Atlas Copco FD560 User manual

Oil-free Air Division - B-2610 Wilrijk - Belgium
*2920137100*
Instruction book for
Air dryers
FD(W)560, -700, -850, -950,
-1200, -1600
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
Registration code
Collection: APC FD
Tab: 38
Sequence: 987
No. 2920 1371 00
1997-12
This instruction book applies exclusively to FD560, -700, -850, -950, -1200
and -1600 dryers filled with R404a refrigerant (see data plate)

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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.
Page
1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General description. . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Air circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Refrigeration circuit . . . . . . . . . . . . . . . . . . . . . . . . 5
1.4 Automatic regulation system . . . . . . . . . . . . . . . . . 5
1.5 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 Dimension drawings . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Installation proposal . . . . . . . . . . . . . . . . . . . . . . . 17
2.3 Installation instructions. . . . . . . . . . . . . . . . . . . . . 17
2.4 Pictographs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . 19
3.1 Initial start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.2 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.3 During operation . . . . . . . . . . . . . . . . . . . . . . . . . . 20
CONTENTS
Page
3.4 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5 Possible causes of unstable or too high pressure
dewpoint temperature . . . . . . . . . . . . . . . . . . . . . . 20
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.1 Automatic expansion valve. . . . . . . . . . . . . . . . . . 21
5.2 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6 Problem solving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1 Limitations/nominal conditions . . . . . . . . . . . . . . 23
7.2 Specific data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8 Conversion list of SI units into British/US units . . . 24

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1 LEADING PARTICULARS
Note: Fig. 2 shows the air and refrigerant flow diagram of
FD560 and FD700. The flow diagram of FD850 up to FD1600
lookssimilar,butthese dryers are provided with two condensate
separators and two liquid separators. The description below is
valid for all dryers described in this book.
1.1 General description
The FD air dryers remove moisture from compressed air by
cooling the air to near freezing point. This causes water and
oil to condense. The condensate is automatically drained. The
air is warmed up before leaving the dryer.
On air-cooled dryers, the condenser has a cooling fan controlled
by a condenser pressure switch. Water-cooled dryers have an
automatic regulating valve in the water outlet of the condenser.
FD560 up to -950 are air-cooled, while FD560 W up to -1600
W are water-cooled dryers. The suffix W is not mentioned
further in the book where the descriptions are valid for both
air- and water-cooled dryers.
1.2 Air circuit (Fig. 2)
Compressed air enters air/air heat exchanger (16) and is pre-
cooled by the outgoing, cold, dried air. Water and oil in the
incoming air start to condense. The air then flows through air/
refrigerantheat exchanger/evaporator(15) wherethe refrigerant
evaporates and withdraws heat from the air. This cools the air
to close to the evaporating temperature of the refrigerant. More
water and oil in the air condense. The cold air then flows
through separator(s) (3) where all the condensate is separated
from the air. The condensate collects in condensate trap (4)
and is automatically drained. From separator(s) (3) the cold
dried air flows through air/air heat exchanger (16), where it
Fig. 1. General view of FD560
50149F

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AI. Air inlet connection
AO. Air outlet connection
M1. Refrigerant compressor/motor
M2. Condenser cooling fan/motor
S2. High pressure shut-down switch
S3. Fan control switch
1. Pressure dewpoint temperature
gauge
2. Insulating block
3. Cyclone condensate separator
4. Condensate trap with automatic
discharge
5. Automatic condensate drain hose
6. Manual condensate drain valve
7. Liquid separator
8. Sight-glass with moisture indicator
9. Refrigerant condenser
10. Liquid refrigerant receiver
11. Refrigerant circuit access
connection(s)
12. Liquid refrigerant dryer
13. Refrigerant expansion valve
14. Refrigerant circuit access
connection
15. Air/refrigerant heat exchanger/
evaporator
16. Air/air heat exchanger
17. Refrigerant/refrigerant heat
exchanger
Fig. 2. Air and refrigerant flow diagram, air-cooled dryers

