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D12IN to D480IN Refrigerated Dryers

D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. Ingersoll Rand Proprietary Information

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D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. Ingersoll Rand Proprietary Information

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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/C Psig/F 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

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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

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2. REFRIGERATION CIRCUITS

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Models D12IN to D180IN

Models D240IN to D480IN

D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. Ingersoll Rand Proprietary Information

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3.

COMPONENT REVIEW D12IN D480IN

1M1 Refrigerant Compressor. 1M2 Condenser Fan Motor. CND Condenser. 1P1 High Pressure Switch. This switch protects the refrigeration system in the event of an overpressure condition within the refrigeration circuit. This switch is set to 30 bar ( 435 psi ) FF Dryer Filter. CPL Capillary Tube. EVA Evaporator. (See Air to Air and Refrigerant to Air Exchanger, Page 8) SCO Condensate Separator. 1V1 Solenoid Drain Valve. (230vac for 50hz models, 115vac for 60htz models) PR Air-to-Air Heat Exchanger. RBF Tap with Strainer ( D240IN to D480IN Only ). VB Hot Gas By-Pass Valve ( D240IN to D480IN Only ). The HGBP valve should be set to maintain between 2.1 - 2.2 barg (30 - 32 psig), depending on site and ambient conditions. As the air compressor modulates or goes online/offline, the compressed air capacity entering the dryer fluctuates. It should be noted that dryer loading can apply not only to capacity changes but thermal load changes due to varying conditions. The dryer must be able to adjust to these varying capacities and maintains performance. All models perform within a wide range of ambient and compressed air temperatures, ensuring optimum performance whatever the application if properly sized for the application. In D-IN/T dryers, refrigerant constantly flows through the evaporator. The flow varies dependent on the percentage of rated air capacity flowing through the dryer. See page 29 for correct adjustment procedures.

D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. Ingersoll Rand Proprietary Information

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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 - D180IN and a vertically mounted on models D240IN and above (see illustration. The air-to-air heat exchanger pre-cools the incoming air and re-heats the outgoing air, giving a high overall efficiency. This cools the incoming compressed air, reducing the amount of refrigeration energy needed to dry the compressed air. The re-heater section raises the temperature of the outgoing compressed air, protecting the dew point, decreasing the relative humidity and eliminating condensation on downstream air piping.

Air to Air Heat Exchanger

Air to Refrigerant Heat Exchanger

A large expansion chamber slows the compressed air down to its critical velocity, forcing moisture to condense. This design ensures maximum separator efficiency across the entire flow range. Liquid water in the air is removed by a high efficiency demister separator.

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4. ELECTRICAL CIRCUITS

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Models D12IN to D72IN (230v/1Ph/50Hz)

D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. Ingersoll Rand Proprietary Information

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Models D108IN to D180IN (230v/1Ph/50Hz)

D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. Ingersoll Rand Proprietary Information

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Models D240IN (230v/1Ph/50Hz)

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Models D300IN to D380IN (230v/1Ph/50Hz)

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Models D480 (230v/1Ph/50Hz)

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Models D12IN to D72IN (115v/1Ph/60Hz)

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Models D108IN to D180IN (115v/1Ph/60Hz)

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Models D300IN to D360IN (230v/1Ph/60Hz)

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5. D12IN to D480IN CONTROLLER

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Controller D12IN to D480IN

5.1

GENERAL DESCRIPTION

The controller controls all relative procedures in starting and stopping the refrigerant compressor. The controller will display in C or F. The controller checks the machine and returns diagnostic information in the presence of a malfunction. The controller also monitors the evaporation temperature via a highly sensitive temperature probe this allows the controller to govern the condenser fan motor speed. A patented microprocessor allows dryers cooling capacity to be adjusted, by changing the fan motor speed. The controller will vary the speed of the condenser fan based on the actual evaporator temperature and the programmed evaporator Setpoint. The default value for the Setpoint is 0.5C (32.9F) if the evaporator temperature is below the setpoint the condensor fan will be off, if the temperature rises above the setpoint the controller will firstly energise the fan for 0.5 seconds (Models D12IN to D180IN) or 2 seconds (Models D240IN and above), then switch to alogarithic control. 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. The controller constantly mointors evaporator temperature and adjusts the frequency of the wave trains accordingly to maintain the correct temperature.

