NIRVANA CYCLING REFRIGERATED DRYER …manualarchive.ingersollrandproducts.com/manuals/manuals/dryers...NIRVANA CYCLING REFRIGERATED DRYER MODELS 200-400 OPERATORS MANUAL ... 7.2 AIR

NIRVANA CYCLING REFRIGERATED DRYERMODELS 200-400

OPERATORS MANUAL

C.C.N. : 80442775 DATE : DECEMBER 2006REV. : A

Ensure that the operator reads and understands thedecals and consults the manuals before maintenanceor operation.

Ensure that the Operation and Maintenance manual isnot removed permanently from the machine.

Ensure that maintenance personnel are adequatelytrained, competent and have read the MaintenanceManuals.

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1Nirvana Cycling Refrigerated Dryer Models 200-400http://air.irco.com

CONTENTS PAGE

1.0 CONTENTS 12.0 INTRODUCTION 23.0 WARRANTY 24.0 REFRIGERATED DRYER

NOMENCLATURE 25.0 RECEIVING AND INSPECTION 35.1 INSPECTIONS5.2 UNPACKING AND HANDLING6.0 SAFETY AND OPERATION

PRECAUTIONS 37.0 PRINCIPLES OF OPERATION 57.1 INTRODUCTION7.2 AIR SYSTEM7.3 MOISTURE REMOVAL SYSTEM7.4 REFRIGERATION SYSTEM7.5 THERMAL MASS CIRCULATING

SYSTEM7.6 CONTROLS7.6.1 BASIC USER INTERFACE7.6.2 EXCHANGER TEMPERATURE

SET POINT AND ALARMS7.6.3 ADJUSTING SET POINTS7.6.4 ALARMS AND

THEIR FUNCTIONS7.6.5 ALERT MESSAGES7.6.6 START MODES7.6.6.1 Manual Mode7.6.6.2 Remote Mode (Optional)7.6.6.3 Auto Restart

CONTENTS PAGE

8.0 INSTALLATION AND INITIAL START-UP 8

8.1 LOCATION AND MOUNTING8.2 PIPING AND VALVES8.3 FILTRATION8.4 ELECTRICAL CONNECTION8.5 INITIAL START-UP8.5.1 START- UP SEQUENCE9.0 SCHEDULED MAINTENANCE 109.1 INTRODUCTION9.2 REFRIGERANT CONDENSER9.3 CONDENSATE DISCHARGE

SYSTEM9.4 PANEL FILTER ELEMENT9.5 PREFILTERS AND

AFTERFILTERS9.5.1 THREADED FILTERS10.0 TECHNICIAN MODE 1311.0 TROUBLESHOOTING 1511.1 INTRODUCTION11.2 PROBLEM / ACTION GUIDE12.0 WIRING DIAGRAMS 1713.0 GENERAL ARRANGEMENT 1914.0 REPLACEMENT PARTS 2015.0 ENGINEERING

SPECIFICATIONS 21

CONTENTS

Ingersoll Rand Nirvana Cycling™ refrigerated air dryer removesmoisture, oil vapor, and other contaminants from compressed air. Thesecontaminants are detrimental to pneumatically operated appliances,controls, instruments, machinery and tools. This removal isaccomplished by cooling the air with a refrigeration unit to a temperatureat which moisture in the air is condensed and separated from the airstream. The temperature the air is cooled to, normally between 34° and38°F (1° and 3°C), is known as dew point. This dryer can be easily

2 Nirvana Cycling Refrigerated Dryer Models 200-400http://air.irco.com

installed into various pneumatic systems in which dry air is required ordesired. Please refer to Principles of Operation for complete operatingdetails.

• For warning label information with French translations, refer to pages5 and 6.

• Pur obtenir l’informatione des etiquettes dangereuses avec latraductione en francais, s’il vous plait consul ter les pages 5 and 6.

The Company warrants that the equipment manufactured by it anddelivered hereunder will be free of defects in material and workmanshipfor a period of twelve months from the date of placing the Equipment inoperation or eighteen months from the date of shipment from the factory,whichever shall first occur. The Purchaser shall be obligated to promptlyreport any failure to conform to this warranty, in writing to the Companyin said period, whereupon the Company shall, at its option, correct suchnonconformity, by suitable repair to such equipment or, furnish areplacement part F.O.B. point of shipment, provided the Purchaser hasstored, installed, maintained and operated such Equipment inaccordance with good industry practices and has complied with specificrecommendations of the Company. Accessories or equipment furnishedby the Company, but manufactured by others, shall carry whateverwarranty the manufactures have conveyed to the Company and whichcan be passed on to the Purchaser. The Company shall not be liable forany repairs, replacements, or adjustments to the Equipment or any costsof labor performed by the Purchaser or others without Company's priorwritten approval.

