Atlas Copco OSC Air Treatment Solutions Instruction Manual

Atlas Copco OSC Air Treatment Solutions

Air treatment solutions

• Aftercoolers & condensate treatment

Reliable and clean air

The air that leaves a compressor reaches 100% humidity. It also contains oil (unless you are using an oil-free compressor) and solid particles. Together, they form an abrasive, often acidic, oily sludge. Without air treatment, this murky mix will enter your compressed air system, corroding pipe work, damaging pneumatic tools and potentially compromising final products.

Atlas Copco offers a wide range of aftercoolers, drains and condensate treatment solutions, extending our premium quality throughout your compressed air system.

Remove oil

• Condensate treatment Because oil poses an environmental risk, compressed air condensate must be treated appropriately. Atlas Copco’s condensate management solutions separate and safely dispose of the oil in compressed air before it enters the system.

Remove water Drains

• The remaining humidity in compressed air turns into water as the air cools while it moves through the system. Because water causes corrosion and damage, drains must be installed throughout your network. Atlas Copco has a range of drains, automatic or electronic, that will keep your aftercooler, dryer, air receiver, and other equipment working optimally.

Aftercoolers

• All Atlas Copco compressors are equipped with an aftercooler. It cools the air, turning up to 70% of the humidity into water, which is then immediately drained. However, production facilities with extremely high ambient temperatures might need additional cooling. Atlas Copco’s add-on aftercoolers prevent excess moisture from entering your compressed air system.

OSC condensate treatment

• If the oil in compressor condensate is not removed before it enters the sewage system, it can cause significant environmental damage. Therefore, condensate treatment is not only the responsible thing to do; in most countries it’s the law. Thanks to its multi-stage filtration, Atlas Copco’s OSC removes oil from your compressor’s condensate with unmatched precision to achieve an oil content of 10 ppm at outlet. In addition, the OSC offers zero-hassle maintenance thanks to its easily removable filter bags and cartridges.

Highly effective multi-stage filtration

1. Inlet : The condensate enters the unit via one single or multiple inlets. It passes through a diffuser and depressurizes in the expansion chamber. The diffuser removes bigger solid particles from the condensate so that these cannot compromise the filter media.
2. First chamber: The oil-water mixture seeps through the polypropylene filter, which adsorbs the oil, but not the water. The condensate remains in the chamber for a while, starting a secondary, natural filtration as the remaining free oil floats to the top and is adsorbed by the filter bag.
3. Second chamber: A removable cartridge, filled with activated carbon or organoclay, separates the remaining oil droplets from the condensate.
4. Outlet : Clean condensate exits from the removable cartridge with almost no residual oil content, allowing for safe discharge into the sewer system.

Effectiveness

• Dual-stage filtration with polypropylene and activated carbon removes a wider range of oil types.
• Organoclay cartridges are available to take on stronger emulsions in the second chamber.
• The discharge condensate contains so little residual oil (10 ppm, 5 ppm if required), that it can be drained without environmental risk and in compliance with regulations.

Reliability

• You can verify filtration performance using the test outlet.
• A service indicator signals the polypropylene filter is saturated.
• An overflow indicator monitors correct water passage.

Ease of use

• The simple yet robust design allows for easy installation without special set-up.
• Easily removable filter bags and cartridges simplify and shorten maintenance.
• You enjoy a long service interval of 4,000 hours.

Flexibility

• OSC 12-15 are small single-use units. The larger units are serviceable.
• OSC 12-625 are two-stage units, while the OSC 1250-2500 are three-stage units.
• OSC 2500 uses a flow divider to evenly split the flow between units

OSC technical specifications

• Capacity is based on the compressor running at 7 brag/100 sprig or 12 hours per day, with all condensate from the compressor, the air receiver, the filters and refrigerant dryer piped into the unit.

Model| Max capacity – Mild climate

without dryer & filters

| Max capacity – Mild climate

with dryer & filters

---|---|---
l/s| m 3 /hr| cfm| l/s| m 3 /hr| cfm
OSC 12| 15| 54| 32| 12| 43| 25
OSC 25| 31| 113| 66| 25| 90| 53
OSC 50| 63| 225| 132| 50| 180| 106
OSC 85| 106| 383| 225| 85| 306| 180
OSC 170| 213| 765| 450| 170| 612| 360
OSC 300| 375| 1350| 795| 300| 1080| 636
OSC 625| 781| 2813| 1655| 625| 2250| 1324
OSC 1250| 1563| 5625| 3311| 1250| 4499| 2648
OSC 2500| 3125| 11250| 6621| 2500| 8998| 5296

• All capacities are based on an outlet oil content of 10 mg/l.

