Atlas Copco FX 1 User manual

Atlas Copco
Refrigerant compressed air dryers
FX 1, FX 2, FX 3, FX 4, FX 5, FX 6, FX 7, FX 8, FX 9, FX 10, FX 11,
FX 12
Instruction book

Atlas Copco
Refrigerant compressed air dryers
FX 1, FX 2, FX 3, FX 4, FX 5, FX 6, FX 7, FX 8, FX 9,
FX 10, FX 11, FX 12
From following serial No. onwards: CAI814019
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.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.
2016 - 09
No. 2920 7112 40
www.atlascopco.com

Table of contents
1 Safety precautions..........................................................................................................4
1.1 SAFETY ICONS................................................................................................................................... 4
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................4
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................5
1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 6
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 7
2 General description........................................................................................................9
2.1 INTRODUCTION...................................................................................................................................9
2.2 AIR SYSTEM.................................................................................................................................... 11
2.3 REFRIGERATION SYSTEM....................................................................................................................12
2.4 AUTOMATIC REGULATION SYSTEM........................................................................................................ 12
2.5 ELECTRICAL SYSTEM.........................................................................................................................13
3 Installation.....................................................................................................................14
3.1 DIMENSION DRAWINGS.......................................................................................................................14
3.2 INSTALLATION PROPOSAL................................................................................................................... 14
3.3 PICTOGRAPHS................................................................................................................................. 16
4 Operating instructions................................................................................................. 17
4.1 WARNINGS......................................................................................................................................17
4.2 CONTROL PANEL.............................................................................................................................. 17
4.3 DIGITAL CONTROLLER........................................................................................................................18
4.4 STARTING....................................................................................................................................... 23
4.5 DURING OPERATION..........................................................................................................................24
4.6 STOPPING.......................................................................................................................................24
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5 Maintenance instructions............................................................................................ 26
6 Device settings............................................................................................................. 27
7 Problem solving............................................................................................................28
8 Technical data...............................................................................................................31
8.1 REFERENCE CONDITIONS AND LIMITATIONS............................................................................................ 31
8.2 AIR DRYER DATA.............................................................................................................................. 31
9 Pressure equipment directives................................................................................... 34
10 Declaration of conformity............................................................................................ 35
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1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 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.
1. The dryers are designed for normal indoor use.
2. The operator must employ safe working practices and observe all related work safety requirements
and regulations.
3. If any of the following statements does not comply with the applicable legislation, the stricter of the
two shall apply.
4. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel.
5. The dryer is not considered capable of producing air of breathing quality. To obtain air of breathing
quality, the compressed air must be adequately purified according to the applicable legislation and
standards.
6. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the dryer,
press the emergency stop button, switch off the voltage and depressurize the dryer. In addition, the
power isolating switch must be opened and locked. For plug versions, remove the plug from the wall
socket and secure it.
7. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people.
Never use the air to clean dirt from your clothes. When using the air to clean equipment, do so with
extreme caution and wear eye protection.
8. The owner is responsible for maintaining the dryer in safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.
9. It is not allowed to walk or stand on the dryer or its components.
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1.3 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. Lifting acceleration and deceleration must be kept
within safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. Place the dryer where the ambient air is as cool and clean as possible. If necessary, install a suction
duct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air.
3. Any blanking flanges, plugs, caps or desiccant bags must be removed before connecting the pipes.
4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the
working pressure.
5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can
lead to internal fire or explosion.
6. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
7. Ensure that all piping is free to expand under heat and that it is not in contact with or close to
flammable materials.
8. No external force may be exerted on the air outlet valve. The connected pipe must be free of strain.
9. If remote control is installed, the machine must bear a clear sign stating "Danger: This machine is
remotely controlled and may start without warning".
The operator has to make sure that the machine is stopped and that the isolating switch is open and
locked before any maintenance or repair. As a further safeguard, persons switching on remotely
controlled machines shall take adequate precautions to ensure that there is no one checking or
working on the machine. To this end, a suitable notice shall be affixed to the starting equipment.
10. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available
and that the exhausted cooling air does not recirculate to the inlet.
11. The electrical connections must correspond to the applicable codes. The machines must be earthed
and protected against short circuits by fuses in all phases. A lockable power isolating switch must be
installed near the equipment.
12. On machines with automatic start-stop system or if the automatic restart function after voltage failure
is activated, a sign stating "This machine may start without warning" must be affixed near the
instrument panel.
13. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
must be protected by a pressure-relieving device or devices as required.
14. Piping or other parts with a temperature in excess of 80˚C (176˚F) and which may be accidentally
touched by personnel during normal operation must be guarded or insulated. Other high-temperature
piping must be clearly marked.
15. For water-cooled machines, the cooling water system installed outside the machine has to be
protected by a safety device with set pressure according to the maximum cooling water inlet pressure.
16. If no safety valve is present in the air net close to the desiccant dryer (e.g. safety valve of
compressor), full flow safety valves must be installed on the dryer vessels.
17. If the maximum pressure of the compressor is higher than the design pressure of the dryer, a full flow
safety valve must be installed between the compressor and the dryer in order to blow off the excessive
pressure in case the safety valve of the dryer should be out of order or blocked.
18. When unit is not permanently secured to the floor in the vertical position or mounted horizontally,
access to electrical equipment is feasible through the unit base. In this case additional barriers must be
provided during installation. Tag with "warning high voltage" symbol
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Also consult following safety precautions: Safety precautions during operation and 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.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.4 Safety precautions during operation
Precautions during operation
1. Always be careful when touching any piping or components of the dryer during operation. On dryers
using heat to regenerate the desiccant, some parts will become very hot.
2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose
or air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make
sure that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to
the remote start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors
or particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork closed during operation. Bodywork should be opened for short periods only, e.g.
to carry out routine checks. Wear ear protectors when removing a panel.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A)
shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• There are no leaks
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good
condition, free of wear or abuse
9. If warm cooling air from dryers is used in air heating systems, e.g. to warm up a working area, take
precautions against air pollution and possible contamination of the breathing air.
10. Do not remove any of, or tamper with, the sound dampening material.
11. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure
shall be protected by a pressure relieving device or devices as required.
12. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must be
respected. Local regulations remain applicable if they are more strict.
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Also consult following safety precautions: Safety precautions during installation and 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.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.5 Safety precautions during maintenance or repair
Precautions during maintenance or repair
1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress - do not start" shall be attached to the
starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be affixed to
the remote starting equipment.
7. Close the dryer air outlet valve before connecting or disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of
pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions
against toxic vapours of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
11. Never weld on, or in any way modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and
that they function correctly.
17. Protect the motor, electrical and regulating components, etc. to prevent moisture from entering them,
e.g. when steam-cleaning.
18. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the
bodywork, is in good condition. If damaged, replace it by genuine material from the manufacturer to
prevent the sound pressure level from increasing.
19. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
20. The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if
required, use breathing protection.
• 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;
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flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then
seek medical first aid.
21. The following safety precautions are stressed when handling desiccant:
• Take precautions not to inhale desiccant dust.
• Check that the working area is adequately ventilated; if required, use breathing protection.
• Do not overfill the dryer when replacing desiccant.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during operation.
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.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
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2 General description
2.1 Introduction
General views
FX 1 up to FX 5
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FX 6 up to FX 12
Introduction
The FX 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.
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2.2 Air system
Air flow diagram
Reference Name
4 Evaporator
5 Condensate separator
6 Impurity trap
10 Heat exchanger
11 Digital dewpoint indicator
13 Condensate drain
Description
Compressed air enters heat exchanger (10) and is cooled by the outgoing, cold, dried air. Water in the
incoming air starts to condense. The air then flows through heat exchanger/evaporator (10 and 4) where the
refrigerant evaporates, causing the air to be cooled further to close to the evaporating temperature of the
refrigerant. More water in the air condenses. The cold air then flows through separator (5) where all the
condensate is separated from the air. The condensate is automatically drained in the condensate drain.
The cold, dried air flows through heat exchanger (10) where it is warmed up by the incoming air to
approximately 10˚C (18˚F) below the incoming air temperature.
Condensation in the air net cannot occur unless the air is cooled to below the pressure dewpoint, indicated
by the dewpoint indicator (11).
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2.3 Refrigeration system
Refrigerant flow diagram
Reference Name
1 Refrigerant compressor
2 Condenser
4 Evaporator
7 Expansion capillary tube
8 Refrigerant filter
Description
Compressor (1) delivers hot, high-pressure refrigerant gas which flows through condenser (2) where most
of the refrigerant condenses.
The liquid flows through the refrigerant dryer/filter (8) to capillary tube (7). The refrigerant leaves the
capillary tube at evaporating pressure.
