The importance of air preparation units in pneumatic systems
Air preparation units, also known as FRL units (Filter, Regulator, and Lubricator), are critical components in pneumatic systems. These units ensure that compressed air is delivered at optimal quality, improving the efficiency and longevity of pneumatic components while minimising downtime.
Typical components of an air treatment unit
An air treatment unit or air preparation unit consists of at least some of the following elements:
Depending on the application, additional elements such as residual pressure relief valves, soft start-up valves, membrane air dryers, or pressure switches can be incorporated.
SMC's modular designs allow for customised configurations, meeting specific industrial requirements while maintaining compact and efficient layouts.
Why use a compressed air treatment unit?
The compressed air generated by compressors often contains contaminants like debris, oil, and moisture, which can negatively affect the performance and lifespan of pneumatic systems. Additionally, pipeline erosion can cause particles to enter the system.
Common issues caused by contaminated compressed air:
- Lubrication deterioration
- Clogging of passages or pilot holes
- Failure to start in low-temperature conditions (freezing)
- Internal mechanical failures
- Water generation within the system
- Pressure drops, clogged filters, and jammed auto drains
- Leaks due to damaged seals
- Reduced product quality: This is especially relevant in applications such as painting, blowing, printing, etc.
- Contaminated compressed air can also impact automation components, including: Valve and actuator failures caused by grease washout
- Seized auto drains due to rust inside the ducts
- Air leaks caused by damaged seals
- Corrosion in regulators
- System saturation due to increased moisture
Solution: Air preparation units, or FRL units, ensure compressed air is delivered in optimal condition by:
- Filtering out particles, moisture, and oil
- Regulating pressure to meet system requirements
- Lubricating air to protect pneumatic components.
By maintaining proper air quality, these units enhance equipment performance, prevent system failures, and improve process efficiency in industrial applications.
How to select the right air preparation unit?
Choosing the right air treatment FRL unit requires careful consideration of several factors:
- Specific application: The air quality required varies depending on the application. Our air treatment guide will help you identify the appropriate air quality class for your application and select the products that best suit it.
- Key aspects to evaluate when selecting a maintenance unit:
- What connection size is required? It is advisable to calculate the necessary peak flow. Use our flow rate calculation software to calculate peak flow and size the components of your maintenance unit accordingly.
- Is a pressure relief valve necessary? It is advisable to include one to allow you to pressurize or depressurize the machine, for example, during industrial maintenance tasks.
- Is pressure regulation required? A pressure regulator is typically essential for adjusting network pressure to the optimal level for your equipment. This regulation can be manual or remote with electro-pneumatic regulators.
- Is a sensor required to measure the flow? While not essential, it is advisable to include sensors to monitor the state of the compressed air system and make decisions that drive the efficiency of industrial processes.
- Is the use of an air lubricator required? Most SMC pneumatic actuators come pre-lubricated, so a lubricator may not always be needed. However, for high-frequency applications or actuators without built-in lubrication, lubricators are recommended.
To create a custom air treatment unit tailored to your specific needs, try our airline equipment configurator. It allows you to design a solution perfectly suited to your line.
What maintenance does an FRL unit require?
Proper filter maintenance is crucial, as saturated cartridges are a common cause of failures in compressed air network components, including actuators, valves, and the maintenance units themselves.
To ensure optimal performance, SMC recommends replacing the filter cartridges every 2 years or sooner if the pressure drop exceeds 0.1 MPa (1 Bar).
Reach out to our team of experts to find the perfect air treatment unit for your specific application requirements.
