D12IN to D480IN Refrigerated Dryer Service Manual

D12IN to D480IN Refrigerated DryersD-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. ©Ingersoll Rand Proprietary Information Page 1 THIS PAGE IS LEFT INTENTIONALLY BLANK D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. ©Ingersoll Rand Proprietary Information Page 2 CONTENTS 1. 2. 3. 4. SAFETY INFORMATION REFRIGERATION CIRCUITS D12IN - D180IN D240IN - D480IN COMPONENT REVIEW ELECTRICAL CIRCUITS D12IN to D72IN (230v/1Ph/50Hz) D108IN to D180IN (230v/1Ph/50Hz) D240IN (230v/1Ph/50Hz) D300IN to D380IN (230v/1Ph/50Hz) D480 (230v/1Ph/50Hz) D12IN to D72IN (115v/1Ph/60Hz) D108IN to D180IN (115v/1Ph/60Hz) D300IN to D380IN (230v/1Ph/60Hz) D12IN to D480IN CONTROLLER General Description Automatic Re-start After Power Outage LED Display Functionality Of The Keys Autotest Function Condensate Discharge Parameters Modification Of The Parameters Description Of The Parameters REPLACING THE CONTROLLER Calibration Of the Temperature Probe D240IN - D480IN WARNINGS ESA ES2 ALARMS HtA Ht2 PF1 ASt DEHYDRATION AND EVACUATION PROCEDURE KTY81-121 RESISTANCE CHART PRESSURE / TEMPERATURE CHARTS (R134a) Bara/ºC Psig/ºF DEFAULT CONTROLLER SETTINGS 50Hz Models 60Hz Models CORRECTION FACTORS TECHNICAL DATA SHEETS 50Hz Models 60 Hz Models MATERIAL SAFETY DATA SHEETS (R134a) 4 5 6 6 7 9 10 11 12 13 14 15 16 17 19 20 21 21 22 22 23 23 26 28 29 30 30 30 31 31 31 33 35 35 37 39 40 41 43 44 45 46 49 49 63 83 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. ©Ingersoll Rand Proprietary Information Page 3 1. SAFETY Important: Do not operate this equipment until the safety information and instructions in this user guide have been read and understood by all personnel concerned. Only competent personnel trained, qualified, and approved by Ingersoll Rand should perform installation, commissioning, service and repair procedures. Use of the equipment in a manner not specified within this user guide may result in an unplanned release of pressure, which may cause serious personal injury or damage. When handling, installing or operating this equipment, personnel must employ safe engineering practices and observe all related regulation, health & safety procedures, and legal requirements for safety. Ensure that the equipment is depressurized and electrically isolated, prior to carrying out any of the scheduled maintenance instructions specified within this user guide. Most accidents that occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules and procedures. Accidents can be avoided by recognizing that any machinery is potentially hazardous. Ingersoll Rand can not anticipate every possible circumstance which may represent a potential hazard. The warnings in this manual cover the most known potential hazards, but by definition can not be all-inclusive. If the user employs an operating procedure, item of equipment or a method of working which is not specifically recommended by Ingersoll Rand the user must ensure that the equipment will not be damaged or become hazardous to persons or property. BEFORE SERVICING OR DISMANTLING ALL PRESSURE MUST BE RELEASED FROM THE SYSTEM AND ITS ASSOCIATED PIPEWORK AND ANY ELECTRICAL SUPPLY ISOLATED. Grounding Improper grounding can result in electrical shock and can cause severe injury or death. This product must be connected to a grounded, metallic, permanent wiring system or an equipment-grounding terminal. All grounding must be performed by a qualified electrician and comply with national and local electrical codes. In the event of an electrical short circuit, grounding reduces the risk of electric shock by providing an escape path for the electric current. Ground must be established with a grounding wire sized according to the voltage and minimum branch circuit requirements. Ensure good bare metal contact at all grounding connection points, and ensure all connections are clean and tight. Check grounding connections after initial installation and periodically thereafter to ensure good contact and continuity has been maintained. Check with a qualified electrician or service technician if the grounding instructions are not completely understood, or if in doubt as to whether the product is properly grounded. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. ©Ingersoll Rand Proprietary Information Page 4 2. 2008. REFRIGERATION CIRCUITS D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 5 . June. June.Models D12IN to D180IN Models D240IN to D480IN D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 6 . 2008. See page 29 for correct adjustment procedures.32 psig). 2008.2. The flow varies dependent on the percentage of rated air capacity flowing through the dryer. ensuring optimum performance whatever the application if properly sized for the application. This switch is set to 30 bar ( 435 psi ) FF Dryer Filter. (230vac for 50hz models. 115vac for 60htz models) PR Air-to-Air Heat Exchanger. CND Condenser. 1P1 High Pressure Switch. ©Ingersoll Rand Proprietary Information Page 7 . The HGBP valve should be set to maintain between 2. refrigerant constantly flows through the evaporator. It should be noted that dryer loading can apply not only to capacity changes but thermal load changes due to varying conditions.3.2 barg (30 . June. 1V1 Solenoid Drain Valve. All models perform within a wide range of ambient and compressed air temperatures. In D-IN/T dryers.1 . RBF Tap with Strainer ( D240IN to D480IN Only ). the compressed air capacity entering the dryer fluctuates. This switch protects the refrigeration system in the event of an overpressure condition within the refrigeration circuit. EVA Evaporator. (See Air to Air and Refrigerant to Air Exchanger. As the air compressor modulates or goes online/offline. depending on site and ambient conditions. Page 8) SCO Condensate Separator. