Filter regulator combo

Types of Filter Regulator Combos

A filter regulator combo is a crucial component of pneumatic systems used to ensure the correct operation of tools and equipment. It combines an air filter, which removes moisture and contaminants, and a pressure regulator that controls and adjusts the air pressure.

Manufacturers typically classify FRLs combo units according to the following factors:

• By Functionality

  An AFFS (A Ferro Fluid Seal) is an air filter model with a water separator. It's designed to catch liquid using the gravitational separator. AFFS is ideal for people wanting to remove water from the compressed air.

  An AFDS (A Ferro Dynamic Seal) is an air filter model with a water separator and dessicant. It's designed to catch liquid and humidity using the gravitational separator and dessicant. AFDS is ideal for people wanting to remove water and humidity from the compressed air.

  Filter regulators are devices that simultaneously remove particulates and moisture from compressed air while also controlling the pressure provided by the compressor. They are typically used to provide controlled clean air to tools and actuators in a compressed air system.

  FRL units refer to the combination of air filters, pressure regulators, and lubricators in a single unit. Unlike the other components in this set, lubricators are often crucial to pneumatic systems and tools, which often require lubricated compressed air. As such, lubricants are usually used to prolong the lifetime of bearing components.

• By Ports

  A 1-port filter regulator combo means that the unit can connect to only one tube. It's usually placed at the air supply entry point.

  A 2-port filter regulator combo is typically placed at air tools or equipment. It's used to provide regulated filtered air to various tools and fittings.

• By the size of particles

  The standard size classification of air filter regulators is as follows:

  General Purpose (50-micron filter elements): These filter elements are visible to the naked eye and work to remove big particles, such as leaves and globules. They are typically used to remove the vast majority of contaminants that do not affect the tool or equipment function.

  Fine (5-micron filter elements): These filter elements are often made to a specific ID/OD and work to remove small particles that cause internal engine wear. They may be used in pneumatic systems that require precision operation and high cleanliness standards.

  Absolute (1-micron filter elements): Absolute filter elements work to remove water vapor and human hair. They are used in high-precision aerospace applications and similar industries requiring near-perfect cleanliness.

Specification and Maintenance of Filter Regulator Combos

Specifications

These are some of the specifications that apply to filter-regulator combos.

• Flow Rate: This is the valve's capacity to let air move through it. The unit of measure is usually cubic feet per minute (CFM). Filter/regulator combos have various typical flow rates. The common ones are 20 CFM to 100 CFM.
• Connector Size: Filter-regulator combos can have different kinds of connectors. The size of the filter regulator air compressor connector is usually the same as the hose it will pair with. Typical connector sizes include 1/4, 3/8, and 1/2 inch NPT.
• Operating Pressure: This refers to the air pressure that the regulator will control. It affects how much the filter will catch. Combo units work well at an operating pressure between 5 PSI and 150 PSI.
• Reservoir Capacity: This is the amount of water that the reservoir in the filter can hold. It is usually in ounces or liters. The reservoir capacity for many filter/regulator combos ranges from 4 oz to 32 oz.
• Temperature Rating: This component can work well in temperatures between 32 °F and 175 °F. Some models may function at lower or higher temperature limits.
• Separator Technology: Some manufacturers create units that separate water through gravitational force. Others use advanced technologies to separate oil mist from air using coalescing filters.
• Drain Method: When determining the maintenance of a filter regulator combo, it is important to note the drainage method. The combo can have a manual drain, an automatic drain, or a semi-automatic drain.

Maintenance Tips

• Inspect the unit: Regularly check the exterior and parts of the filter regulator combo. Look out for air leaks, damages, or sign of wear. Early detection of small issues can prevent big problems later.
• Drain the water from the reservoir: Water from the reservoir can build up pressure or lead to corrosion. Draining the water reduces the risk of problems.
• Clean the knock-off: Water collected in the filter regulator knocks off can build up algae, dirt, or bacteria. Cleaning it regularly prevents this from happening.
• Check air filter: Carry out inspection on the air filter to see if dirt or debris blocks it. Remove any blockage. If it’s dirty, clean or replace it, depending on the manufacturer’s instruction.
• Lubricate throttle valve: This combo device has a throttle valve connected to the regulator. Lubricate the moving parts of the throttle valve to prevent wear. Lubrication allows free movement and accurate control of air pressure.