The effects of corrosion, erosion and normal wear and tear arespecifically excluded. Performance warranties are limited to thosespecifically stated within the Company's proposal. Unless responsibilityfor meeting such performance warranties are limited to specified tests,the Company's obligation shall be to correct in the manner and for theperiod of time provided above.

THE COMAPANY MAKES NO OTHER WARRANTY ORREPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED ORIMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIESOF MERCHANTABILITY AND FITNESS FOR A PARTICULARPURPOSE, ARE HERBY DISCLAIMED.

Correction by the Company of nonconformities whether patent or latent,in the manner and for the period of time provided above, shall constitutefulfillment of all liabilities of the Company for such nonconformitieswhether based on contract, warranty negligence, indemnity, strict liabilityor otherwise with respect to or arising out of such Equipment.

The Purchaser shall not operate Equipment which is considered to bedefective, without first notifying the Company in writing of its intention todo so. Any such use of Equipment will be at Purchaser's sole risk andliability.

Note that this is Ingersoll Rand standard warranty. Any warranty in forceat the time of purchase of the equipment or negotiated as part of thepurchase order may take precedence over this warranty.

2.0 INTRODUCTION

3.0 WARRANTY

4.0 REFRIGERATED DRYER NOMENCLATURE

NOMINAL*FLOW CONDENSER

PREFIX (SCFM) TYPE RATING POWERNVC 200-400 A = AIR (BLANK) = NEMA 1 (BLANK) = 460-3-60

W = WATER N4 = NEMA 4 230-1-60230-3-60575-3-60380-3-50220-3-50

* Nominal Flows indicated are for 100°F inlet temperature, 100°F ambient temperature and 100 psig compressed air pressure.


5.1 INSPECTIONUpon receiving your Ingersoll Rand air dryer, please inspect the unitclosely. If rough handling has been detected, please note it on yourdelivery receipt, especially if the dryer will not be uncrated immediately.Obtaining the delivery person’s signed agreement to any noteddamages will facilitate any insurance claims.

5.2 UNPACKING AND HANDLING

a WARNINGUnder no circumstances should any person attempt to lift heavyobjects without proper lifting equipment (i.e., crane, hoist, slings or forktruck). Lifting any unit without proper lifting equipment, may causeserious injury.

5.0 RECEIVING AND INSPECTION

To facilitate handling during shipment, all dryer packages have beenmounted on a base that provides for forklifting between two basechannels. Forks should extend all the way through forklift channels toreduce unnecessary forces to the dryer during moving. Slings can beused to lift the crates, but spreader bars must be used to prevent theslings from exerting a force against the sides of the crates or the dryer.

6.0 SAFETY AND OPERATION PRECAUTIONS

Because an air dryer is pressurized and contains rotating parts, thesame precautions should be observed as with any piece of machineryof this type where carelessness in operation or maintenance could behazardous to personnel. In addition to obvious safety rules that shouldbe followed with this type of machinery, safety precautions as listedbelow must be observed:

1. Only qualified personnel shall be permitted to adjust, performmaintenance or repair this air dryer.

2. Read all instructions completely before operating unit.3. Pull main electrical disconnect switch and disconnect any separate

control lines, if used, before attempting to work or performmaintenance on the unit.

4. Do not attempt to service any part while machine is in an operationalmode.

5. Do not attempt to remove any parts without first relieving the entireair system of pressure.

6. Do not attempt to remove any part of the refrigeration system withoutremoving and containing refrigerant in accordance with the EPA andlocal regulations.

7. Do not operate the dryer at pressures in excess of its rating.8. Do not operate the dryer without guards, shields and screen in place.9. Inspect unit daily to observe and correct any unsafe operating

conditions.

OSHAHeading Descriptions

a WARNING“Warning” is used to indicate a hazardous situation which has someprobability of death or severe injury. Warning should not be consideredfor property damage accidents unless personal injury risk is present.

a CAUTION“Caution” is used to indicate a hazardous situation which may result inminor or moderate injury.

a NOTICE“Notice” is used to indicate a statement of company policy as themessage relates directly or indirectly to the safety of personnel orprotection of property. Notice should not be associated directly with ahazard or hazardous situation and must not be used in place of“Danger,” “Warning,” or “Caution.”

a NOTICEThe user of any air dryer manufactured by Ingersoll Rand, is herebywarned that failure to follow the above Safety and OperationPrecautions may result in personal injury or equipment damage.However, Ingersoll Rand does not state as fact, nor does it mean toimply, that the preceding list of Safety and Operating Precautions is allinclusive, and further, that the observance of this list will prevent allpersonal injury or equipment damage.

Nirvana Cycling Refrigerated Dryer Models 200-400http://air.irco.com

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6.0 SAFETY AND OPERATION PRECAUTIONS

Air Under Pressure Will CauseInjury, Death Or Property Damage.• Do Not Exceed Pressure Rating.• Relieve Press. Before Servicing.• Do Not Modify/Repair/Rework ASME Coded Pressure Vessels As Insurance Rating Affected.