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 1M2 Condenser Fan Motor. CPL Capillary Tube. COMPONENT REVIEW D12IN – D480IN 1M1 Refrigerant Compressor. VB Hot Gas By-Pass Valve ( D240IN to D480IN Only ). The dryer must be able to adjust to these varying capacities and maintains performance. decreasing the relative humidity and eliminating condensation on downstream air piping. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 8 . The re-heater section raises the temperature of the outgoing compressed air. Liquid water in the air is removed by a high efficiency demister separator. reducing the amount of refrigeration energy needed to dry the compressed air. forcing moisture to condense. June. This design ensures maximum separator efficiency across the entire flow range.D180IN and a vertically mounted on models D240IN and above (see illustration.Air to Air and Refrigerant to Air Exchanger All D-IN dryers utilise an air to air and air to refrigerant heat exchanger horizontally mounted on units D12IN . 2008. protecting the dew point. Air to Air Heat Exchanger W D Air to Refrigerant Heat Exchanger A large expansion chamber slows the compressed air down to its critical velocity. giving a high overall efficiency. The air-to-air heat exchanger pre-cools the incoming air and re-heats the outgoing air. This cools the incoming compressed air. 4. ELECTRICAL CIRCUITS D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. June. ©Ingersoll Rand Proprietary Information Page 9 . 2008. ©Ingersoll Rand Proprietary Information Page 10 . June.Models D12IN to D72IN (230v/1Ph/50Hz) D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June. ©Ingersoll Rand Proprietary Information Page 11 . 2008.Models D108IN to D180IN (230v/1Ph/50Hz) D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. Models D240IN (230v/1Ph/50Hz) D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. ©Ingersoll Rand Proprietary Information Page 12 . June. ©Ingersoll Rand Proprietary Information Page 13 . June.Models D300IN to D380IN (230v/1Ph/50Hz) D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. ©Ingersoll Rand Proprietary Information Page 14 . 2008. June.Models D480 (230v/1Ph/50Hz) D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 15 .Models D12IN to D72IN (115v/1Ph/60Hz) D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June. 2008. ©Ingersoll Rand Proprietary Information Page 16 . 2008. June.Models D108IN to D180IN (115v/1Ph/60Hz) D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 17 .Models D300IN to D360IN (230v/1Ph/60Hz) D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. June. THIS PAGE IS LEFT INTENTIONALLY BLANK D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June. 2008. ©Ingersoll Rand Proprietary Information Page 18 . ©Ingersoll Rand Proprietary Information Page 19 . 2008.5. June. D12IN to D480IN CONTROLLER D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. The controller checks the machine and returns diagnostic information in the presence of a malfunction. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. The default value for the Setpoint is 0. When operating in alogarithmic control the controller sends a series of ‘wave trains’ or pulses to the fan the quicker the frequency of the series of pulses the faster the fan will rotate.9ºF) if the evaporator temperature is below the setpoint the condensor fan will be off. June. The controller also monitors the evaporation temperature via a highly sensitive temperature probe this allows the controller to govern the condenser fan motor speed. The controller will display in °C or °F.5ºC (32.1 GENERAL DESCRIPTION The controller controls all relative procedures in starting and stopping the refrigerant compressor.5 seconds (Models D12IN to D180IN) or 2 seconds (Models D240IN and above). A patented microprocessor allows dryer’s cooling capacity to be adjusted. then switch to alogarithic control. The controller will vary the speed of the condenser fan based on the actual evaporator temperature and the programmed evaporator Setpoint. The controller constantly mointors evaporator temperature and adjusts the frequency of the wave trains accordingly to maintain the correct temperature. by changing the fan motor speed. ©Ingersoll Rand Proprietary Information Page 20 .Controller D12IN to D480IN 5. if the temperature rises above the setpoint the controller will firstly energise the fan for 0. if it is a requirement for the dryer not to automatically re-start after power failure. June.3 LED DISPLAY DISPLAY DESCRIPTION the unit is ON with low load and the measured temperature is less than -1ºC the unit is ON with normal load and the measured temperature is between -1ºC and +4ºC the unit is ON with normal-high load and the measured temperature is between +4ºC and +8ºC the unit is ON with high load and the measured temperature is above +8ºC Dryer is turned off LED STATUS ON Flashing ON ON Flashing OFF DESCRIPTION Compressor Is Energised Programming Mode Activated Condensate Drain Is Energised Speed of The Fan = 100% Speed Of The Fan < 100% Fan Not Running Page 21 D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. Attention: Automatic restart after power outage cannot be disabled from the controller. It is the frequency and length of the pulses or ‘wave trains’ that change the fan speed. 