D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. Ingersoll Rand Proprietary Information

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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. It is the frequency and length of the pulses or wave trains that change the fan speed. In models D240IN to D480IN, in order to greater adjust the dryers cooling capacity, a hot gas by-pass valve cooperates with the variable speed system. 5.2 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. Please note there will be a two minute delay before the dryer restart after power has be restored. Attention: Automatic restart after power outage cannot be disabled from the controller, if it is a requirement for the dryer not to automatically re-start after power failure. The dryer must be connected to a suitable device with a manual reset that will trip on power loss. 5.3 LED DISPLAY DISPLAY DESCRIPTION the unit is ON with low load and the measured temperature is less than -1C the unit is ON with normal load and the measured temperature is between -1C and +4C the unit is ON with normal-high load and the measured temperature is between +4C and +8C the unit is ON with high load and the measured temperature is above +8C 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
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D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. Ingersoll Rand Proprietary Information

5.4 FUNCTIONALITY OF THE KEYS TEST: When pressed for 3 sec. during normal operation, it will activate the condensate drain. SET: When pressed and released during normal operation, it displays the evaporator set value in decimal the default value is 0.5C (32.9F) When pushed for 10 seconds, it allows the user to change the C8 and C9 condensate drain parameters programming menu (see relevant table). When pushed after having set new configuration values, it stores the applied modifications. DOWN: When pressed while setting the drain set point, it decreases the displayed value of one unit per second, during the first 10 seconds, then one unit every 0,1 sec. When pushed for 10 seconds during normal operation, it starts an automatic test cycle of the controller. UP: When pressed while setting the drain set point, it increases the displayed value of one unit per second, during the first 10 seconds, then one unit every 0,1 sec. ON / OFF: When pressed for 1 second, it activates or deactivates the dryer. When the dryer is deactivated, the LED display will read OFF.

NOTE: When the controller is in the OFF position, some parts of the dryer may still be energized. Therefore, for safety purposes, disconnect the electrical power before performing any operation on the unit.
5.5 AUTOTEST FUNCTION

An auto test function allows the user to test the functionality of the controller and the components connected to it, 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 LEDs, then test in sequence outputs to the compressor, condensate drain, condenser fan then the alarm output (if fitted). It will then illuminate all the characters on the LED character display, and finally display the firmware version of the controller. e.g. d10 = firmware version 1.0. If, whilst display the firmware a key is pressed then the display will show F1 through to F5 dependant on which key is pressed. If after 5 seconds no key is pressed once the LED has displayed the firmware version, the controller will revert back to standard operation.
D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. Ingersoll Rand Proprietary Information Page 22

5.6 CONDENSATE DISCHARGE PARAMETERS. During normal operation only access to parameters C8 (Condensate close time) and C9 (Condensate open time) is allowed, access to all other parameters is disabled. 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 code of the first modifiable parameter (C8) and its value. Only if strictly necessary, use the UP and/or DOWN keys to change the displayed parameter value. Press the SET key to store the previously changed parameter value or to browse the parameters without changing them. 15 seconds after the last performed operation, 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

5.7 MODIFICATION OF THE PARAMETERS To gain access to all parameters press the UP and DOWN keys together for 5 seconds. The LED display will the flash POn for 3 seconds once the parameter programming mode has been activated. Once access is unlocked, 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. After programming has been completed, the controller will again automatically block access to the parameters except for C8 and C9. To change any further parameters the programming mode will have to be reactivated by following the procedure above.

