Spoiler Alert: Advanced variable speed drive (VSD) compressor technology effectively prevents condensate buildup, ensuring smooth operation even in humid conditions.
Understanding moisture in compressed air
All compressed air contains moisture, and the compression process increases its concentration. As air is cooled in an aftercooler, much of this moisture condenses and is removed before reaching the outlet. The amount of water entering a compressor depends on the surrounding climate.
In tropical regions with hot and humid conditions, significantly more moisture enters the compressor. Fortunately, as long as the internal temperature remains sufficiently high, condensation inside the compressor is avoided. However, problems may arise during low-load operation when the compressor's internal temperature drops. This cooling can cause condensation to form inside the drivetrain, leading to a milky oil emulsion that may result in corrosion or equipment failure.
The role of proper sizing
A critical factor in condensation control is correctly sizing the compressor according to air demand and environmental conditions. To further help with this potential issue, the latest oil-injected VSD compressors from Atlas Copco feature smart temperature control, preventing internal condensation.
Fact: Air compressor sizing significantly impacts condensation levels
The operating temperature plays a major role in condensation within the drivetrain. Fixed-speed air compressors operate at consistently high temperatures, producing less condensate compared to cooler-running VSD machines, where condensation increases during low-demand periods.
While fixed-speed machines might seem advantageous, proper compressor sizing accounts for 90% of condensation management. If the compressor operates at medium speed consistently, condensation becomes negligible, which is applicable to both fixed-speed and VSD compressors.
In high-humidity environments, precise sizing is essential. Oversizing a compressor increases condensation risk, making it advisable to limit excess capacity to no more than 15% above actual air demand.
Advanced VSD Technology Prevents Condensation
VSD compressors incorporate integrated inverters and motors for efficiency, with advanced algorithms for condensation control. Atlas Copco’s VSD+ models include a condensate prevention cycle, while VSDs models intelligently optimize oil temperature to strike a balance between energy efficiency and condensate reduction.
With superior efficiency and moisture management, advanced VSD compressors perform reliably in nearly all environments, including high humidity. They also deliver up to 35-60% greater energy efficiency than fixed-speed models*, offering substantial cost savings over their lifespan.
Why Compressor Technology Matters
If you’re comparing air compressors, it’s important to invest in a machine that is designed as a complete system. While many manufacturers will simply add an inverter, this doesn’t make them highly effective VSD’s – especially when it comes to moisture. In addition to the latest compressor and inverter technology, all Atlas Copco VSD compressors come with a built-in aftercooler and optional refrigerant dryer.
Atlas Copco understands the diverse conditions its customers face worldwide, delivering robust, energy-efficient machines that perform in varying environments.
*Comparing the energy savings of our model GA fixed-speed series.*