5. a hot gas by-pass valve cooperates with the variable speed system. ©Ingersoll Rand Proprietary Information . Please note there will be a two minute delay before the dryer restart after power has be restored.It is important to note that unlike inverter or other VSD drives neither the voltage or hertz frequency of the electrical signal to the fan changes. in order to greater adjust the dryer’s cooling capacity. 5. In models D240IN to D480IN.2 Automatic Re-start After Power Outage All D-IN/T dryers will automatically restart after power failure providing the dryer was running without a HTA. HT2 or ASt alarms. The dryer must be connected to a suitable device with a manual reset that will trip on power loss. 2008. 5.5 AUTOTEST FUNCTION An auto test function allows the user to test the functionality of the controller and the components connected to it. condensate drain. the LED display will read OFF. 5. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ON / OFF: When pressed for 1 second. condenser fan then the alarm output (if fitted). d10 = firmware version 1. When pushed for 10 seconds during normal operation. June. it starts an automatic test cycle of the controller. then test in sequence outputs to the compressor. for safety purposes. If. 2008. it stores the applied modifications.1 sec. When pushed after having set new configuration values. it allows the user to change the C8 and C9 condensate drain parameters programming menu (see relevant table). then one unit every 0. during normal operation. and finally display the firmware version of the controller. If after 5 seconds no key is pressed once the LED has displayed the firmware version. it increases the displayed value of one unit per second. it will activate the condensate drain. ©Ingersoll Rand Proprietary Information Page 22 . When the dryer is deactivated.0. then one unit every 0.1 sec. Therefore. the test is performed by pressing the DOWN button for 10 seconds the testing procedure is as follows:The controller will first test the small LED’s. e. It will then illuminate all the characters on the LED character display. the controller will revert back to standard operation. SET: When pressed and released during normal operation. it activates or deactivates the dryer.5ºC (32. during the first 10 seconds. disconnect the electrical power before performing any operation on the unit. NOTE: When the controller is in the OFF position. some parts of the dryer may still be energized. it decreases the displayed value of one unit per second. DOWN: When pressed while setting the drain set point. during the first 10 seconds. UP: When pressed while setting the drain set point. it displays the evaporator set value in decimal the default value is 0. whilst display the firmware a key is pressed then the display will show F1 through to F5 dependant on which key is pressed.9ºF) When pushed for 10 seconds.4 FUNCTIONALITY OF THE KEYS TEST: When pressed for 3 sec.g. 6 CONDENSATE DISCHARGE PARAMETERS. access to all other parameters is disabled. Once access is unlocked. 15 seconds after the last performed operation. After programming has been completed. To change any further parameters the programming mode will have to be reactivated by following the procedure above. To change the condensate drain parameters push the SET key for 10 seconds to enter the parameters configuration menu: the display will show in sequence the set point value. the controller will return automatically to the normal operation mode. Parameter C8 C9 Description Condensate Drain Close Time Condensate Drain Open Time Range 1 to 999 (minutes) 1 to 999 (seconds) Default Value 1 D12-144IN D180IN D240-480IN 1 2 3 5.5. ©Ingersoll Rand Proprietary Information Page 23 . it will be possible to enter programming mode by pressing the SET key for 10 seconds the user should now be able to change all the parameters of the controller. 2008.7 MODIFICATION OF THE PARAMETERS To gain access to all parameters press the UP and DOWN keys together for 5 seconds. Only if strictly necessary. The LED display will the flash POn for 3 seconds once the parameter programming mode has been activated. Press the SET key to store the previously changed parameter value or to browse the parameters without changing them. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June. During normal operation only access to parameters C8 (Condensate close time) and C9 (Condensate open time) is allowed. the controller will again automatically block access to the parameters except for C8 and C9. the code of the first modifiable parameter (C8) and its value. use the UP and/or DOWN keys to change the displayed parameter value. 0…30. 2008. June.Pos.0 °C °F (0=exclude alarm) 0. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Par.…999 min 0.0…30.0 °C +14.0…30.9…+10.0 °C o °F 1…999 min 1…999 s 0=LtA 1=ESA -9.0…30.9…+10.0 °C °F (0= exclude alarm) 0.0 °C °F 0…999 s 0. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version.0…+50. ©Ingersoll Rand Proprietary Information Page 24 .0…999s fore switching to logarithmic control.0 °F 0.0 °C o °F 0=°C 1=°F 0 = integer 1= decimal 0…999 s Fan starting delay after compressor starting 0…999 s The number of HtA or Ht2 alarms within time C17 before ASt Maximum time for Ast alarm 0…20 0=Exclude Alarm ASt 0…999min Time the fan will run at minimum speed be. _C1 _C2 _C3 _C4 _C5 _C6 _C7 _C8 _C9 _C10 _C11 _C12 _C13 _C14 _C15 _C16 _C17 _tAt Description Setpoint High temperature differential alarm (In relation to C1) High temperature alarm delay Low temperature differential alarm (ESA) (In relation to C1) Restarting temperature differential from ESA (In relation to C4) Low temperature alarm delay Fan stop temperature differential (In relation to Setpoint C1) Condensate valve close time Condensate valve open time Visualization in case of low temperature alarm Temerature probe calibration (Offset) Unit of temperature Temperature Visualisation Resolution Compressor Starting Delay Range -9. 