Frl Overview 0508

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FACTS• The air leaving a compressor is dirty, hot, wet and generally at a higher pressure than the

downstream equipment requires.• Typically, a 100 SCFM (50 dm3/sec) compressor will push 1,200 gallons (4,500 liters) of water and 2 gallons

(8 liters) of degraded compressor oil into the system in a year.• This will also include considerable amounts of dirt particles.• Black iron air lines can create considerable rust in an air system.• Before this air can be used, it needs to

- be treated to remove the contaminants- have its pressure reduced to the correct level- have oil added for lubrication (during air tool operation)

• Most air tool failures can be attributed to improperly filtered and lubricated air.• A tool can ingest a lot of debris sitting in an abrasive environment with an exposed inlet. Always cover the tool

inlet when disconnected from an air line.

Protect Air Tools to Ensure Optimal Tool Performance and Tool Life

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A filter in the compressor room is an excellentinvestment, however, a downstream filter isstill required. Air traveling from the compressorroom will pick up pipe scale and other contam-inants as it travels through the piping system.In addition to filtering out foreign particles, thefilter is designed to separate residual moistureas well. The filter has a manual drain whichshould be drained regularly by pushing on thesmall button in the assembly at the bottom.There is a max.... the max. drain level.

Push ButtonManual Drain

The air filter is installed at the inlet to prevent moisture and debris contained in compressed air fromentering the pneumatic tool.

Rotary vane air tools require lubrication to achieve adequate service life.

Regulators are required to reduce the incoming compressed air pressure to 90 PSIG.

Our design has a control spring which acts on a diaphragm to regulate the air pressure. Ourregulator has a visible pressure dial gauge. It is important to note that our regulator hascompensation built into the unit that allows

it to respond faster to changes in theincoming pressure and flow. This feature becomes very noticeable inplants where there is other machinerybeing started and turned off, whichwill cause sudden drops and/or spikes in the inlet pressure.

Vane life is extended by factors of 10 throughlubrication. Motor bearings also benefit greatlythrough lubrication. Dynabrade air tools shouldbe lubricated at a rate of 1 drop/minute/20 SCFM.

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4

Orangemark

Flow Characteristics (representative values)Condition: Inlet pressure 102 PSIG

Pressure Characteristics (representative values)Condition: Inlet pressure 102 PSIG

Outlet pressure 29 PSIGFlow rate .7 SCFM

5

6

10681106711067310675

1/2" NPT

Air

218

145

7 to 123

23°F – 140°F

5

Polycarbonate

Standard

Relieving type

3.8

Setpressure

range PSIG

Max.flow rate *1

SCFM

Port size

Fluid

Proof pressure (PSIG)

Max. operating pressure (PSIG)

Set pressure range (MPa)

Ambient and fluid temperature

Nominal filtration rating (μm)

Bowl material

Bowl guard

Regulator construction

Weight (lb)

10681 7–123 200

*1: Indicates the maximum flow rate at inlet pressure 101 PSIG or the maximumflow rate at inlet pressure 101 PSIG and set pressure 72.5 PSIG

Applicable to remove solid foreign objects sized 5 μm or more and oversaturated water contained in the compressedair, control (regulate) the outlet pressure, suppress fluctuations of the outlet pressure affected by fluctuations of theinlet pressure and apply oil to pneumatic tools at the outlet side.

10681

Top ViewLubricator Regulator Filter

Front View

Front View - Bowls Removed

Side Views

Filter

RegulatorLubricator

Bottom ViewFilter Regulator Lubricator

Air feed air linein port

Manual drainPress orange button todischarge contaminants

5 Micron FilterElement (p/n 10645)Clean/replace asrequired

Filter Baffle (P/N 10646)Turn counterclockwise to removefor filter access/replacement

Oil feed hose

Sinteredbronze filter

Embeddedpressuregauge is astandardfeature

Ozone resistantrubber material(HNBR)

Improved visibilityfor lubricant dripwith graduation forlubricant control

Improvedvisibility forlubricantdrip withgraduationfor lubricantcontrol

Air feed air lineout port

Black cappedport - screwopen to fillwith oil Wall mounting

bracketsSMC ID - can’tbe eliminated

Manual drainPress orange button to discharge contaminants

SMC ID - can’tbe eliminated

Minimum/maximumoil levels shown

Manual drain (pressorange button to discharge contaminants)

Maximum drainlevel (discharge contaminantsbefore this levelis reached)

Pressureregulatorknob

Pressure regulator knob

Mountingbracket

Mountingbracket

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2

3

INSTALLATIONAttach componentinto the fitting of thebracket with spacer

Lock the lever pininto the retainer

Tighten the bolt

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2

3

7 8

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Recommended Air System Set-Up

A sufficient supply of compressed air is necessaryThe air system must be able to deliver an adequate volume of air and maintain the rated operating pressure at the inlet of the tool.

