FD 450
FD 450
FD 450
Instruction Book
Important:
This book applies exclusively to FD dryers as from following serial numbers onwards and filled with
refrigerant R404a; see data plate:
FD260: AIQ-124 045
FD300: AIQ-140 200
FD380: AIQ-129 800
FD450: AIQ-140 550
FD700: AIQ-750 005
This instruction book meets the requirements for instructions specified by the machinery
directive 89/392/EEC and is valid for CE as well as non-CE labelled machines
1998-03
*2920135101*
Instruction book
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 on the cover of this book.
Repair operations must 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 section "Principal data".
The company reserves the right to make changes without prior notice.
Contents
Page Page
1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.4 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . 3 3.5 Possible causes of unstable or too high pressure
1.2 Air circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 dewpoint temperature . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Refrigeration circuit . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Automatic regulation system . . . . . . . . . . . . . . . . . 8 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.5 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5.1 Automatic expansion valve . . . . . . . . . . . . . . . . . . 17
2.1 Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . . 8 5.2 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2 Installation proposal . . . . . . . . . . . . . . . . . . . . . . . 13
2.3 Installation instructions . . . . . . . . . . . . . . . . . . . . . 13 6 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . 15 7.1 Limitations/nominal conditions . . . . . . . . . . . . . . 19
3.1 Initial start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 7.2 Specific data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . 16 8 Conversion list of SI units into British/US units . . . 20
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F6837
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1.3 Refrigeration circuit (Fig. 2) In expansion valve (13) some of the expanding liquid refrigerant
evaporates, for which the required heat is withdrawn from the
Compressor (M1) delivers hot, high-pressure refrigerant gas, refrigerant itself.
which flows, via the coil of liquid separator (7), through
condenser (9) where most of the refrigerant condenses. On The refrigerant enters the heat exchanger/evaporator (15) where
air-cooled condensers, a fan control switch (S3) stops and starts it withdraws heat from the compressed air by further
the fan motor (M2) at falling or rising condenser pressure. On evaporation. Dependent on the compressed air load, all, or
water-cooled condensers, an automatic valve (3-Figs. 5) almost all, refrigerant evaporates at constant pressure and
regulates the cooling water flow, thus controlling the temperature. The vapour refrigerant leaving evaporator (15)
temperature, which is directly dependent on the pressure. The flows into liquid separator (7). The liquid separator prevents
cooled refrigerant then collects in receiver (10). any droplets from entering compressor (M1) because warm
refrigerant, leaving the compressor, flows through the coil of
The liquid leaves the receiver (10) via its syphon outlet and the liquid separator and evaporates the surrounding liquid.
flows through liquid refrigerant filter/dryer (12) to expansion From liquid separator (7) the refrigerant gas is sucked in by the
valve (13) where it expands to evaporating pressure. compressor.
T1 L1 L2 L3 1X1 PE
F2
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Fig. 4a
S3 S2 2 7
5
M2 M1. Refrigerant compressor/motor
M2. Condenser cooling fan motor
S2. High pressure shut-down switch
S3. Fan control switch
9 6 1. Condensate trap with automatic
discharge
2. Refrigerant shut-off valve
3. Condenser
4. Liquid refrigerant receiver
5. Fan
F6839 6. Refrigerant dryer/filter
7. Refrigerant expansion valve
8. Liquid separator
9. Electric cubicle
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Fig. 5a
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1.4 Automatic regulation system (Fig. 2) Altering the set point value (indicated "L1"):
- Press key (5); the current value blinks on the display.
Expansion valve (13) maintains the evaporating temperature - Press the up (1) or down (2) key until the desired value is
between 1 and -1°C (34 and 30°F); these are the approximate reached.
limit temperatures at zero and maximum air load respectively. - To store the new value, press key (5) or wait a few seconds.
At partial or no load, the excess cooling capacity is transferred
in liquid separator (7). The condenser pressure must be kept Altering the differential value (indicated "HY1"):
as constant as possible to obtain stable operation of expansion - Press key (4); the current value blinks on the display.
valve (13). Therefore, on air-cooled dryers, fan control switch - Press the up (1) or down (2) key until the desired value is
(S3) stops and starts cooling fan (M2). On water-cooled dryers, reached.
the temperature is controlled by an automatic regulating valve - Press key (5) or wait a few seconds to store the new value.
on the water circuit. The switch or regulating valve ensures
proper operation at low air load and/or low ambient temperature. If the temperature increases above the preset value, alarm
indicator lamp (H3-Fig. 10) will light up.
1) Optional equipment.
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Fig. 6a. Dimension drawing of FD260 up to FD380 50/60 Hz and FD450 50 Hz
9
10
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Fig. 6c. Dimension drawing of FD700 50/60 Hz
11
12
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2.3 Installation instructions 4. A sticker dealing in short with the operating instructions
and explaining the pictographs is delivered with the
1. Install the dryer where the ambient air is as clean as possible literature set. Affix the sticker next to the control panel.
and where the temperature of the air will never exceed or Make yourself familiar with the instructions and pictographs
drop below the temperature limits (see section 7). Keep explained.
the ventilation gratings of the dryer free. 5. On water-cooled dryers, connect the water cooling pipes to
2. Connect the compressed air lines to the marked inlet and the marked in and out connections. It is recommended to
outlet pipes of the dryer; if required, via valves and fit a manual shut-off valve in the water inlet.
preferably a by-pass valve. Apply a sealing medium to the 6. Remove all the bags with silica gel attached to the dryer.