0 … 2. 2008. (Time Fan ESA) The time the fan will operate a 100 % before de-energizing the compressor when the dryer goes to the state of ESA (If tES = 0 = the function is disabled) ES2 temperature Mode of alarm ASt If the parameter is set to 0. If the parameter is set to 1.1…20. Fan speed increment 1…99 s 20 _tdI 1…99 s 21 22 _dFI _tEF 0.+14°F 0…1 28 _dSP Visualisation Mode 0=OMI 1=UtE If the parameter is set to OMI.-10°C -4°F…. In this eventuality the parameter must be set to ASt = 0 for the alarm to be reset 1…20 1…10 0…30 s 26 27 _tE2 _Ast -20°C…. Time to wait for the temperature to stabilize below the Setpoint before decreasing fan speed. The user can reset the alarm. The user cannot rest the alarm and the controller is locked.0 s age signal on startup (if parameter = 0 the function is disabled).19 _tSA Time to wait for the temperature to stabilize above the Setpoint before increasing fan speed. ©Ingersoll Rand Proprietary Information Page 25 . The dewpoint will be displayed in decimal ºC or ºF depending on the parameter C12 If the parameter is set to Ute (default) the dewpoint will be display as a bar graph D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 23 24 25 _MSP _CMI _tES Minimum fan speed Fan control constant.0 The time the fan will be supplied with a volt.0. June. The maximum time allowable in minutes for the temperature of the evaporator to be equal to or below the values C1-C4 before the alarm ESA. 7. Note the drain cycle will remain as standard. 6. C8 Condensate valve close time. Note the fan output will remain energized and the drain cycle will remain as standard. C4 Low temperature alarm differential.8 DESCRIPTION OF THE PARAMETERS 1.0 to 50 °F). C1 Setpoint. June. The warning will automatically be reset when the temperature of the evaporator is equal to C1-C4+C5 5. The low temperature alarm will reset when evaporator temperature exceeds C1-C4+C5. The maximum time allowable time in minutes for the temperature of the evaporator to be equal to or above values C1+C2 before fault HtA. C6 Low temperature alarm delay. 4. The minimum temperature allowed below Setpoint C1. The temperature which the dryer will automatically reset after an ESA alarm. 2. C3 High temperature alarm delay. 8. The maximum increase in temperature allowed above Setpoint C1. adjustable between -9.9ºC to +10. C7 Fan stop temperature differential If the temperature should fall bellow C1-C7 the controller will immediately de-energize the fan to stop freezing conditions. if the temperature fall below the Setpoint the controller will de-energize the fan. This is the temperature that the controller will vary the condensor fan speed to maintain. ©Ingersoll Rand Proprietary Information Page 26 . 2008. If the evaporator temperature is equal to or greater than C1+C2 for the time specified in parameter C3 the controller will de-energize the dryer compressor and fault HtA will be displayed on the LED display. if temperature of the evaporator rises above the Setpoint the controller will activate the fan and vary its speed to maintain the correct temperature.0 °C (14. The setpoint value of the temperature of the evaporator. C2 High temperature differential alarm.5. whilst in normal operation D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 3. Interval time in minutes that the condensate solenoid will remain closed (de-energized) during the condensate drain cycle. If the evaporator temperature is equal to or less than C1-C4 for the time specified in parameter C6 the controller will de-energize the dryer compressor and condenser fan and fault ESA will be displayed on the LED display. C5 Restarting temperature differential from ESA. or to 1 decimal place. The minimum time allowable between stopping and restarting the dryer compressor. In order to protect the dryer and the operator. 15. 0=Celsius 1=Fahrenheit 13.9. C16 Nº of HtA or Ht2 alarms within time C17 before ASt. 16. 2008. C12 Unit of Temperature. The minimu time delay in seconds before the fan will start after the dryer compressor has been activated. When the fan switches from 0 (fan stopped) to 1 MSP (Fan minimum speed) the fan will continue to run at minimum speed for the time of tAt before switching to algorithmic control. 12. C13 Temperature Visualization Resolution. A small time is not permitted in this parameter as this would cause the compressor to over heat and not give time for the refrigerant pressures to equalize. C9 Condensate valve open time. 18. ©Ingersoll Rand Proprietary Information Page 27 . The controller LED is able to show to different warning messages in case of low temperature LtA = Low Temperature Alarm and ESA = Energy Saving Activated. Adjustable between 0 and 20. The maximum time allowed that the programmed number of HtA or Ht2 alarms (C16) will be issued before ASt. C15 Fan starting delay. C11 Off Set. June. 10. C10 Visualization in case of low temperature alarm. C17 Maximum time for Ast alarm. The controller can display the actual evaporator temperature (see parameter 28). Used to calibrate the temperature sensor to the LED display (Sect. 0 = LtA 1=ESA 11. Interval time in seconds that the condensate valve will be energized (open) during the condensate drain cycle whilst in normal operation. xx). 