D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. Ingersoll Rand Proprietary Information

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Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Par. _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 -9.9+10.0 C +14.0+50.0 F 0.030.0 C F (0=exclude alarm) 0.999 min 0.030.0 C F (0= exclude alarm) 0.030.0 C F 0999 s 0.030.0 C o F 1999 min 1999 s 0=LtA 1=ESA -9.9+10.0 C o F 0=C 1=F 0 = integer 1= decimal 0999 s

Fan starting delay after compressor starting 0999 s The number of HtA or Ht2 alarms within time C17 before ASt Maximum time for Ast alarm 020 0=Exclude Alarm ASt 0999min

Time the fan will run at minimum speed be- 0999s fore switching to logarithmic control,

D-IN Dryers Service Manual Ingersoll Rand Global Service Education Team Draft Version, June, 2008. Ingersoll Rand Proprietary Information

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19

_tSA

Time to wait for the temperature to stabilize above the Setpoint before increasing fan speed. Time to wait for the temperature to stabilize below the Setpoint before decreasing fan speed. Fan speed increment

199 s

20

_tdI

199 s

21 22

_dFI _tEF

0.120.0

The time the fan will be supplied with a volt- 0.0 2.0 s age signal on startup (if parameter = 0 the function is disabled).

23 24 25

_MSP _CMI _tES

Minimum fan speed Fan control constant. (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. The user can reset the alarm. If the parameter is set to 1. The user cannot rest the alarm and the controller is locked. In this eventuality the parameter must be set to ASt = 0 for the alarm to be reset

120 110 030 s

26 27

_tE2 _Ast

-20C.-10C -4F.+14F 01

28

_dSP

Visualisation Mode 0=OMI 1=UtE If the parameter is set to OMI. The dewpoint will be displayed in decimal C or F depending on the parameter C12 If the parameter is set to Ute (default) the dewpoint will be display as a bar graph

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5.8 DESCRIPTION OF THE PARAMETERS 1. C1 Setpoint. The setpoint value of the temperature of the evaporator, adjustable between -9.9C to +10.0 C (14.0 to 50 F). This is the temperature that the controller will vary the condensor fan speed to maintain. if temperature of the evaporator rises above the Setpoint the controller will activate the fan and vary its speed to maintain the correct temperature, if the temperature fall below the Setpoint the controller will de-energize the fan. 2. C2 High temperature differential alarm. The maximum increase in temperature allowed above Setpoint C1. 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. Note the fan output will remain energized and the drain cycle will remain as standard. 3. C3 High temperature alarm delay. 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. 4. C4 Low temperature alarm differential. The minimum temperature allowed below Setpoint C1. 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. Note the drain cycle will remain as standard. The warning will automatically be reset when the temperature of the evaporator is equal to C1-C4+C5 5. C5 Restarting temperature differential from ESA. The temperature which the dryer will automatically reset after an ESA alarm. The low temperature alarm will reset when evaporator temperature exceeds C1-C4+C5. 6. C6 Low temperature alarm delay. 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. 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. 8. C8 Condensate valve close time. Interval time in minutes that the condensate solenoid will remain closed (de-energized) during the condensate drain cycle, whilst in normal operation

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9. C9 Condensate valve open time. Interval time in seconds that the condensate valve will be energized (open) during the condensate drain cycle whilst in normal operation. 10. C10 Visualization in case of low temperature alarm. 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. (Default). 0 = LtA 1=ESA 11. C11 Off Set. Used to calibrate the temperature sensor to the LED display (Sect. xx). 12. C12 Unit of Temperature. 0=Celsius 1=Fahrenheit 13. C13 Temperature Visualization Resolution. The controller can display the actual evaporator temperature (see parameter 28). The number can be displayed a a whole number rounded up or down accordingly, or to 1 decimal place. 0=Integer (whole number) 1=Decimal 14. C14 Compressor start delay. The minimum time allowable between stopping and restarting the dryer compressor. 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. 15. C15 Fan starting delay. The minimu time delay in seconds before the fan will start after the dryer compressor has been activated. 16. C16 N of HtA or Ht2 alarms within time C17 before ASt. In order to protect the dryer and the operator. If the dryer has repetitive alarms HtA or Ht2 the controller will issue an alarm ASt. Adjustable between 0 and 20. If the parameter is set to 0 ASt alarm will be disabled. 17. C17 Maximum time for Ast alarm. The maximum time allowed that the programmed number of HtA or Ht2 alarms (C16) will be issued before ASt. 18. tAt Time before the fan switches to algorithmic control. 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.