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is warmed up by the incoming air to approx. 10°C (18°F)
below the incoming air temperature. Reheating the dried air
reduces its relative humidity, so that condensation in the air
net cannot occur unless the air is cooled to below the pressure
dewpoint temperature indicated by gauge (1).
1.3 Refrigeration circuit (Fig. 2)
Compressor (M1) delivers hot, high-pressure refrigerant gas,
which flows, via the coil(s) of liquid separator(s) (7), through
condenser (9) where most of the refrigerant condenses. On
air-cooled condensers, a fan control switch (S3) stops and starts
the fan motor (M2) at falling or rising condenser pressure. On
water-cooled condensers, an automatic valve (3-Fig. 5a)
regulates the cooling water flow, thus controlling the
temperature, which is directly dependent on the pressure. The
cooled refrigerant then collects in receiver (10).
The liquid leaves the receiver (10) via its syphon outlet and
flows through liquid refrigerant dryer (12), via refrigerant/
refrigerantheat exchanger (17) and sight-glass (8), to expansion
valve (13) where it expands to evaporating pressure.
Inexpansion valve(13) someof theexpanding liquidrefrigerant
evaporates, for which the required heat is withdrawn from the
refrigerant itself.
Therefrigerant enters the heat exchanger/evaporator (15) where
it withdraws heat from the compressed air by further
evaporation. Dependent on the compressed air load, all, or
almost all, refrigerant evaporates at constant pressure and
temperature. The vapour refrigerant leaving evaporator (15)
flows into liquid separator(s) (7) via refrigerant/refrigerant heat
exchanger (17). The liquid separator prevents any droplets
from entering compressor (M1) because warm refrigerant,
leaving the compressor, flows through the coil(s) of the liquid
separator(s) and evaporates the surrounding liquid. From liquid
separator(s) (7) the refrigerant gas is sucked in by the
compressor.
The dryers are provided with a sight-glass (8). The sight-glass
allows to check the refrigerant flow in the line. During normal
operation, the liquid flow must be clear. In general, vapour
bubblesindicate ashortage ofrefrigerant. Note thatfluctuations
in the load may cause bubbles to pass in the flow for a short
time. The center of the glass is provided with a moisture
indicator which is green when the liquid refrigerant is free of
moisture. It will turn into yellow when the refrigerant contains
moisture, indicating that the liquid dryer needs to be replaced.
1.4 Automatic regulation system
(Fig. 2)
Expansion valve (13) maintains the evaporating temperature
between 1 and -1°C (34 and 30°F); these are the approximate
limit temperatures at zero and maximum air load respectively.
At partial or no load, the excess cooling capacity is transferred
in liquid separator(s) (7). The condenser pressure must be kept
as constant as possible to obtain stable operation of expansion
valve (13). Therefore, on air-cooled dryers, fan control switch
(S3) stops and starts cooling fan (M2). On water-cooled dryers,
the temperature is controlled by an automatic regulating valve
on the water circuit. The switch or regulating valve ensures
properoperation atlow airload and/orlow ambient temperature.
1.5 Electrical system
These dryers are three-phase units.
The refrigerant compressors are equipped with a crankcase
heater. When voltage is supplied, the heater is energized. It
keeps the oil in the crankcase warm to prevent condensing of
refrigerant in the compressor housing, which could result in
serious damage of the compressor at restart (liquid knock).
F1. Fuses, fan motor
F2/F3. Fuse, secondary side (24 V) of transformer
K1. Motor contactor, refrigerant compressor
L1/3. Terminal, mains
PE. Earth terminal
T1. Transformer
Fig. 3. Electric cubicle (typical example)

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On air-cooled dryers, fan control switch (S3-Fig. 4b) will start
fan motor (M2-Figs. 4) 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.
High pressure shut-down switch (S2-Fig. 4b) stops the
compressor motor when the pressure in the refrigerant circuit
reachesthe upperset pointof theswitch. The compressormotor
will automatically restart when the pressure drops to the lower
set point.
Themotors havea built-inthermic protection. Ifthe compressor
motor stops without apparent reason, it will most probably be
the thermic protection which has tripped. In such case, the
compressor will restart when the motor windings have cooled
down, which may take up to 2 hours.
An electronic thermostat with display and alarm functions is
installed on the instrument panel (Fig. 10). Display (3-Fig. 11)
shows the pressure dewpoint temperature. The set point value,
i.e. the pressure dewpoint temperature at which the alarm
indicator lamp (H3-Fig. 10) lights up, can be checked by
pressing key (5-Fig. 11); the value will blink for 5 seconds on
the display. The differential value (∆t), i.e. the temperature
difference between alarm on and alarm off, can be checked by
pressing key (4-Fig. 11); the value will blink on the display for
approx. 5 seconds.
Altering the set point value (indicated "L1"):
- Press key (5); the current value blinks on the display.
- Press the up (1) or down (2) key until the desired value is
reached.
- To store the new value, press key (5) or wait a few seconds.
Fig. 4a. Side view of FD950

