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Air Filter Regulator Lubricator

FRL Unit

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What's the FRL?

FRL Unit: It’s a combination equipment which composed of Filter, Regulator, & Lubricator.

What does FRL Unit do?

We offen use it as one unit to ensure clean air in a pneumatic system but we also use it individually. Having a proper FRL unit installed in a pneumatic system provides higher reliability of the components downstream, reduced power waste due to over pressurization, and increased component lifetime. The three components work together to do the following:

FRL Unit-Filtrate Contaminant

Remove water, dirt and other harmful debris from an air system. This is often the first step in improving the air quality.

FRL Unit-Regulate The Output Pressure

Adjust and control the air pressure of a system to ensure that down-line components do not exceed their maximum operating pressures. This is the second step in the FRL system.

FRL Unit-Lubricate The Downstream Components

It reduce the internal friction in tools or equipment by releasing a controlled mist of oil into the compressed air. This is often done last and right before the component needing lubrication.

What's The Compressed air Filter?

Air leaving a standard screw or piston compressor will generally have a high water content, as well as a high concentration of oil and other contaminants.

A compressed air filter or air line filter is the device we use it to filter impurities from atmospheric air or the compressed air, like dust, oil and moisture, to make compressed air viable for use.

Normally we install it on the compressor output port or in the compressed air line.

And we assemble some on the machinery, or the pneumatic system. When we combine the filer with a regulator and an oiler, we call it as an air set.
Just like air dryers, they are a crucial part of the air treatment process to make sure your compressed air is clean and safe to use, and to increase your equipment’s life span.

What's Air Regulator?

Air pressure regulators is a device which we generally use it for reducing pressure levels to a specified value though adjust the knob on the regulator.

Be with ultimately lowers costs and provides an element of safety. Additionally, pneumatic equipment often has optimum air pilot pressure that needs to be carefully monitored in order to achieve reliable performance. At Dg-Pnetic we have a wide range of air pressure regulators, ranging from general purpose units covering everyday industrial applications, to more specialised precision regulators.

What's The Air Lubricator?

A lubricator is a device which adds controlled quantities of tool oil into a compressed air system to reduce the friction of moving components.

Most air tools, cylinders, valves, air motors, and other air-driven equipment require lubrication to extend their useful life. Normally we install it in downstream of the compressor and upstream from the air tool or component. It provides a continuous stream of atomised oil to the points to the usage system, in this way the lubricant provides much more effective and longer-term protection of the friction surfaces. Once we add a lubricator to the line, it must be used continuously.

The Difference Between The FR.L And FRL Unit

The Structure Of FR.L Unit

The Structure Of FRL Unit

Above figures show the structure of FR.L unit and FRL Unit.

They are both composed of Filter, regulator, and lubricator and normally we use it to deliver clean air, at a fixed pressure, and lubricated (if needed) to ensure proper pneumatic component operation and increase their operation lifetime. We could buy filters, regulators, and lubricators, or FR individually or as a package depending on what is essential to ensure the proper air specifications are being met for downstream equipment.

The difference is FR.L save space , and with lower cost comapred with FRL.

As the FR is a completed whole device, integrating the air filter and regulator. But in FRL, we could seperate the filter and regulator, and we can use them in single. There are fastenings for the combination.

How many types FRL Unit there are?

As all of the FRL performed the same function in the system, so normally they are classified according to the Application.

Mainline FRL Unit

Normally there are two types mainline FRL. One is for the higher pressure usage, which the pressure is from the 1.0Mpa-3.0Mpa. The main material is steel or aluminium. Considering the lower pressure FRL, the working pressure will not more than 0.8Mpa.

Normal Purpose FRL Unit

We install it on the domestic comrpessor,on the machinery, or on some automation system.

Stainless Steel FRL Unit

Normally we adopt it in the food machinery, or the medical equipment.And the cost is much higher than previous FRL.

How to choose a FRL Unit for your pneumatic system?

Selecting the best FRL will go a long way to guarantee system efficiency while avoiding undesirable component wear and tear.
You can consider the following factors when selecting a compressor air filter.

Type of Application

Different applications require different types of compressor air filters.
Each filter has a different set of filtration requirements and fittings.
You should refer to the requirements of your filtration or consult a reputable company before settling for a given type of filter.

Filter Micron Rating

Similarly, the cleanliness required for the compressed air will determine the micron rating of the filter you select.
You should select a filter that will achieve the desired level of cleanliness and still maintaining good service intervals.

Flow Rate

The size and of the filter you select will depend on the application level of airflow.
Understanding the maximum allowable pressure drop will assist you to decide on the best size of a filter to select.
The manufacturers will provide a chart showing the pressure drop versus the supply flow.
These charts indicate the performance of a filter at a given intake pressure.
Look through the chart and select the models whose port size and other features meet your system requirement.

Efficiency and Quality

You should choose a filter that will effectively remove the contaminants at the desired level of efficiency at a minimum pressure drop.
Note that filters might have similar micron and flow rate rating but significantly differ in their effectiveness in removing contaminants.
High-performance filters might cost you more initially but will give you better results compared to ordinary filters.

Temperature

At what temperature will your compressed air filter operate?
High performance filters are available for high temperatures (over 450°C).

Environmental standards

Compressed air filters are subject to the ISO 8573 standard, which specifies the purity classes of compressed air for the presence of solid particles, water and oil, regardless of their location in the compressed air system.
This standard also provides general information on pollutants in compressed air systems and refers to other parts of ISO 8573 with regard to the measurement of compressed air purity or the specification of compressed air purity requirements.
Lastly, the ISO 8573-1:2010 standard also identifies gaseous and microbiological pollutants.

About The Drain Valve For The Filter

In its natural state, air can hold a substantial amount of water vapor. The function of creating compressed air significantly reduces the vapor-holding capacity. The compression process forces water molecules to clump together and form condensation. The effect is similar to a rainstorm inside the tank.
A drain valve performs the critical function of allowing excess water vapor to escape into the atmosphere. The removal of condensation helps prevent the formation of corrosion that will eventually damage the compressor and shorten its lifespan. By eliminating water from the compressed air system, the drain valve also reduces wear on tools and equipment powered by the compressor unit.

Examples of the many types of air compressor drain valves include:
Float-operated: This valve allows water to flow into a special housing. When the water inside the tank reaches a predetermined level, a float triggers the drain’s opening and lets the excess water drain out.
Timer-controlled: A timer-controlled valve opens and closes at pre-set intervals. This type of system is ideal for highly regulated operating environments.
Zero-loss: This type of drain valve contains a sensor probe that monitors water accumulation inside the tank. When the water reaches a specified level, the probe delivers an electrical signal to a solenoid. The drain then opens, but the water flow stops before the release of compressed air.

Lubricator Oil To Fill FRL Unit

Many customers use the incorrect type of lubricating oil in lubricators that cause the polycarbonate bowls to prematurely crack.

The typical air tool oil used for pneumatic air tools is not recommended for automotive equipment since the wear characteristics are not sufficient for component long life. This is why it is important to use the correct lubricants in the bowls.
The use of kerosene, animal or vegetable fats should be avoided for additives or cleaning agents. Also, the use of any penetrants such as WD40 should NEVER be used on any rubber seals.
SMC recommends to use an ISO VG-32 oil which is a 32 weight viscosity such as 76 multi-way HD32 and other related brands of ISO-VG 32 type.
ARO/IR recommends to use an SAE-10 non-detergent light lubricant in their bowls.