threaded connections. 7. Check that the primary side connection of the transformer
3. Fit manual condensate drain valve (2-Fig. 8) onto the (T1-Fig. 3) corresponds with the supply voltage.
condensate drain pipe. 8. Check that the electrical installation corresponds to the local
Lay out the condensate drain hose (3-Fig. 8) via a funnel codes. The dryer must be earthed and protected against
towards a drain collector to allow visual inspection. The short circuits by fuses of the inert type in all phases. An
hose must pitch downwards, away from the dryer and the isolating switch must be installed near the dryer. Connect 3
open end must never dip into the water of the drain collector. cables from the main fuses to terminals (L1, L2 and L3-
If the condensate drain has been led down outside the Fig. 3), connect the earth cable to the earth terminal (PE-
compressor room where the pipe may be exposed to freezing Fig. 3).
temperatures, the pipe must be insulated.
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Fig. 8. FD380 W
Fig. 9. Pictographs
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Safety precautions 1. At least 4 hours before starting, the mains supply to the
The operator must apply all relevant safety precautions, dryer must be switched on to energize the crankcase heater,
including those mentioned in this book. which warms up the oil. The indicator lamp (H1) is then
alight.
Altitude operation 2. Open the refrigerant shut-off valves (11-Fig. 2 and on water-
Consult Atlas Copco if operating above 3000 m. cooled dryers also 4-Fig. 5a) as follows: take the protecting
cap off the valve, then screw the spindle fully out and refit
Moving/lifting the cap.
The dryer can be moved by a lift truck using the slot in the 3. On air-cooled dryers, press run/stand-by button (S1). Check
frame. Make sure that the forks protrude from the other side of that the sense of rotation of the fan motor is correct. Cooling
the frame. The dryer can also be lifted after inserting beams in air must be drawn in through the condenser (3-Figs. 4) and
the slot. Make sure that the beams cannot slide and that they blown over the refrigerant compressor (M1-Fig. 4a) to
protrude from the frame equally. The chains must be held outside the dryer. If wrong, switch off the voltage and reverse
parallel to the bodywork by chain spreaders in order not to two of the three phase connections at the mains terminals.
damage the dryer. The lifting equipment must be placed in
such a way that the dryer will be lifted perpendicularly. Lift
smoothly and avoid twisting. 3.2 Starting (Fig. 10)
1) Optional equipment
Fig. 10. Instrument panel
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energize the crankcase heater. Never start the dryer without - Condenser externally clogged (air-cooled dryers)
preheating as this may cause serious damage to the - Malfunctioning of fan control switch (S3-Fig. 4b) on
refrigerant compressor. air-cooled dryers or malfunctioning of the cooling water
Check that voltage on indicator lamp (H1) is alight. regulating valve (3-Figs. 5) on water-cooled dryers
2. On water-cooled dryers, open the cooling water shut-off
valves. Note: The pressure dewpoint temperature will deviate from
3. Press run/stand-by button (S1). Check that dryer on nominal when the nominal conditions are exceeded, e.g. a
indicator lamp (H2) is alight. pressure dewpoint temperature of +7°C can be considered as
4. If the air inlet valve is closed, open it a little to pressurize normal if the air flow, the air inlet temperature or the ambient
the dryer gradually; open the valve when the dryer is temperature is higher than nominal.
pressurized.
5. Approx. 5 minutes later, load the dryer by opening the air
outlet valve.
Close the by-pass valve if installed.
6. After approx. 10 minutes, the nominal pressure dewpoint 4 MAINTENANCE
temperature will be reached.
Maintenance and repair work other than routine attention,
especially on the refrigeration circuits, must only be carried
3.3 During operation out by qualified personnel and with the proper equipment.
1. Dryer overload
- Compressed air flow exceeds capacity of dryer
- Working pressure too low
- Air inlet temperature too high
- Ambient temperature too high
- On water-cooled dryers, insufficient cooling water flow
2. Refrigeration system problems or maladjustment
- Maladjustment of the refrigerant expansion valve (7- 1) - Not necessary when an electronic interval drain has been
Fig. 4b and 9-Fig. 5b) installed.
- Shortage of refrigerant in circuit through leakage - At initial start-up the condensate trap must be flushed more
frequently.
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F6843
The regulating and safety devices are factory-adjusted to obtain The automatic expansion valve (7-Fig. 4b and 9-Fig. 5b) is a
optimum performance of the dryer. Altering the setting of any regulator which keeps the evaporator pressure, and
of the devices must be avoided. consequently also the temperature, stable. The valve is factory-
set to keep the evaporator pressure at no-load at a minimum of
5.2 bar(e) (75 psig), which corresponds to 1°C (34°F).
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 35 38
Ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 25 38
Inlet relative vapour pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1
Pressure dewpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 3 4
Cooling air/water inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 25 38
Limitations
Maximum compressed air inlet pressure . . . . . . . . . . . . . . . . . . . . . . . bar(e) 14.5 14.5
Min.-max. ambient air/water inlet temperature . . . . . . . . . . . . . . . . . . °C 0-45 0-45
Min.-max. compressed air inlet temperature . . . . . . . . . . . . . . . . . . . . °C 0-55 0-55
Maximum cooling water inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 10 10
Refrigerant
Difluormonochlormethane CHF2Cl . . . . . . . . . . . . . . . . . . . . . . . . . . . R404a R404a R404a
Total charge, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 8 8 8
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Refrigerant
Difluormonochlormethane CHF2Cl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . R404a R404a
Total charge, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg 8 16
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