The refrigerant enters evaporator (4) where it withdraws heat from the compressed air by further
evaporation at constant pressure. The heated refrigerant leaves the evaporator and flows through the liquid
separator (9) back to the compressor (1).
2.4 Automatic regulation system
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Reference Name
3 Cooling fan
9 Hot gas bypass valve
Description
The condenser pressure must be kept as constant as possible to obtain stable operation. Fan control switch
therefore stops and starts the cooling fan (3).
If, under partial or no load, the evaporator pressure drops below a certain level, the hot gas bypass valve
opens and hot, high-pressure gas is fed to the evaporator circuit to prevent the evaporator pressure from
dropping any further.
2.5 Electrical system
Description
The fan control switch starts the fan motor 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.
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3 Installation
3.1 Dimension drawings
The dimension drawings can be found on the CD-ROM, delivered with the dryer.
Dimension drawing Model
2202 7549 00 FX 1 up to FX 5
2202 7463 00 FX 6 and FX 7
2202 7464 00 FX 8 up to FX 10
2202 7465 00 FX 11 and FX 12
Text on drawings Translation or explanation
Electric cable outlet Outlet for electric cable
Condensate pipe drain outlet Outlet for condensate drain hose or pipe
Air inlet Air inlet
Air outlet Air outlet
Air flow Air flow direction
Bushings UL version only Bushings (UL certification version only)
Female Female connection
Male Male connection
All dimensions: mm / inch All dimensions are in mm or inch as indicated on the
drawing
3.2 Installation proposal
Moving
Use a suitable tool (pallet carrier, fork lift truck) to move the dryer.
Do not use metal cables for lifting.
Move the dryer gently.
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Example of compressor/dryer room
Installation proposal for FX 1 up to FX 5
Installation proposal for FX 6 up to FX 12
Reference Description
- Install the refrigerant air dryer on a level floor, suitable for its weight.
- The recommended minimum distance between the top of the unit and the ceiling is 1.5
m (58.5 in).
The minimum distance between the wall and the back of the dryer must be 1.5 m (58.5
in).
Lay out the condensate drain hose via a funnel towards a drain collector to allow visual
inspection. The hose must slope downwards.
If the condensate drain has been fitted outside the dryer room where it may be exposed
to freezing temperatures, it must be insulated.
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Reference Description
- The power cable must be connected by a qualified electrician.
Connect the dryer to the correct voltage; if necessary, check the unit data plate.
Check that the electrical installation corresponds to local codes. The dryer must be
earthed and protected against short circuits using an automatic cut-out device with a
differential device.
An isolating switch must be installed near the dryer.
- Connect the compressed air lines to the marked inlet and outlet pipes of the dryer (see
Dimension drawings). Provide an air inlet valve and outlet valve. If a bypass pipe and
valve are installed, the dryer can be serviced while it is bypassed.
1 Location of isolating switch and fuses.
2 Minimum distance 1.5 m (58.5 in).
3.3 Pictographs
Pictographs
Reference Name
1 Warning, under tension
2 Warning, air not fit for breathing
3 Warning, high pressure
4 Warning, rotating fan
5 Warning, hot surface
6 Switch off the voltage and depressurize the dryer before maintenance or repair
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4 Operating instructions
4.1 Warnings
Safety precautions
The operator must apply all relevant safety precautions, including those mentioned in this manual.
Altitude operation
Consult your supplier if operating above 3000 m (9843 ft).
4.2 Control panel
Description
FX 1 up to FX 12
Reference Name
1 Digital controller, used for:
1. pressure dewpoint indication (main function)
2. alarms information
3. maintenance interval scheduling
2 Dryer on/off switch
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4.3 Digital controller
Identification
Front panel of the controller
Reference Name
1 Alarm icon
2 Refrigerant compressor icon
3 Fan icon
4 PDP (dewpoint) temperature
5 Unit (°C or °F)
6 Alarm LED
7 Button to snooze or to reset the alarm (only for remote alarm function).
8 SET button
9 UP button
10 DOWN button
8+9 Back to previous screen
8+10 Menu
Icons
Icon Name Mode Function
Alarm Off No active alarms
On Probe failure alarm
High temperature or low
temperature alarm
Service alarm
Refrigerant compressor Off Dryer off
On Dryer on
Flashing + SE Maintenance warning
Flashing + L2 Dewpoint too low
Dryer is stopped
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