The supply of air must be free of contaminationThe types of contamination that need to be eliminated are water(condensation produced by the temperature change while compressingthe air), rust scale (rust particles produced inside iron pipes), andatmospheric dust, (dust that is pulled into the compressor from thework environment). Also, it is important to keep dust and debrisfrom entering the air motor when the tool is disconnected from the air supply hose. Always keep the tool air inlet, hose ends,plugs and couplers clear of dust.

Lubrication (oil) through the air supply is importantSupplying oil to rotary vane air motors reduces friction and wear of the moving parts and provides protection for steel components.

Filter-Regulator-Lubricator is RecommendedAs an air tool manufacturer, Dynabrade recommends the use of a Filter-Regulator-Lubricator at each tool station. We also encourage theuse of correctly sized accessories that will deliver a sufficient supply ofair. Some examples of Dynabrade air tool accessories are Dynaswivel®

airline connectors, quick disconnect fittings, and in-line blow guns. All of these accessories make for suitable additions to any compressed air system.

Pneumatic Power Tools HaveSeveral Advantages overElectric Power Tools

One of the major advantages is durability, however, to make full use of that advantage some important steps must be followed.

LUBRICATOR SETTING1 DROP PER MINUTE20 SCFM (566 LPM)

LUBRICATOR SETTING

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Closed loop pipe system(Sloped in the direction of air flow)

To tool station

Regulator

10681

LubricatorFilter

Air flow

Air flow

Drain valve

Air compressor and receiver

Refrigeratedair dryer

Ball Valve

Ballvalve

Drainvalve

Air tool

Coupler

Air hose

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Series AC

Safety InstructionsThese safety instructions are intended to prevent a hazardous situation and/or equipment damage. Theseinstructions indicate the level of potential hazards by labels of “Caution,” “Warning” or “Danger.” To ensuresafety, be sure to observance ISO 444Note 1), JIS B 8370Note 2) and other safety practices.

Explanation of the LabelsLabels Explanation of the Labels

Danger In extreme conditions, there is a possible result of serious injury or loss of life.

Warning Operator error could result in serious injury or loss of life.

Caution Operator error could result in injuryNote 3).

Note 1) ISO 4414: Pneumatic fluid power - General rules relating to systems

Note 2) JIS B 8370: General Rules for Pneumatic Equipment

Note 3) Injury indicates light wounds, burns and electrical shocks that do not require hospitalization or hospital visits for long-term medical treatment

Selection/Handling/Applications1. The compatibility of the pneumatic equipment is the responsibility of the person who designs the

pneumatic system or decides its specifications.Since the products specified here are used in various operating conditions, their compatibility for the specific pneumatic system must bebased on specifications or post analysis and/or tests to meet the specific requirements. The expected performance and safety assuranceare the responsibility of the person who has determined the compatibility of the system. This person should continuously review thesuitability of all items specified, referring to the latest catalog information with a view to giving due consideration to any possibility ofequipment failure when configuring a system.

2. Only trained personnel should operate pneumatic machinery and equipment.Compressed air can be dangerous if handled incorrectly. Assembly, handling or repair of the systems using pneumatic equipment shouldbe performed by trained and experienced operators. (Understanding JIS B 8370 General Rules for Pneumatic Equipment, and other safetyrules are included.)

3. Do not service the machinery/equipment or attempt to remove components until safety is confirmed.1. Inspection and maintenance of the machinery/equipment should only be performed once measures to prevent falling or runaway of the

driven objects have been confirmed.

2. If the equipment must be removed, confirm the safety process as mentioned above. Turn off the supply pressure for the equipment andexhaust all residual compressed air in the system, and release all the energy (liquid pressure, spring, condenser, gravity).

3. Before the machinery/equipment is restarted, take measures to prevent quick extension of a cylinder piston rod, etc.

4. If the equipment will be used in the following conditions or environment, please contact Dynabrade firstand be sure to take all necessary safety precautions.

1. Conditions and environments beyond the given specifications, or if product is used outdoors.

2. Installation on equipment in conjunction with atomic energy, railway, air navigation, vehicles, medical equipment, food and beverages,recreation equipment, emergency stop circuits, clutch and brake circuits in press applications, or safety equipment.

3. An application which has the possibility of having negative effects on people, property, requiring special safety analysis.