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19. tSA Time to wait for the temperature to stabilize above the Setpoint before increasing fan speed. 20. tdI Time to wait for the temperature to stabilize below the Setpoint before decreasing fan speed 6.0 REPLACING THE CONTROLLER In the event of failure the controller will need to replaced. All controllers are shipped from aftermarket in a standard configuration, because of this some parameters on the new controller may have to be changed to ensure correct dryer performance. D-IN Units (D12IN - 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 - C 1 - F -9.9 to +10
D12-144IN

Default Value 1
D180IN

1 50Hz Models 0
D12- 180IN No Adjustment

2 60hz Models 1
D240- 480IN See page 29

D-IT Units (D25IT - 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 - C 1 - F -9.9 to +10
D25- 60IT

Default Value 1

C9

D102 170IT

2 1 -5.4

C12 C11

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6.1 Calibration of the temperature probe D240IN - D480IN For models fitted with a Hot Gas By-pass Valve, if the controller has to be replaced the temperature probe must be calibrated to the suction pressure to ensure correct dryer performance. 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. (See page 39). 1. Install the charging manifold hoses onto the Schrader valves on the high and low pressure circuits. Attention must be paid to keep refrigerant losses to a minimum. Switch the dryer ON without any load. Please note if the power the to dryer has been removed there will be a 2 minute delay before the dryer starts. Press the controller UP and DOWN keys together for 5 seconds. The LED display will the flash POn for 3 seconds to confirm that parameter programming mode has been activated. Once access is unlocked, press the SET key for 10 seconds the user should now be able to change the parameters of the controller. 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. Not forgetting to press the SET key to confirm any changes. Change parameter C13 to: 1 (Decimal). Change parameter Dsp to: OMI (temperature visualisation). Again not forgetting to press the SET key to confirm any changes. If no further buttons are pressed the controller will save and exit from programming mode. Note the main LED should now have changed and be displaying the evaporator temperature in C for 50hz models (where 20 = 2.0C) or in F for 60hz models. Allow the dryer to operate for at least 5 minutes to allow the refrigerant temperatures and pressures to stabilise. If necessary adjust the Hot Gas By-pass Valve to obtain a suction pressure of 2.1 - 2.2 barg (30 - 32 psig), whilst the condensing pressure is approximately 13.5 - 13.9 barg (196 - 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. After completion of setting. Using the PT charts (see page 39) verify the reading on the LED display is aligned with the suction pressure, otherwise using the method described in step 3 modify parameter C11 so that the LED display is equal to suction temperature.

2. 3.

4.

5.

6.

7. 8.

9.

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10. Set the controller with the parameters C12=1, C13=0, dsp=UtE. Remove with care the instruments from circuit without leakages. 7.0 WARNINGS Low Evaporator Temperature Warnings ESA This occurs when the evaporator temperature drops below -1C (30.2F) for a period of 5 minutes. To prevent freezing of the evaporator this warning will de-energise the refrigerant compressor and condenser fan, however will not issue a general alarm and condensate drain cycle will remain as standard. When the evaporator temperature rises to 6C (42.8F), the outputs to the compressor and fan motor should be reenergised and the dryer will resume normal operation. ES2 This occurs should the evaporator temperature drop below -18C (-0.4F). This alarm is immediate without any time delay. This warning will de-energise the refrigerant compressor and condenser fan, however will not issue a general alarm and condensate drain cycle will remain as standard. When the evaporator temperature rises to 6C (42.8F), the outputs to the compressor and fan motor will be reenergised and the dryer will resume normal operation. Probable Causes No or low compressed air load. Increase compressed air low through the dryer, the unit should automatically re-start once evaporator temperature reaches 6C (42.8F). Temperature probe incorrectly positioned. Ensure that the temperature probe is correctly positioned under the insulation between the capillary device and evaporator.