Application Scenarios of Filter Regulator Combo

Air filter regulator combos are used in many industries and applications. Here are some of them.

• Tools

  A user can install an air filter regulator combo in a tool system. That will ensure the air tools receive clean, dry, and regulated air. This enhances the performance of the tools. It also minimizes wear due to contaminants and humidity.

• Manufacturing

  Compressed air is a common energy source in the manufacturing industry. Air filter regulator combos are installed on the air lines feeding pneumatic machines and devices. The filters clean the air. The regulators control the pressure to desired levels. Quality products and consistent performance are always assured.

• Spray Guns

  An air filter regulator spray gun combo is used in painting applications. It controls the pressure and filters the moisture and impurities in the air. This allows smooth and even paint atomization. The outcome is a quality paint finish.

• Packaging

  Packaging operations often use pneumatic systems. Examples include conveyor belts, sealing machines, and vacuum handlers. Air filter regulator combos can be used in these systems. They ensure the compressed air is clean and properly pressurized. This maintains the reliability and efficiency of the machines.

• Agriculture

  Air filter regulator combos are applied through drip irrigation systems in greenhouses and farms. They clean and regulate the pressure of the compressed air used in greenhouses for plant protection. This promotes healthy growth of the plants.

• Automotive

  In the automotive industry, air filter regulator combos are used in vehicle assembly lines. They are also used in repairs and maintenance. The devices provide clean and controlled air to pneumatic tools like wrenches and hoists. Air tool users can also use the combos to improve tool performance and extend service life.

• Air Cylinders and Grippers

  An air cylinder is a mechanical device that uses compressed air to produce a force for linear motion. Air filter regulators are frequently used in conjunction with air cylinders. They control the airflow as precisely needed to power the cylinder. This gives the cylinder its desired speed and operating force. Pneumatic grippers are the robotic devices used to grasp or hold parts. Like the air cylinders, grippers also use air filters and regulators to control the gripper's opening and closing force.

How to Choose Filter Regulator Combos

When purchasing air filter regulator combos, it is better to go through some of the factors that will help choose the best equipment for the intended purpose. Some of the things to check include:

• Flow Rate:

  This is the amount of air that passes through the regulator in a given time. It is usually measured in cubic feet per minute (CFM). Comparing the flow rate for various filter regulators helps users find the one that has a perfect air supply.

• Storage Tank Size:

  A vacuum pump or air compressor can supply air in combination with a filter regulator. However, the size of the storage tank can affect the performance of the filter regulator. A small storage tank might deplete air supplies fast. Hence, the filter regulator might not deliver air at a constant pressure. On the other hand, a large storage tank can store more compressed air. It enables the filter regulator to function without interruptions.

• Calibration:

  The air filter regulator can come with different measurements depending on the manufacturer. Calibration determines how fine users can adjust the air supply. It's best to choose a filter regulator that is calibrated with the specific tool or equipment in mind. This way, it will provide a perfect air supply match.

• Drain Mechanism:

  The combo units come with different types of drain mechanisms. Selecting the drain mechanism provides insights into the process of condensate removal from the filter bowl. Some typical options include manual drain, semi-automatic drain, or fully automatic drain.

• Construction Material:

  Depending on the application, it's best to choose a filter regulator with construction materials that can withstand the environmental conditions. For corrosive environments, prefer alloy or aluminum coated with epoxies for resistance.

Filter regulator combo Q&A

Q1: Why is it called a filter reg?

A1: A filter reg is a substance that combines two separate components, namely the air filter and pressure regulator, into a single unit.

Q2: What is the purpose of an air filter/regulator combo?

A2: The main purpose of an air filter/regulator combo is to clean the air by removing contaminants while simultaneously controlling and regulating the air pressure supplied to other tools or equipment.

Q3: What are the two types of air filters?

A3: There are two commonly used air filters: the drop air filter and the duplex air filter.

Q4: What is the difference between a qualifier and a regulator?

A4: The qualifier is used to describe a filter that removes moisture from compressed air. On the other hand, the regulator is a device that controls the amount of compressed air sent to a specific tool by controlling its speed.