4. If the products are used in an interlock circuit, prepare a double interlock style circuit with a mechanical protection function for theprevention of a breakdown. And, examine the devices periodically if they function normally or not.

Exemption from Liability1. Dynabrade is exempted from liability for any damages caused by operations not contained in the catalogs

and/or instruction manuals, and operations outside of the specification range.2. Dynabrade is exempted from liability for any loss or damage whatsoever caused by malfunctions of its

products when combined with other devices or software.

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F.R.L. Unit Precautions 1Be sure to read before handling

Design

Warning1. The standard bowl for the air filter, regulator and lubricator as well

as the sight dome for the lubricator are made of polycarbonate. Donot use in an environment where they are exposed to, or come incontact with organic solvents, chemicals, cutting oil, synthetic oil,alkali, and thread lock solutions.

2. Avoid applications where pressurized air is frequently introducedto and released from the standard bowl of an air filter, regulator, orlubricator. It may cause the bowl to be damaged. Use of a metalbowl is recommended for such occasions.

3. Consult with Dynabrade if the intended application calls forabsolutely zero leakage due to special atmospheric requirements,or if the use of a fluid other than air is required.

4. Regulator and filter regulatorBe sure to install a safety device to prevent damage of malfunctionof the outlet side components when the output pressure exceedsthe set pressure value.

Selection

Warning1. The mineral grease used on internal sliding parts and seals may

run down to outlet side components.

2. Regulator and filter regulatora. Residual pressure release (outlet pressure release) is not

complete by releasing the inlet pressure. To release residualpressure, select a model with a back flow mechanism. Using amodel without a back flow mechanism makes for inconsistentresidual pressure release (i.e. residual pressure may or may notbe released) depending on the operating conditions.

b. Contact Dynabrade if air will not be consumed in the system fora long period of time, or if the outlet side will be used with asealed circuit and a balanced circuit, as this may cause the setpressure of the outside to fluctuate.

c. Set the regulating pressure range for the outlet pressure of theregulator in a range that is 85% or less of the inlet pressure. Ifset to above 85%, the outlet pressure will be easily affected byfluctuations in the flow rate and inlet pressure and becomeunstable.

d. A safety margin is calculated into the maximum regulatingpressure range appearing in the catalog’s specification table.However, the outlet pressure may exceed the set pressure dueto a delay in the valve’s closing.

e. Contact Dynabrade when a circuit requires the use of aregulator having relief sensitivity with high precision and setting accuracy.

3. Lubricatora. Contact Dynabrade when the lubricator is used in high

frequency operations, such as in a press.

b. Lubrication cannot be properly performed if the operating flowrate is too low. Select proper size lubricator by referring to theminimum dripping flow rate provided in this catalog.

c. Avoid the use of a lubricator that causes back flow as this maycause damage to internal parts.

d. Use a check valve to prevent the lubricant from back flowingwhen redirecting the piping on the side.

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F.R.L. Unit Precautions 2Be sure to read before handling

Mounting

Caution1. To avoid reversed connections of the air inlet/outlet, make

connections after confirming the “IN/OUT” mark or arrows thatindicate the direction of air flow. Reversed connections can causemalfunction.

2. Components with a bowl, e.g., air filter, filter regulator, lubricator,must be installed vertically with the bowl downward so that faultydrain discharge and dripping can be verified.

3. Ensure sufficient top, bottom, and front clearance for maintenanceand operation of each component. Refer to the dimensions sectionfor the minimum clearance for each component.

4. Regulator and filter regulatorBe sure to unlock the knob before adjusting the pressure and tolock it after the pressure is set.

Adjustment

Warning1. Regulator and filter regulator

a. Set the regulator while verifying the displayed values of the inletand outlet pressure gauges. Turning the knob excessively cancause damage to the internal parts.

b. Do not use a tool on the pressure regulator knob as this cancause damage. It must be operated manually.

Caution1. Regulator and filter regulator

a. Be sure to check the inlet pressure before setting the outletpressure.

b. To set the pressure using the knob, turn the knob in thedirection that increases pressure and lock the knob after thepressure is set. If this is done in the direction that decreasespressure, the pressure may drop from the original set pressure.Turning the knob clockwise increases the outlet pressure, andturning it counterclockwise reduces the pressure.

Piping

Warning1. To screw piping materials into components, tighten with a

recommended tightening torque while holding the female threadside. If the minimum tightening torque is not observed, this cancause a looseness and seal failure. On the other hand, excesstightening torque can cause damage to the threads. Furthermore,tightening without holding the female thread side can causedamage due to the excess force that is applied directly to thepiping bracket.

