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Air dryers offer improved efficiency and reliability

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Air dryers offer improved efficiency and reliabilityEfficiency, reliability and customer convenience are the key benefits of the redesigned Atlas Copco FD 5-95 dryer range. The main features are the saver cycle control and the patented counter-flow heat exchanger with integrated water separator. Adding a dryer to a compressor configuration (the FD 5-95 is compatible with compressors up to 30kW) protects the end product while extending the lifetime of equipment, as it removes moisture, aerosols and dirt particles from compressed air. This dryer range is used in a variety of applications and industries including packaging, workshops, assembly, textiles, woodworking, plastics production and moulding, automotive, construction materials manufacturing, printing as well as oil and gas activities.

Energy efficiency

Because of the integrated saver cycle control, the FD 5-95 is now a fully cycling dryer, providing excellent energy efficiency. This algorithm is based on relative humidity and controls the start and stop function of the dryer's compressor. By adjusting the working cycle to the actual load, this feature has a major positive influence on energy consumption.

Moreover, the R134a refrigerant delivers better performance while using less energy. Compared to other dryers, it also has a very low CO2 output and, therefore, a low global warming potential.

The overall design of the FD 5-95 also offers an indirect energy saving through low pressure drop. This is mainly caused by the counter-flow heat exchanger and the integrated water separator, which together result in reduced energy consumption for the compressor.

Reliable constant dry air

In order to protect both the production process and the quality of the end product, the dryer needs to be reliable in every situation, even when facing high ambient temperatures. The most innovative feature of the FD 5-95 is the patented counter-flow heat exchanger with integrated water separator. Maximising the use of cold energy makes this type of exchanger far more efficient than the cross-flow heat exchanger or the tube-in-tube heat exchanger. Atlas Copco also claims that it succeeds in evacuating condensation (even at reduced flow) by integrating the water separator in the counter-flow heat exchanger. As a result, the pressure dew point is controlled and the quality of the end product is protected. Finally, condensation is further removed by the zero-loss electronic drain. All these features improve the reliability of the compressed air delivered by the existing compressor configuration when a FD 5-95 is added.

Customer convenience

The redesigned FD dryer has been equipped with the next-generation Elektronikon. This electronic controller gathers all annunciations in one location for customer convenience: PDP, ambient temperature, relative humidity and alarms. Other advantages are the automatic restart after power failure and remote alarm.

Available models have increased in numbers, making it easier to match the dryer to the FAD of an existing compressor, thereby saving even more energy. The standard maximum pressure has also been improved. The FD 60-95 can provide up to 13bar, while the FD 5-50 can deliver as high as 16bar. (The high-pressure variant delivers 20bar.)

Finally, there have been several standard and optional adaptations to reduce the footprint of the FD 5-95 dryer. A smaller dryer eases the installation, while maintenance is further aided by standard features such as a zero-loss electronic drain with easy cleaning (a timer drain for 20bar units) and a click-on front panel. (Other available options such as spin-on filters, integrated condensate treatment, IP54 protection and wall-mounting kit are available.)

13 February 2009

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