0=Integer (whole number) 1=Decimal 14. If the parameter is set to 0 ASt alarm will be disabled. C14 Compressor start delay. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. If the dryer has repetitive alarms HtA or Ht2 the controller will issue an alarm ASt. (Default). 17. tAt Time before the fan switches to algorithmic control. The number can be displayed a a whole number rounded up or down accordingly. tSA Time to wait for the temperature to stabilize above the Setpoint before increasing fan speed.60IT Default Value 1 C9 D102– 170IT 2 1 -5.19. because of this some parameters on the new controller may have to be changed to ensure correct dryer performance.480IN See page 29 D-IT Units (D25IT .D180IN) Parameter C8 C9 C12 C11 Description Condensate Drain Close Time Condensate Drain Open Time Unit of Temperature Temperature probe calibration Range 1 to 999 (minutes) 1 to 999 (seconds) 0 .ºC 1 .0 REPLACING THE CONTROLLER In the event of failure the controller will need to replaced. All controllers are shipped from aftermarket in a standard configuration.9 to +10 D25. 2008.ºF -9. June.ºF -9.D170IT) Parameter C8 Description Condensate Drain Close Time Condensate Drain Open Time Unit of Temperature Temperature probe calibration Range 1 to 999 (minutes) 1 to 999 (seconds) 0 .9 to +10 D12-144IN Default Value 1 D180IN 1 50Hz Models 0 D12. tdI Time to wait for the temperature to stabilize below the Setpoint before decreasing fan speed 6. D-IN Units (D12IN . 20. ©Ingersoll Rand Proprietary Information Page 28 .4 3 C12 C11 D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version.ºC 1 .180IN No Adjustment 2 60hz Models 1 D240. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June.1 . whilst the condensing pressure is approximately 13. Attention must be paid to keep refrigerant losses to a minimum. After completion of setting.D480IN For models fitted with a Hot Gas By-pass Valve. Note the main LED should now have changed and be displaying the evaporator temperature in ºC for 50hz models (where 20 = 2.6.9 barg (196 . Press the controller UP and DOWN keys together for 5 seconds. Again not forgetting to press the SET key to confirm any changes. Change parameter C13 to: 1 (Decimal). Press the SET key until parameter C12 is displayed adjust this parameter using the UP or DOWN buttons to: 0 for 50hz models or 1 for 60hz models. Using the PT charts (see page 39) verify the reading on the LED display is aligned with the suction pressure.13. Change parameter Dsp to: OMI (temperature visualisation). otherwise using the method described in step 3 modify parameter C11 so that the LED display is equal to suction temperature. Install the charging manifold hoses onto the Schrader valves on the high and low pressure circuits. (See page 39). Once access is unlocked.0ºC) or in ºF for 60hz models. If necessary adjust the Hot Gas By-pass Valve to obtain a suction pressure of 2.2. Switch the dryer ON without any load.32 psig). 2. ©Ingersoll Rand Proprietary Information Page 29 .1 Calibration of the temperature probe D240IN . 5. Allow the dryer to operate for at least 5 minutes to allow the refrigerant temperatures and pressures to stabilise.202 psig). Note: adjust the screw of HGBV by a maximum of 5° angle and wait each time a minimum of 2 minutes before making further adjustments. if the controller has to be replaced the temperature probe must be calibrated to the suction pressure to ensure correct dryer performance. press the SET key for 10 seconds the user should now be able to change the parameters of the controller. 1. 7. Not forgetting to press the SET key to confirm any changes.2 barg (30 .5 . Please note if the power the to dryer has been removed there will be a 2 minute delay before the dryer starts. 3. If no further buttons are pressed the controller will save and exit from programming mode. 8. 6. To perform this operation correctly you will need a digital or analogue refrigerant charging manifold preferably with ball valve hoses (to keep refrigerant losses to a minimum) and a Pressure Temperature (PT) chart for R134a refrigerant. The LED display will the flash POn for 3 seconds to confirm that parameter programming mode has been activated. 9. 4. 2008. This warning will de-energise the refrigerant compressor and condenser fan. When the evaporator temperature rises to 6°C (42.8°F). 7. Increase compressed air low through the dryer. This alarm is immediate without any time delay.8°F). When the evaporator temperature rises to 6°C (42. Ensure that the temperature probe is correctly positioned under the insulation between the capillary device and evaporator.10. dsp=UtE. the outputs to the compressor and fan motor will be re–energised and the dryer will resume normal operation. however will not issue a general alarm and condensate drain cycle will remain as standard. Remove with care the instruments from circuit without leakages.4°F). the outputs to the compressor and fan motor should be re–energised and the dryer will resume normal operation. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. Set the controller with the parameters C12=1. 