Recommended tightening torque Unit: lb.- ft.

Connection Thread 3/8" 1/2"

Torque 16.2 to 17.7 20.6 to 22.1

* Alternatively tightening by hand, then tighten further approximately1/6 turn using a tightening tool.

2. Avoid excessive torsional moment or bending moment other thanthose caused by the equipment’s own weight as this can causedamage. Support external piping separately.

3. Piping materials without flexibility such as steel tube piping areprone to be affected by excess moment load and vibration from thepiping side. Use flexible tubing in between to avoid such an effect.

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Maintenance

Warning1. When disassembly or installation is required during the

maintenance, repair, or replacement of a device, be sure to followthe instructions provided in the instruction manual or safetyinstructions in this catalog.

2. Perform periodical inspections to detect any cracks, scratches, orother deterioration of the transparent resin bowl of the air filter,filter regulator, and lubricator or the sight dome of the lubricator.

Replace with a new bowl, sight dome, or metal bowl when anykind of deterioration is found, otherwise this can cause damage.

3. Perform periodical inspections to detect dirt on the transparentresin bowl of the air filter, filter regulator, and lubricator or the sightdome of the lubricator. When you find dirt on any of the abovedevices, clean with a mild household cleanser. Do not use othercleaning agents, otherwise this can cause damage.

4. Air filtera. Replace the element every 2 years or when the pressure drop

becomes 15 PSIG (1 Bar), whichever comes first, to preventdamage to the element.

b. Release accumulated condensate periodically before it reachesthe maximum capacity. Condensate that flows out to the outletside can cause malfunctions.

Caution1. Perform periodical inspections of the filter element and replace it

as necessary. Check the element whenever the outlet pressuredrops below normal or air does not flow smoothly duringoperation.

2. Regulator and filter regulatorCheck the sliding part or seat of the internal valve when a settingmalfunction or relief leakage occurs and temporary or emergencyrepairs need to be made.

3. LubricatorCheck the dripping amount once a day. Drip failure can causedamage to the components being lubricated.

F.R.L. Unit Precautions 3Be sure to read before handling

Piping

Caution1. Lubricator

Try to avoid riser piping and branch lines as much as possible onthe outlet side, otherwise proper lubrication will be compromised.

Air Supply

Caution1. When there is excessive condensate, install a device that

eliminates water such as a dryer or water separator (drain catch)on the inlet side of the air filter.

Filter• Five-micron filter element is standard.• Manual push-button drain easily

discharges contaminants.

Part Number Air Inlet Thread10671 1/2" NPT

Filter-Regulator• Unit has modular connections with

mounting brackets for easy installation.

Part Number Air Inlet Thread10677 1/2" NPT

Filter-Regulator-Lubricator• Unit has modular connections with

mounting brackets for easy installation.

Part Number Air Inlet Thread10681 1/2" NPT

FRL Flow CharacteristicsFlow • SCFM (LPM) Pressure Drop Across FRL • PSI (Bar)

15 (425) 2.0 (.14)30 (850) 3.0 (.21)45 (1274) 6.0 (.41)60 (1699) 7.0 (.48)75 (2124) 8.0 (.55)

Regulator-Lubricator• Unit has modular connections with

mounting brackets for easy installation.

Part Number Air Inlet Thread10679 1/2" NPT

Regulator• Compensation built into unit responds faster

to changes in incoming pressure and flow.• Built-in PSI pressure dial guage.

Part Number Air Inlet Thread10673 1/2" NPT

Lubricator• Built-in check valve permits tool to be

filled with oil without having to turn offair pressure.

• Adjustable oil drop to meter amountof oil into air system.

Part Number Air Inlet Thread10675 1/2" NPT

Additional Specifications: Maximum Operating Pressure 145 PSIG.

*Each unit includes two bushingsfor easy conversion to 3/8" NPT.

Filter-Regulator-LubricatorCost-Effective Maintenance for Air Supply Systems

1067110677

10679

10681

10673

10675

Visit our Website for more Tools and Related Accessorieswww.dynabrade.com

Dynabrade Air LubeHelp Prevent DowntimeDynabrade Air Lube (10W/NR)• Formulated for pneumatic equipment.• Absorbs up to 10% of its weight in water.• Prevents rust and formation of gum/sludge for longer tool

operation with greater power and less downtime.

Part Number 95821118 ml (4 oz.)

Part Number 95842473 ml (1 pt.)

Part Number 958433.8 l (1 gallon)

Part Number 96101Display Box• 24 - 118 ml (4 oz.) bottles