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Temperature probe incorrectly calibrated. See page 29 for calibration procedure. Low refrigerant charge. Using a service manifold check the high and low refrigerant pressures. In case of doubt contact your Ingersoll Rand service department. 8.0 ALARMS High Evaporator Temperature Alarms HtA This alarm occurs when the evaporator temperature reaches 14.5C (58.1F) for a period of 6 minutes. 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, the condensate drain cycle will remain as standard. As this is an alarm it must be reset manually from the control panel by pressing ON / OFF button on the controller. Ht2 This alarm occurs should the evaporator temperature reaches 45C (113F). This is an immediate alarm without any delay. 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, the condensate drain cycle will remain as standard. Reset manually from the control panel by pressing ON / OFF button on the controller. Probable Causes High compressed air load. Using the technical data sheets and the correction factor tables check the volume flow, temperature and pressure of the incoming compressed air are with the working parameters of the dryer. Condenser dirty Check that the airflow through the condenser is not obstructed, clean if necessary. High ambient temperature Check that the ambient conditions are not exceeding the working parameters of the dryer. 50C (122F). Temperature probe incorrectly positioned. Ensure that the temperature probe is correctly positioned under the insulation between the capillary device and evaporator.

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Temperature probe incorrectly calibrated. See page 29 for calibration procedure. 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, 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.

Manual Reset

Defective Condenser Fan Using the Autotest function (See page 22) carefully check the outputs from the controller to the condenser fan. 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. 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.

Pin 5

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Low refrigerant charge. Using a service manifold check the high and low refrigerant pressures. In case of doubt contact your Ingersoll Rand service department. Defective Refrigerant Compressor Check the current draw and head temperature of the compressor if excessive the compressor will need to be replaced. If replacing a refrigerant compressor it will be necessary to replace the drier filter also. See page 35 relating to evacuation and recharging procedures. Temperature Probe Error PF1 This fault occurs when the controller cannot read a resistance within an acceptable range from the PTC temperature probe. Probable Causes Loose connection Check for loose connections between the controller and the PTC temperature probe.

Temperature Probe Connection

Incorrectly calibrated temperature probe See page 29 for correct probe calibration procedures. Defective temperature probe Remove temperature probe from the dryer, using the resistance charts (See page 37) measure the resistance across the probe, if the resistance is not within the range of the temperatures or the probe is open circuit, the probe is defective and will need to be replaced.

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Water in the system (High Pressure Dew Point) Probable Causes High compressed air load. Using the technical data sheets and the correction factor tables check the volume flow, temperature and pressure of the incoming compressed air are with the working parameters of the dryer. Condenser dirty Check that the airflow through the condenser is not obstructed, clean if necessary. High ambient temperature Check that the ambient conditions are not exceeding the working parameters of the dryer. 50C (122F). Condensate drain not functioning. Clean the condensate drainage system pre-filter.

Coil

Pre-filter

Replace the coil of the drainage solenoid valve if burned. Clean or replace the drainage solenoid valve if clogged/jammed. 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.