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Fig. 4b. Side view of FD700
M1. Refrigerant compressor/motor
M2. Condenser cooling fan/motor
S2. High pressure shut-down switch
S3. Fan control switch
1. Condensate trap with automatic
discharge
2. Refrigerant shut-off valve
3. Condenser
4. Liquid refrigerant receiver
5. Fan
6. Sensor, high pressure shut-down
switch
7. Refrigerant expansion valve
8. Sight-glass with moisture indicator
9. Liquid separator
10. Refrigerant dryer
11. Sensor, fan control switch
12. Float valve
Figs. 4. Side views of air-cooled FD units

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Altering the differential value (indicated "HY1"):
- Press key (4); the current value blinks on the display.
- Press the up (1) or down (2) key until the desired value is
reached.
- Press key (5) or wait a few seconds to store the new value.
If the temperature increases above the preset value, alarm
indicator lamp (H3-Fig. 10) will light up.
An automatic interval drain 1) may be connected between
condensate trap (4-Fig. 2) and manual drain valve (6-Fig. 2) to
flush the trap regularly. The interval time and opening time
can be adjusted.
1) Optional equipment.
Fig. 5a. Side view of FD1600

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Fig. 5b. Side view of FD1600
M1. Refrigerant compressor/motor
1. Liquid refrigerant receiver
2. Condenser
3. Flow regulating valve
4. Refrigerant shut-off valve
5. Electric cubicle
Figs. 5. Side views of water-cooled FD units
6. Condensate trap with automatic discharge
7. Refrigerant shut-off valve
8. Refrigerant dryer
9. Refrigerant expansion valve
10. Sight-glass with moisture indicator
11. Float valve
12. Liquid separator

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2 INSTALLATION
2.1 Dimension drawings (Figs. 6)
Fig. 6a. Dimension drawing of FD560

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Fig. 6b. Dimension drawing of FD560 W

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Fig. 6c. Dimension drawing of FD700

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Fig. 6d. Dimension drawing of FD700 W

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Fig. 6e. Dimension drawing of FD850 and FD950

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Fig. 6f. Dimension drawing of FD850 W, FD950 W and FD1200 W

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Fig. 6g. Dimension drawing of FD1600 W

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2.2 Installation proposal (Fig. 7)
2.3 Installation instructions
1. Install the dryer where the ambient air is as clean as possible
and where the temperature of the air will never exceed or
drop below the temperature limits (see section 7). Keep
the ventilation gratings of the dryer free.
2. Connect the compressed air lines to the marked inlet and
outlet pipes of the dryer; if required, via valves and
preferably a by-pass valve. Apply a sealing medium to the
threaded connections.
3. Fit manual condensate drain valve (2-Fig. 8) onto the
condensate drain pipe.
Lay out the condensate drain hose (3-Fig. 8) via a funnel
towards a drain collector to allow visual inspection. The
hose must pitch downwards, away from the dryer and the
open end must never dip into the water of the drain collector.
If the condensate drain has been led down outside the
compressorroom wherethe pipemay beexposed tofreezing
temperatures, the pipe must be insulated.
4. A sticker dealing in short with the operating instructions
1. FD dryer
2a. DD-type general-purpose prefilter
2b. PD-type high-efficiency prefilter
2c. DD-type afterfilter
3. Air receiver with condensate drain
4. Pressure gauge
5. Drain pipes
6. Dryer outlet valve
7. By-pass system
8. By-pass valve
9. Dryer inlet valve
Fig. 7. Installation proposal

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Oil-free Air Division Instruction book
and explaining the pictographs is delivered with the
literature set. Affix the sticker next to the control panel.
Makeyourself familiarwith theinstructions andpictographs
explained.
5. On water-cooled dryers, connect the water cooling pipes to
the marked in and out connections. It is recommended to
fit a manual shut-off valve in the water inlet.
6. Remove all the bags with silica gel attached to the dryer.
7. Check that the primary side connection of the transformer
(T1-Fig. 3) corresponds with the supply voltage.
8. Check that the electrical installation corresponds to the local
codes. The dryer must be earthed and protected against
short circuits by fuses of the inert type in all phases. An
isolating switch must be installed near the dryer. Connect 3
cables from the main fuses to terminals (L1, L2 and L3-
Fig. 3), connect the earth cable to the earth terminal (PE-
Fig. 3).
AI. Air inlet connection
AO. Air outlet connection
1. Cable gland
2. Manual condensate drain
3. Automatic condensate drain
4. Water inlet, condenser
5. Water outlet, condenser
Fig. 8. FD1200 W