Reference conditions

• Relative air humidity: 60%
• Air inlet temperature: 25°C (77°F) Running hours per day: 12 hours Effective working pressure: 7 bar (102 psi)

Running hours

• Multiply the OSC FAD capacity by the appropriate correction factor to adjust for different running hours:

Separation performance
For an outlet oil carry-over of 10 mg/l. 5 mg/l can also be achieved when applying correction factors. Contact Atlas Copco for precise derating.

Dimensions

Options

• Manifold for multiple condensate inlets
• Wall mounting kit (for sizes 12-25)
• Test capsule (standard for sizes 12-25)
• Drip tray
• Electronic alarm

WSD water separators

• Atlas Copco’s WSD prevents condensed water from building up in your air system. The water separator comes as standard with Atlas Copco’s aftercoolers and can also be installed at any point in your system. Made entirely of rustproof material, these cyclone-based separators remove water aerosols to protect system components such as dryers and filters. Maintenance-free and without moving parts, they come with an automatic or a manual drain.

Your benefits

• Reliability – The corrosion-proof drain prevents condensed water from building up in your air system.
• Minimal maintenance – The water separator is maintenance-free because it does not have moving parts.
• Energy savings – The intelligent drain function monitors condensate build-up and drains it only when required to avoid air loss.
• Flexible installation – WSD water separators can be installed at any point in your air net.

Type| Capacity range| Maximum working pressure| Connections| Dimensions| Weight
---|---|---|---|---|---
Height| Width| Length
l/s| cfm| bar(e)| psi| inlet/outlet| mm| inch| mm| inch| mm| inch| kg| lbs
WSD 25| 7-60| 15-127| 20| 290| G 1| 332| 13.0| 130| 5.1| 185| 7.3| 1.1| 2.4
WSD 80| 50-150| 106-318| 20| 290| G 1½| 432| 17.0| 130| 5.1| 185| 7.3| 3.5| 7.7
WSD 250| 125-350| 265-742| 20| 290| G 2½| 532| 20.9| 160| 6.3| 230| 9.0| 12.5| 27.6
WSD 750| 300-800| 636-1695| 20| 290| 83 mm*| 532| 20.9| 160| 6.3| 230| 9.0| 14.0| 30.9

• Blind flange to be machined up to this diameter.

IWD electronic drains

The IWD electronic drain collects and removes liquid moisture from your air system effectively, reliably and efficiently. The zero-loss drain only releases its moisture content when it reaches a pre-set level. Leaving a minimal amount of moisture, the IWD ensures no energy can escape as the receiver empties. Thanks to its special housing, the IWD can be used in oil- lubricated and oil-free installations.

Type| Maximum compressor capacity| Maximum dryer capacity| Maximum pressure| Dimensions| Weight
---|---|---|---|---|---
Height| Width| Length
l/s| cfm| l/s| cfm| bar| psi| mm| inch| mm| inch| mm| inch| kg| lbs
IWD 50| 50| 106| 100| 212| 16| 232| 120| 4.7| 60| 2.4| 136| 5.4| 0.4| 0.9
IWD 105| 105| 222| 210| 445| 16| 232| 116| 4.6| 69| 2.7| 160| 6.3| 0.5| 1.1
IWD 125| 125| 265| 250| 530| 16| 232| 140| 5.5| 69| 2.7| 163| 6.4| 0.6| 1.3
IWD 250| 250| 530| 500| 1059| 16| 232| 155| 6.1| 69| 2.7| 163| 6.4| 0.7| 1.5
IWD 500| 500| 1059| 1000| 2119| 16| 232| 214| 8.4| 69| 2.7| 163| 6.4| 1.2| 2.6
IWD 2665| 2667| 5651| 5333| 11300| 16| 232| 230| 9.1| 123| 4.8| 173| 6.8| 1.8| 4.0
IWD 5000| 5000| 10594| 10000| 21189| 16| 232| 230| 9.1| 148| 5.8| 247| 9.7| 3.45| 7.6

Climatic conditions

• ambient temperature 20°C (68°F)
• relative humidity 60%

WD automatic drains

• The WD 80 drain valve provides completely automatic drainage of the water that collects at the lowest point of a compressed air system (e.g. at the bottom of a receiver or cyclone separator). Its patented design ensures minimal maintenance.