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ASt An ASt alarm occurs when there are three HTA or HT2 alarms within a one hour period. The alarm is to protect the operator from injury and equipment from damage. If an ASt alarm occurs follow the troubleshooting procedures for Hta or HT2, in case of doubt contact your Ingersoll rand service team. The Ast alarm is re-settable by pressing the ON / OFF key. 9.0 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. Dehydrate the circuit by pulling it under vacuum using the double vacuum procedure. 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. Use a large diameter hose to connect the vacuum pump to the system and keep it as short as possible. Flush system by breaking the vacuum with dry nitrogen and bringing the system pressure to 0.4 barg (5psi). Second evacuation: Pull down the entire system to 500 microns and hold for 10 minutes with minimal rise in microns. A large rise would be a sign of a leak. WARNING: Do not run compressor while under vacuum as it will cause the compressor motor to burn out. Refrigerant Charging: This procedure describes the minimum operations that need to be completed to successfully charge dryers with the correct quantity of refrigerant. These procedures must only be carried out by qualified personnel holding the correct licenses in accordance with local legislation. 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, be sure that refrigeration system is dehydrated and evacuated! WARNING: Never exceed the normal charge. In cases of overcharging, the compressor can be seriously damaged. For correct refrigerant charge see the technical data sheets.
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Charging Procedure 1. Connect the service manifold to the suction line on the compressor for low pressure and to the discharge line for the high pressure, on units D12IN D180IN it will be necessary to remove the high refrigerant pressure switch to gain access to the high pressure Schrader connector. This may already be done during the evacuation process. Connect the charging hose to the refrigerant-charging bottle, which should be placed on a suitable scale for weighing the charge. Open the valve on the charging bottle. Establish the correct amount of R134a to be added to the system. The charging hose should have no loss fittings. If the hose does not have no loss fittings, the hose will need to be purged first. With the charging bottle on the scale, open the high side gauge valve. (Normally the refrigerant flows by itself into the system, if not, you can warm up the charging bottle by using warm water) WARNING: Do not use a blow torch or naked flames.

2.

3. 4. 5.

NOTE: If the flow of refrigerant stops before the unit is fully charged, follow these next steps. You should have at least 90% of the full charge in the system, if not, the system was not properly charged or evacuated. 1. 2. 3. 4. 5. 6. 8. Close the high side valve. Calculate how much more will be needed too fully charge the system. Start the unit. Open the suction-side valve and slowly weigh in the rest of the charge. Once the unit is fully charged, close the valves on the gauges and on the charging bottle. Start the unit if not already running. Remove the gauges and refit the appropriate caps.

Compressor Oil: For normal working conditions there is no need to remove or add oil to a compressor. Remember, an excess of oil is as dangerous as a lack of oil. Where there has been a severe oil leak, only add original polyolester compressor oil. Adding oil must be done on the suction side with a special oil pump to overcome the refrigerant pressure. Follow the pump directions or, or in case of doubt contact your Ingersoll Rand service department.

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10.0 KTY81-121 RESISTANCE CHART

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11.0 Pressure Temperature Charts

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R134a Pressure Temperature Chart (Bara / C)


Note: Pressures in bar are Actual Not Gauge

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Pressure Temperature Chart (psig / F)

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12.0 Default Controller Settings

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Default Controller Parameters 50hz Models

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Default Controller Parameters 60hz Models

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13. Correction Factors

D12IN to D480IN
Inlet Temperature
Inlet Air Temperature (F / C) Correction Factor 86 / 30 1.2 95 / 35 1 104 / 40 0.85 113 / 45 0.71 122 / 50 0.56 131 / 55 0.42

Ambient Temperature
Ambient Air Temperature (C / F) Correction Factor 25 / 77 1 30 / 86 0.96 35 / 95 0.92 40 / 104 0.88 42 / 108 0.85 45 / 113 0.76

Inlet Pressure
Inlet Pressure (barg / psig) Correction Factor 3/ 44 0.7 4/ 58 0.78 5/ 78 0.85 6/ 87 0.93 7 / 102 1 8 / 116 1.06 9 / 131 1.11 10 / 145 1.15 12 / 174 1.2 14 / 203 1.24

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. Example: D300IN has nominal capacity of 300 m3/hr. At an inlet temperature of 40C, ambient temperature of 35C and pressure of 8 barg. The new capacity of this dryer is 300 x .85 x .92 x 1.06 = 249 m3/hr To select a dryer basis system flow take the required system flow and divide by the appropriate factors. Example: Requirement is 200 m3/min at inlet temperature of 45C, ambient temperature of 30C and pressure of 9 barg. The corrected flow will be 200 / .71 / .96 / 1.11 = 264 m3/hr. Select the closest dryer rated above 264: choose the D300IN. Note: Correction factors are to be used for general sizing guidance. Dryer performance is guaranteed at nominal rating only.

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14. TECHNICAL DATA SHEETS 50hz Models

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TECHNICAL DATA SHEETS 60hz Models

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15.0 MATERIAL SAFETY DATA SHEETS R134a

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