book Electrical system Description FD dryers are single-phase electrical units. See Electrical diagrams. Fan control switch (P) starts fan motor (M2) as soon as the condenser pressure reaches the upper set point of the switch and will stop the fan motor when the condenser pressure decreases to its lower set point. The compressor motor has a built-in thermic protection.

  • Page 20: Elektronikon® Α Regulator

    aerocompressors.ru Instruction book Elektronikon® α regulator ® Elektronikon α regulator Control panel General description ® The Elektronikon α regulator automatically controls the dryer, i.e.: • It switches the dryer on and off in order to save energy (Energy Efficient Mode) •...

  • Page 21: Starting And Stopping The Dryer

    aerocompressors.ru Instruction book Name Function Start/Stop button Push button to start and stop the dryer Display Indicates the dryer operating condition, actually measured values and programmed parameters Pictograph Dewpoint temperature (measured) Pictograph Ambient temperature (measured) Pictograph Relative humidity (calculated, based on ambient air temperature and dewpoint temperature) Pictograph Energy efficient mode...

  • Page 22: Screen

    aerocompressors.ru Instruction book Screen Control panel Normally the screen shows: • The dewpoint temperature on the display (2) • The dryer status by means of pictographs underneath the display Typical screen example: 3 °C Explanation: • The dewpoint temperature is shown on the display (3°C) •...

  • Page 23: Alarm Indicators

    aerocompressors.ru Instruction book Reference Designation Pictograph for dewpoint temperature Pictograph for ambient temperature Pictograph for relative humidity Pictograph for indication of regular operation mode or energy efficient mode When selecting one of the first three items, the corresponding actual value is shown on the display. See section Modifying dewpoint/ambient temperature unit to change between °C and °F.

  • Page 24: Modifying The Temperature Unit

    aerocompressors.ru Instruction book • The dryer will switch off • The voltage free contact will switch (can be used as an external alarm) The dryer will restart automatically as soon as the LAT is again above 0.3 °C (32.54 °F). 2.

  • Page 25: Modifying Ambient Temperature Offset

    aerocompressors.ru Instruction book • Press the enter key (3) again to confirm the selection Modifying ambient temperature offset Description Standard relative humidity calculation is based on measured dewpoint (LAT) and ambient temperature. The air temperature at the outlet of the dryer can however exceed the ambient temperature with some degrees. This has a positive impact on the real relative humidity of the air.

  • Page 26: 3.10 Error Messages

    aerocompressors.ru Instruction book Control panel When selecting the Regular/Energy Efficient Mode item (see section Scrolling through all screens), the dryer regulation mode can be changed as follows: • Press the enter key (3) once • Press the left scroll key (1) or the right scroll key (2) to choose between ‘ON’ and ‘OFF’ •...

  • Page 27: Installation

    Instruction book Installation Dimension drawings FD 40 and FD 50 2920 7083 01...
  • Page 28 aerocompressors.ru Instruction book FD 60 up to FD 95 Dimension drawing of standard FD65 and FD95 2920 7083 01...
  • Page 29 aerocompressors.ru Instruction book Dimension drawing of FD60 up to FD95 with integrated filter option (and OSD) 2920 7083 01...

  • Page 30: Installation Proposal

    Instruction book Installation proposal FD 40 and FD 50 2920 7083 01...
  • Page 31 aerocompressors.ru Instruction book FD 60 up to FD 95 References to text on the Description drawing Ventilation proposal for dryer without optional filters Ventilation proposal for dryer with optional filters Air flow Minimum free area to be reserved for the dryer installation 2920 7083 01...
  • Page 32 If applicable, a QD active carbon filter can be installed downstream of the PD filter to remove undesired oil vapours and odours. The standard dryers FD 40 up to FD 95 are supplied without filters. Power supply cable to be sized and installed by a qualified electrician. Fuses: see...

  • Page 33: Electrical Diagrams

    Instruction book Electrical diagrams Service diagram of FD 40 and FD 50 2920 7083 01...
  • Page 34 Instruction book Service diagram of FD 40 Service diagram of FD 50 2920 7083 01...
  • Page 35 aerocompressors.ru Instruction book Service diagram FD 60 up to FD 70 2920 7083 01...
  • Page 36 aerocompressors.ru Instruction book Service diagram FD 95 2920 7083 01...