Type| Maximum working pressure| Drain capacity| Connections| Dimensions| Weight
---|---|---|---|---|---
Height| Width| Length
bar(e)| psi| l/h| mm| inch| mm| inch| mm| inch| kg| lbs
WD 80| 20| 290| 200| G ½| 182| 7.2| 132| 5.2| 132| 5.2| 2.7| 5.9

EWD electronic drains

• The EWD range of electronic drains offers safe, dependable and efficient condensate drainage. The intelligent drain function monitors condensate build-up and removes the liquid only when necessary, avoiding compressed air loss. Special EWD drains are also available for oil-contaminated condensate and with additional hard coating for oil-free and aggressive condensate.

Type| Maximum compressor capacity | Maximum dryer capacity | Maximum pressure| Dimensions| Weight
---|---|---|---|---|---
Height| Width| Length
l/s| cfm| l/s| cfm| bar| psi| mm| inch| mm| inch| mm| inch| kg| lbs
EWD 50| 65| 138| 130| 275| 16| 232| 115| 4.5| 70| 2.8| 171| 6.7| 0.7| 1.5
EWD 50 A*| 65| 138| 130| 275| 16| 232| 115| 4.5| 70| 2.8| 171| 6.7| 0.7| 1.5
EWD 50 B***| 650| 1380| 1729| 3640| 16| 232| 115| 4.5| 70| 2.8| 171| 6.7| 0.7| 1.5
EWD 50 L| 650| 1380| 1729| 3640| 16| 232| 115| 4.5| 70| 2.8| 171| 6.7| 0.7| 1.5
EWD 75| 98| 208| 194| 411| 16| 232| 141| 5.6| 65| 2.6| 150| 5.9| 0.8| 1.8
EWD 75 C| 98| 208| 194| 411| 16| 232| 141| 5.6| 65| 2.6| 150| 5.9| 0.8| 1.8
EWD 75 CHP| 98| 208| 194| 411| 63| 913| 141| 5.6| 65| 2.6| 150| 5.9| 0.9| 2.0
EWD 330| 433| 917| 866| 1835| 16| 232| 162| 6.4| 93| 3.7| 212| 8.3| 2.0| 4.4
EWD 330 C| 433| 917| 866| 1835| 16| 232| 162| 6.4| 93| 3.7| 212| 8.3| 2.0| 4.4
EWD 330 CHP| 433| 917| 866| 1835| 25| 362| 162| 6.4| 93| 3.7| 212| 8.3| 2.0| 4.4
EWD 1500| 1950| 4132| 3900| 8264| 16| 232| 180| 7.1| 120| 4.7| 252| 9.9| 2.9| 6.4
EWD 1500 C| 1950| 4132| 3900| 8264| 16| 232| 180| 7.1| 120| 4.7| 252| 9.9| 2.9| 6.4
EWD 16K C **| 21670| 45920| 43340| 91830| 16| 232| 280| 11.0| 254| 10.0| 280| 11.0| 5.9| 13.0

Climatic conditions

• ambient temperature 35°C (95°F)
•  relative humidity 70%
•  Suitable for oil-free condensate.
•  Standard + indicative LEDs and potential free alarm.
•  With vario function: pause between detection of high condensate level and opening of valve (not oil-adjusted).
•  With vario function: pause between detection of high condensate level and opening of valve (oil-adjusted).
• C = With anti-corrosion coating for oil-free condensate.
• HP = High-pressure version

TWD timer drains

• Compact, easy to install and fully automatic, the TWD is a cost-effective drain solution for compressed air filters and vessels. Pre-selecting the timing and length of each drain cycle minimizes compressed air loss.