2008. To prevent freezing of the evaporator this warning will de-energise the refrigerant compressor and condenser fan. Probable Causes No or low compressed air load.0 WARNINGS Low Evaporator Temperature Warnings ESA This occurs when the evaporator temperature drops below -1°C (30. however will not issue a general alarm and condensate drain cycle will remain as standard. C13=0.8°F). Temperature probe incorrectly positioned. ES2 This occurs should the evaporator temperature drop below -18°C (-0. June. ©Ingersoll Rand Proprietary Information Page 30 .2°F) for a period of 5 minutes. the unit should automatically re-start once evaporator temperature reaches 6°C (42. Temperature probe incorrectly positioned. Condenser dirty Check that the airflow through the condenser is not obstructed. This is an immediate alarm without any delay. ©Ingersoll Rand Proprietary Information Page 31 . Probable Causes High compressed air load.Temperature probe incorrectly calibrated.0 ALARMS High Evaporator Temperature Alarms HtA This alarm occurs when the evaporator temperature reaches 14. Low refrigerant charge. In case of doubt contact your Ingersoll Rand service department.5°C (58. the condensate drain cycle will remain as standard. June. 8. clean if necessary. Reset manually from the control panel by pressing ON / OFF button on the controller. The controller will active the general alarm output and deenergise the refrigerant compressor the condenser fan will be energised at full speed for a period of 10 seconds. Using a service manifold check the high and low refrigerant pressures. The controller will active the general alarm output and de-energise the refrigerant compressor the condenser fan will be energised at full speed for a period of 10 seconds.1°F) for a period of 6 minutes. temperature and pressure of the incoming compressed air are with the working parameters of the dryer. 2008. Ht2 This alarm occurs should the evaporator temperature reaches 45°C (113°F). High ambient temperature Check that the ambient conditions are not exceeding the working parameters of the dryer. 50°C (122°F). See page 29 for calibration procedure. Ensure that the temperature probe is correctly positioned under the insulation between the capillary device and evaporator. As this is an alarm it must be reset manually from the control panel by pressing ON / OFF button on the controller. the condensate drain cycle will remain as standard. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. Using the technical data sheets and the correction factor tables check the volume flow. June. ©Ingersoll Rand Proprietary Information Page 32 . if the switch is defective it will need to be replaced care will need to be taken when removing the switch from the Schrader connection to avoid damage to pipe work and keep refrigerant losses to a minimum.Temperature probe incorrectly calibrated. Pin 5 D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. if no voltage is detected the controller is defective and will need to be replaced if the correct voltage is detected replace the condenser fan. See page 29 for calibration procedure. If the fan fails to operate check the wiring to the fan from the controller if no loose wires are detected. remove the outputs plug on the back of the controller and carefully check for a 230vac output for 50hz models or 115vac for 60hz models on pin 5. High pressure switch tripped or defective. All units are fitted with a 30 bar (435 psi) pressure switch fitted with a manual reset button check if the switch has tripped and check wiring to and from the switch. 2008. Manual Reset Defective Condenser Fan Using the Autotest function (See page 22) carefully check the outputs from the controller to the condenser fan. 2008. See page 35 relating to evacuation and recharging procedures. In case of doubt contact your Ingersoll Rand service department. Using a service manifold check the high and low refrigerant pressures. If replacing a refrigerant compressor it will be necessary to replace the drier filter also. Defective temperature probe Remove temperature probe from the dryer. Probable Causes Loose connection Check for loose connections between the controller and the PTC temperature probe. if the resistance is not within the range of the temperatures or the probe is open circuit. Defective Refrigerant Compressor Check the current draw and head temperature of the compressor if excessive the compressor will need to be replaced. Temperature Probe Connection Incorrectly calibrated temperature probe See page 29 for correct probe calibration procedures. June.Low refrigerant charge. the probe is defective and will need to be replaced. using the resistance charts (See page 37) measure the resistance across the probe. Temperature Probe Error PF1 This fault occurs when the controller cannot read a resistance within an acceptable range from the PTC temperature probe. ©Ingersoll Rand Proprietary Information Page 33 . D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. Clean the condensate drainage system pre-filter. clean if necessary. Check the C8 and C9 parameters of the electronic control board (see section xx for correct drain valve settings) Carefully check for an output on Pin 1 on the controller outputs socket whilst activating the condensate drain test if no voltage is detected replace the controller. Using the technical data sheets and the correction factor tables check the volume flow. Condenser dirty Check that the airflow through the condenser is not obstructed. Coil Pre-filter Replace the coil of the drainage solenoid valve if burned. Clean or replace the drainage solenoid valve if clogged/jammed. Condensate drain not functioning. 50°C (122°F). June. 2008. ©Ingersoll Rand Proprietary Information Page 34 .Water in the system (High Pressure Dew Point) Probable Causes High compressed air load. High ambient temperature Check that the ambient conditions are not exceeding the working parameters of the dryer. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. temperature and pressure of the incoming compressed air are with the working parameters of the dryer. 2008. A large rise would be a sign of a leak. June.0 DEHYDRATION AND EVACUATION PROCEDURE This procedure describes the minimum operations that have to be done in order to obtain a reliable dehydration and vacuum of the refrigeration system. be sure that refrigeration system is dehydrated and evacuated! WARNING: Never exceed the normal charge. the compressor can be seriously damaged. For correct refrigerant charge see the technical data sheets. These procedures must only be carried out by qualified personnel holding the correct licenses in accordance with local legislation. in case of doubt contact your Ingersoll rand service team. Dehydrate the circuit by pulling it under vacuum using the double vacuum procedure. If an ASt alarm occurs follow the troubleshooting procedures for Hta or HT2. In cases of overcharging. The alarm is to protect the operator from injury and equipment from damage.4 barg (5psi). Flush system by breaking the vacuum with dry nitrogen and bringing the system pressure to 0. The Ast alarm is re-settable by pressing the ON / OFF key. 9. Equipment Required -Filling cylinder R134a -Service manifold with high and low pressure gauges -Filling hoses (no loss fitting) -Weight scale -Micron gauge for testing vacuum NOTE: Before charging. Second evacuation: Pull down the entire system to 500 microns and hold for 10 minutes with minimal rise in microns. WARNING: Do not run compressor while under vacuum as it will cause the compressor motor to burn out. Use a large diameter hose to connect the vacuum pump to the system and keep it as short as possible. ©Ingersoll Rand Proprietary Information Page 35 . D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. First evacuation: Fit the vacuum hose to vacuum pump and the refrigerant system and evacuate the system until a minimum vacuum is reached of 1500 microns.ASt An ASt alarm occurs when there are three HTA or HT2 alarms within a one hour period. Refrigerant Charging: This procedure describes the minimum operations that need to be completed to successfully charge dryers with the correct quantity of refrigerant. Establish the correct amount of R134a to be added to the system. Start the unit. an excess of oil is as dangerous as a lack of oil. 8. follow these next steps. (Normally the refrigerant flows by itself into the system. Connect the charging hose to the refrigerant-charging bottle. on units D12IN D180IN it will be necessary to remove the high refrigerant pressure switch to gain access to the high pressure Schrader connector. Once the unit is fully charged. Open the suction-side valve and slowly weigh in the rest of the charge. 2. 2008. only add original polyolester compressor oil. open the high side gauge valve. Where there has been a severe oil leak. The charging hose should have no loss fittings. you can warm up the charging bottle by using warm water) WARNING: Do not use a blow torch or naked flames. the system was not properly charged or evacuated. 3. 2. ©Ingersoll Rand Proprietary Information Page 36 . which should be placed on a suitable scale for weighing the charge. Connect the service manifold to the suction line on the compressor for low pressure and to the discharge line for the high pressure. With the charging bottle on the scale. Close the high side valve. Remember. This may already be done during the evacuation process. close the valves on the gauges and on the charging bottle. if not. Compressor Oil: For normal working conditions there is no need to remove or add oil to a compressor. June. If the hose does not have no loss fittings. 4. Open the valve on the charging bottle. Adding oil must be done on the suction side with a special oil pump to overcome the refrigerant pressure. Remove the gauges and refit the appropriate caps. 3.Charging Procedure 1. 1. if not. Follow the pump directions or. 5. You should have at least 90% of the full charge in the system. Start the unit if not already running. 4. 6. NOTE: If the flow of refrigerant stops before the unit is fully charged. the hose will need to be purged first. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. Calculate how much more will be needed too fully charge the system. or in case of doubt contact your Ingersoll Rand service department. 5. 2008.10. June.0 KTY81-121 RESISTANCE CHART D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 37 . June.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 38 . 2008. ©Ingersoll Rand Proprietary Information Page 39 . 2008.11. June.0 Pressure Temperature Charts D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. R134a Pressure Temperature Chart (Bara / ºC) Note: Pressures in bar are Actual Not Gauge D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 40 . 2008. June. ©Ingersoll Rand Proprietary Information Page 41 . June. 2008.Pressure Temperature Chart (psig / ºF) D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 42 .THIS PAGE IS LEFT INTENTIONALLY BLANK D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. June. 12. June.0 Default Controller Settings D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. ©Ingersoll Rand Proprietary Information Page 43 . June. ©Ingersoll Rand Proprietary Information Page 44 . 