  • Page 37: Pictographs

    Instruction book Pictographs Pictographs Pictographs for FD 40 up to FD 95 Reference Description Dryer outlet Dryer inlet Automatic condensate drain Warning, voltage Warning: switch off the voltage, depressurise the compressor and read the instruction book before carrying out maintenance work...
  • Page 38 aerocompressors.ru Instruction book Reference Name Oil the gasket, screw on the filter and tighten by hand (approx. one half turn) Consult the instruction manual before carrying out maintenance or repair work Pressure inlet, service point Oil outlet Condensate outlet Separator inlet pressure Pictograph for the filters (optional) Reference Name...

  • Page 39: Operating Instructions

    Warnings Safety precautions The operator must apply all relevant safety precautions, including those mentioned in this manual. Altitude operation Consult Atlas Copco if operating above 3000 m (9843 ft). Starting Control panel Control panel FD 40 up to FD 95...

  • Page 40: During Operation

    Instruction book During operation Condensate drain FD 40 up to FD 95 Procedure Regularly check: • The pressure dewpoint on the control panel of the Elektronikon ® α regulator. The pressure dewpoint will deviate from nominal if the air inlet conditions or volume flow differ from nominal.
  • Page 41 aerocompressors.ru Instruction book Procedure Step Action Close dryer inlet and outlet valves (customer's installation). Press the ON/OFF button (1) on the control panel. Attention Avoid using the ON/OFF button repeatedly within a short time period, as this could cause the thermic protection of the compressor motor to trip. 2920 7083 01...

  • Page 42: Maintenance Instructions

    aerocompressors.ru Instruction book Maintenance instructions Attention Cooling dryers of FD type contain refrigerant HFC. Safety precautions When handling refrigerant R134a, all applicable safety precautions must be observed. Please be aware of the following points: • Contact of refrigerant with the skin will cause freezing. Special gloves must be worn. If contacted with the skin, the skin should be rinsed with water.
  • Page 43 aerocompressors.ru Instruction book For dryers equipped with optional oil/condensate separator (OSD) General view of OSD 22, typical example • Regularly check pressure gauge (2) on the control panel. • Regularly check the oil level of oil can (4). If the oil can is filled with oil, take the can out of the bracket and deliver the oil to the local oil collection service.

  • Page 44: Device Settings

    aerocompressors.ru Instruction book Device settings Regulating and safety devices The regulating and safety devices are factory-adjusted to obtain optimum performance of the dryer. Do not alter the setting of any of the devices. 2920 7083 01...

  • Page 45: Problem Solving

    aerocompressors.ru Instruction book Problem solving Precautions Apply all relevant safety precautions. See section Safety precautions. Consult also section Maintenance instructions. Use only authorised parts. Any damage or malfunction caused by the use of unauthorised parts is not covered by Warranty or Product Liability. Faults and remedies For all references hereafter, consult Air system...
  • Page 46 aerocompressors.ru Instruction book Condition Fault Remedy Condenser pressure too high See 2 or too low Shortage of refrigerant Have circuit checked for leaks and recharged Ambient temperature Error of temperature sensors Check if temperature sensors are well pictograph or dewpoint connected temperature pictograph is flickering...

  • Page 47: Technical Data

    The table below indicates maximal fuse ratings to be used for the dryer supply. For IEC approved dryers, recommended fuse type is gL/gG. For CSA/UL approved dyers, recommended fuse type is Class K5/HRCII-C. Frequency Voltage FD 40 FD 50 50 Hz 230 V 16 A...
  • Page 48 ˚F 37.4 39.2 Cooling air inlet temperature ˚C Cooling air inlet temperature ˚F 100.4 Limitations For FD 40 and FD 50: Units 50 Hz 60 Hz Maximum compressed air inlet pressure bar(e) Maximum compressed air inlet pressure psig 232.06 232.06...

  • Page 49: Air Dryer Data

    Air dryer data Standard version All data are stated under nominal conditions, see section Reference conditions and limitations Air dryer type unit FD 40 FD 50 FD 60 FD 70 FD 95 Volume flow at dryer inlet Volume flow at dryer inlet 84.76...
  • Page 50 Instruction book Air dryer type unit FD 40 FD 50 Total power consumption, including 50 Hz 0.57 0.54 cooler fan Total power consumption, including 50 Hz 0.76 0.72 cooler fan Total power consumption, including 60 Hz 0.73 0.79 cooler fan...

  • Page 51: Pressure Equipment Directives

    aerocompressors.ru Instruction book Pressure equipment directives Components subject to 97/23/EC Pressure Equipment Directive All pressure-bearing components are designed according to the European Directive 97/23/EC category I. 2920 7083 01...

  • Page 52: Declaration Of Conformity

    aerocompressors.ru Instruction book Declaration of conformity Typical example of a Declaration of Conformity document 2920 7083 01...

This manual is also suitable for:

Fd 50Fd 60Fd 70Fd 95

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