Type| Maximum working pressure| Connections| Dimensions| Weight
---|---|---|---|---
Height| Width| Length
bar(e)| psi| inlet| valve| mm| inch| mm| inch| mm| inch| kg| lbs
TWD| 16| 232| G ½-¼| G ½| 126.5| 5| 131| 5.2| 95| 3.7| 0.7| 1.5

HD and TD aftercoolers

• Atlas Copco’s air and water-cooled aftercoolers provide additional moisture management in facilities with extremely high ambient temperatures. Supplied with all necessary parts, they are compact, simple to install and easy to disassemble for cleaning.
• Our HD and TD aftercoolers combine minimal pressure drop with high cooling efficiency and low energy consumption. A negligible pressure drop means no production power is lost. The compressor doesn’t generate extra demand, eliminating additional energy or maintenance costs.

Your benefits:

• Efficiency – Special, highly efficient separation by cyclone results in low pressure drop and energy use.
• Minimal installation & maintenance Easy assembly of connection flanges.
• Reliability – Totally rustproof materials ensure a long lifetime

HD water-cooled aftercooler

Type| Nominal flow | Maximum working pressure| ∆t above cooling water | Water consumption
---|---|---|---|---
l/s| cfm| bar(e)| psi| °C| °F| l/s| m 3 /h| US gal/min
HD 250| 180| 380| 20| 290| 12| 21| 0.4| 1.44| 6.3
HD 650| 530| 1120| 10.5| 150| 11| 20| 1.3| 4.68| 21
HD 1500| 1500| 3180| 16| 230| 4| 7| 3.9| 14.0| 62
HD 3500| 3500| 7420| 16| 230| 4| 7| 8.5| 30.6| 134

• HD water-cooled aftercooler.

Type| Air inlet / outlet connections Ø| Dimensions| Weight| Cooling water
---|---|---|---|---
Height| Width| Length| inlet outlet
inlet| outlet| mm| inch| mm| inch| mm| inch| kg| lbs
HD 250| G 2½| G 2½| 1975| 77.7| 230| 9.0| 483| 19.0| 140| 308| G ½
HD 650| DN 100| DN 100| 2083| 82.0| 500| 19.7| 635| 25.0| 210| 463| G 1
HD 1500| DN 150| DN 150| 840| 33.0| 1574| 62.0| 925| 36.4| 710| 1565| DN 80
HD 3500| DN 200| DN 200| 828| 33.0| 1574| 62.0| 925| 36.4| 715| 1576| DN 80

TD air-cooled aftercooler

Type| Nominal flow | Maximum working pressure| ∆t above

ambient temperature

| Fan motor power
---|---|---|---|---
l/s| cfm| bar(e)| psi| °C| °F| kW| hp
TD 08| 8| 17| 20| 290| 10| 18| 0.05| 0.07
TD 25| 25| 53| 20| 290| 10| 18| 0.12| 0.16
TD 50| 50| 106| 20| 290| 10| 18| 0.18| 0.24
TD 150| 150| 318| 20| 290| 10| 18| 0.75| 1.01
TD 300| 300| 363| 20| 290| 10| 18| 0.75| 1.01
TD 650| 650| 1377| 20| 290| 10| 18| 2.20| 2.95
TD 650| 650| 1377| 10.5| 152| 10| 18| 2.20| 2.95

• Refers to absolute pressure of 1 bar and temperature of 20 °C. Compressed air in at 160 °C.

Type| Air inlet / outlet connections Ø| Dimensions| Weight| N° of cooler cores
---|---|---|---|---
Height| Width| Length
inlet| outlet| mm| inch| mm| inch| mm| inch| kg| lbs
TD 08| G ½| G ½| 188| 7.4| 130| 5.1| 270| 10.6| 6| 13| 1
TD 25| G 1| G 1| 658| 25.9| 402| 15.8| 588| 23.1| 19| 42| 1
TD 50| G 1¼| G 1¼| 735| 28.9| 412| 16.2| 664| 26.1| 23| 51| 1
TD 150| G 2½| G 2½| 1160| 45.6| 435| 17.1| 920| 36.2| 53| 117| 1
TD 300| G 2½| G 2½| 1280| 50.3| 466| 18.3| 1140| 44.8| 73| 161| 1
TD 650| DN 80| DN 100| 1525| 60.0| 716| 28.1| 1780| 70.0| 185| 408| 1

condensate treatment 2935 0838 48 © 2022, Atlas Copco Airpower NV, Belgium. All rights reserved. Designs and specifications are subject to change without notice or obligation. Read all safety instructions in the manual before usage.
atlascopco.com

References

• Atlas Copco | Home of Industrial Ideas

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