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2.4 Pictographs (Fig. 9) 3 OPERATING INSTRUCTIONS
Safety precautions
The operator must apply all relevant safety precautions,
including those mentioned in this book.
Altitude operation
Consult Atlas Copco if operating above 3000 m.
Moving/lifting
The dryer can be moved by a lift truck using the slot in the
frame. Make sure that the forks protrude from the other side of
the frame. The dryer can also be lifted after inserting beams in
the slot. Make sure that the beams cannot slide and that they
protrude from the frame equally. The chains must be held
parallel to the bodywork by chain spreaders in order not to
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.
3.1 Initial start (Fig. 10)
1. At least 4 hours before starting, the mains supply to the
dryer must be switched on to energize the crankcase heater,
which warms up the oil. The indicator lamp (H1) is then
alight.
2. Open the refrigerant shut-off valves (2-Fig. 4a / 4 and 7-
Figs. 5) as follows: take the protecting cap off the valve,
then screw the spindle fully out and refit the cap.
3. On air-cooled dryers,press run/stand-bybutton (S1). Check
thatthe sense of rotation of the fan motor iscorrect. Cooling
air must be drawn in through the condenser (3-Figs. 4) and
blown over the refrigerant compressor (M1-Figs. 4) to
outside the dryer. If wrong, switch off the voltage and
reverse two of the three phase connections at the mains
terminals.
3.2 Starting (Fig. 10)
1. Switch on the voltage at least 4 hours before starting to
energize the crankcase heater. Never start the dryer without
preheating as this may cause serious damage to the
refrigerant compressor.
Check that voltage on indicator lamp (H1) is alight.
2. On water-cooled dryers, open the cooling water shut-off
valves.
3. Press run/stand-by button (S1). Check that dryer on
indicator lamp (H2) is alight.
4. If the air inlet valve is closed, open it a little to pressurize
the dryer gradually; open the valve when the dryer is
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
temperature will be reached.
1. Switch off and depressurize the dryer before starting
maintenance or repairs
2. Manual condensate drain
3. Automatic condensate drain
4. Pressure dewpoint
5. Dryer on-off
6. Voltage on
7. Dewpoint alarm
Fig. 9. Pictographs

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Oil-free Air Division Instruction book
3.3 During operation
At regular intervals check:
1. Pressure dewpoint temperature gauge (P1-Fig. 10).
2. That condensate trap (1-Figs. 4 and 6-Figs. 5) is operative.
If the operation is doubtful, flush the trap as per point 3 1).
3. Regularly open manual drain valve(s) (2-Fig. 8) for approx.
10 seconds to discharge condensate and possible impurities.
3.4 Stopping (Fig. 10)
1. Flush the condensate trap (see section 3.3).
2. Close the dryer air outlet valve. It is not necessary to close
its air inlet valve. Only if the air net requires so, open the
by-pass valve and close the air inlet valve.
3. Press button (S1) to the stand-by position. The dryer stops.
Voltage on lamp (H1) remains alight. The crankcase heater
remains switched on. Disconnect the dryer from the mains
if it is going to be out of service for a long period or when
maintenance is needed.
Leave the isolating switch closed if the dryer has to remain
stand-by.
4. On water-cooled dryers, close the cooling water shut-off
valves.
3.5 Possible causes of unstable or too
high pressure dewpoint
temperature
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-
Fig. 4b and 9-Fig. 5b)
- Shortage of refrigerant in circuit through leakage
- Condenser externally clogged (air-cooled dryers)
- Malfunctioning of fan control switch (S3-Fig. 4b) on
air-cooled dryers or malfunctioning of the cooling water
regulating valve (3-Fig. 5a) on water-cooled dryers
Note: The pressure dewpoint temperature will deviate from
nominal when the nominal conditions are exceeded, e.g. a
pressure dewpoint temperature of +7°C can be considered as
normal if the air flow, the air inlet temperature or the ambient
temperature is higher than nominal.
1) - Not necessary when an electronic interval drain has been
installed.
- At initial start-up the condensate trap must be flushed more
frequently.
H1. Indicator lamp, voltage on
H2. Indicator lamp, dryer on
H3. Alarm indicator lamp, high
pressure dewpoint temperature
P1. Pressure dewpoint temperature
gauge
P2. Temperature gauge, air inlet
P3. Temperature gauge, evaporating
temperature
P4. Temperature gauge, condensing
temperature
S1. Run/stand-by button
The numbered items are pictographs
for:
1. Temperature
2. Air inlet
3. Air outlet
4. Air/air heat exchanger
5. Air/refrigerant heat exchanger
6. Condensate trap
7. Pressure dewpoint temperature
8. Refrigerant expansion valve
9. Start/Stop button
10. Alarm
11. Voltage on
12. Refrigerant compressor
13. Condenser
14. Refrigerant liquid dryer
Fig. 10. Instrument panel