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D12IN to D480IN Refrigerated Dryer Service Manual

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Text of D12IN to D480IN Refrigerated Dryer Service Manual

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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CONTENTS1. 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

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

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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

W

D

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.

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

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4. ELECTRICAL CIRCUITS

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

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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)

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

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Models D300IN to D380IN (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 D480 (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 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

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

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

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

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 Infor

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