2008.Default Controller Parameters 50hz Models D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. Default Controller Parameters 60hz Models D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. ©Ingersoll Rand Proprietary Information Page 45 . June. ©Ingersoll Rand Proprietary Information Page 46 .D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June. 2008. Dryer performance is guaranteed at nominal rating only. 2008.85 x .96 / 1.7 4/ 58 0.71 122 / 50 0. June.11 10 / 145 1.92 x 1.42 Ambient Temperature Ambient Air Temperature (°C / °F) Correction Factor 25 / 77 1 30 / 86 0.06 9 / 131 1. Correction Factors D12IN to D480IN Inlet Temperature Inlet Air Temperature (°F / °C) Correction Factor 86 / 30 1. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version.06 = 249 m3/hr To select a dryer basis system flow – take the required system flow and divide by the appropriate factors.2 95 / 35 1 104 / 40 0.85 6/ 87 0.71 / .92 40 / 104 0. Example: D300IN has nominal capacity of 300 m3/hr. The corrected flow will be 200 / . Note: Correction factors are to be used for general sizing guidance. Example: Requirement is 200 m3/min at inlet temperature of 45°C. At an inlet temperature of 40°C.78 5/ 78 0.56 131 / 55 0. The new capacity of this dryer is 300 x .15 12 / 174 1. ©Ingersoll Rand Proprietary Information Page 47 . ambient temperature of 35°C and pressure of 8 barg. Select the closest dryer rated above 264: choose the D300IN.88 42 / 108 0.11 = 264 m3/hr.85 113 / 45 0.76 Inlet Pressure Inlet Pressure (barg / psig) Correction Factor 3/ 44 0.24 How to use the factors: To determine the capacity of a dryer at non standard conditions – take the nominal rated flow and multiply by the appropriate correction factors.93 7 / 102 1 8 / 116 1.2 14 / 203 1. ambient temperature of 30°C and pressure of 9 barg.85 45 / 113 0.13.96 35 / 95 0. ©Ingersoll Rand Proprietary Information Page 48 . 2008. June.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 14. TECHNICAL DATA SHEETS 50hz Models D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. ©Ingersoll Rand Proprietary Information Page 49 . June. June. 2008. ©Ingersoll Rand Proprietary Information Page 50 .D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. June. ©Ingersoll Rand Proprietary Information Page 51 . D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 52 . 2008. June. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June. 2008. ©Ingersoll Rand Proprietary Information Page 53 . June.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 54 . 2008. ©Ingersoll Rand Proprietary Information Page 55 . 2008. June.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June. ©Ingersoll Rand Proprietary Information Page 56 .D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. ©Ingersoll Rand Proprietary Information Page 57 .D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. June. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 58 . 2008. June. June. ©Ingersoll Rand Proprietary Information Page 59 .D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. June. ©Ingersoll Rand Proprietary Information Page 60 . 2008.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. ©Ingersoll Rand Proprietary Information Page 61 . June.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. June. ©Ingersoll Rand Proprietary Information Page 62 . June. 2008. ©Ingersoll Rand Proprietary Information Page 63 .TECHNICAL DATA SHEETS 60hz Models D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 64 . 2008. June.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June. ©Ingersoll Rand Proprietary Information Page 65 . 2008.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June. 2008.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 66 . D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 67 . 2008. June. ©Ingersoll Rand Proprietary Information Page 68 . June. 2008.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June. ©Ingersoll Rand Proprietary Information Page 69 .D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. June. 2008. ©Ingersoll Rand Proprietary Information Page 70 .D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 71 . 2008. June.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 72 . 2008. June. ©Ingersoll Rand Proprietary Information Page 73 .D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. ©Ingersoll Rand Proprietary Information Page 74 . June. June. 2008. ©Ingersoll Rand Proprietary Information Page 75 .D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. June.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 76 . D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 77 . 2008. June. 2008.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 78 . June. 2008.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. June. ©Ingersoll Rand Proprietary Information Page 79 . June. ©Ingersoll Rand Proprietary Information Page 80 .D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008. 0 MATERIAL SAFETY DATA SHEETS R134a D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008.15. June. ©Ingersoll Rand Proprietary Information Page 81 . D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. ©Ingersoll Rand Proprietary Information Page 82 D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. ©Ingersoll Rand Proprietary Information Page 83 D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. ©Ingersoll Rand Proprietary Information Page 84 D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. ©Ingersoll Rand Proprietary Information Page 85 2008. June. ©Ingersoll Rand Proprietary Information Page 86 .D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. ©Ingersoll Rand Proprietary Information Page 87 . June.D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version. 2008.