READ TECHNICAL MANUAL

ELECTRICAL CONNECTION BOXAll Customer Connections To Be Made At This Location.See Terminal Connection Diagrams, below.Be Certain To Follow All NEC, State, Local and Other ApplicableCodes During Installation.

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GRN

WHT

BLK

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FACTORYWIRING

INCOMINGLINE VOLTAGE

100-125VAC1PH/50-60HZ(BY OTHERS)

(REFER TO UNITNAMEPLATE FOR

POWERREQUIREMENTS)

100-125VAC / 1 PH

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GRN

BLK

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RED L2

FACTORYWIRING




POWERREQUIREMENTS)

200-240VAC / 1 PH

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RED

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FACTORYWIRING




POWERREQUIREMENTS)

200-575VAC / 3 PH

•••

ELECTRICAL CONNECTION BOXCONTAINS HIGH VOLTAGE

• Turn Off Power And Lock Out At ALL Sources Before Opening To Perform Service.• Remote Alarm Contact Wiring Has Control Power From Separate Source.


Air Under Pressure Will CauseInjury, Death Or Property Damage.• Relieve Press. Before Servicing.• Condensate Drain Discharges Under Pressure.• Drain Requires Periodic Cleaning (Service).


Removing fuses will not disconnectpower from dryer. Always disconnectpower from ALL sources beforeperforming service.


HIGH VOLTAGEThis unit is charged with

refrigerant under high pressure.

FAN MAY AUTOMATICALLYSTART AT ANY TIME


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7.1 INTRODUCTIONIngersoll Rand Nirvana Cycling™ dryers remove moisture fromcompressed air by cooling the air temperature to between 34° and 38°F(1 and 3°C). This causes vapors to condense into liquid droplets whichcan then be easily removed from the air. The major systems of the dryerwhich contribute to its operation are the Air System, the MoistureRemoval System, the Refrigeration System, the Thermal MassCirculating System and the Controls. The following paragraphsdescribe each of the systems in greater detail.

7.0 PRINCIPLES OF OPERATION

7.2 AIR SYSTEMThe air system consists of the dryer components which are in contactwith the compressed air. Referring to Figure 1 and following the bold“AIR FLOW,” hot saturated air from the compressor enters theprecooler/reheater where the air temperature is reduced prior toentering the chiller by the cool air exiting the air/moisture separator. Thisprecooling allows for the use of a smaller refrigeration system. The airthen goes into the chiller section where it is further cooled to the desireddew point by a thermal mass fluid. The temperature of the thermal massfluid is maintained by the refrigeration circuit and controls. The aircontinues to the separator where moisture is removed, thereby, allowingthe cool, dry air to return back to the precooler/reheater to be heated bythe incoming moist hot air. The air exiting the “reheater” portion of thedryer should be approximately 15°- 20°F lower than the inlet airtemperature based on standard conditions at full rated flow.

FLOW DIAGRAMFIGURE 1

7.3 MOISTURE REMOVAL SYSTEMIngersoll Rand condensate drains discharge condensed moisture andlubricants (condensate) from compressed air equipment. Thecondensate drain operates as a zero-air-loss drain, returning air that isdisplaced in the drain bowl back into the compressed air system.Consistent discharging of condensate from compressed air equipmentis essential for proper equipment operation and performance.

The condensate drain uses a unique sensing method to determine thelevel of condensate in the drain bowl. A transducer located in the drainbowl continuously sends out a signal 50 times per second. Once thetransducer determines that the level of condensate has reached apredetermined level within the drain bowl, a signal is sent to the no-lossdrain valve to open. This operation permits removal of condensate of upto 80 gallons per hour.

The drain also features a test button that permits manual operation ofthe no-loss drain valve. Depressing the test button illuminates the LEDand energizes the solenoid valve. The LED illuminates to indicate"POWER ON" and goes off when the no-loss drain valve is operated bythe transducer or manual test button.

The condensate flows through the feed line into the drain unit andaccumulates in the container. A capacitive sensor continuously registers

the liquid level and passes a signal to the electronic control as soon asthe container is filled. The pilot valve is then activated and thediaphragm opens the outlet line for discharging the condensate. Whenthe drain unit has been emptied, the outlet line is closed again quicklyand tightly without wasting compressed air."

7.4 REFRIGERATION SYSTEMThe Refrigeration System consists of all the components which handleR-404A. This is a hermetically sealed closed-loop system. Referring toFigure 1 and following the phantom “REFRIG(R-404A) FLOW,” refrigerantis shown leaving the evaporator section where, in the process ofremoving heat, it is changed from a low pressure liquid into a lowpressure gas. This gas enters the suction side of the compressor whereit is compressed into a high pressure gas. The high pressure gas iscooled in the condenser section until it becomes a high pressure liquid.It then goes through a permanent filter dryer that ensures therefrigeration system is free of contaminants. A small diameter capillarytube (expansion valve on water-cooled dryers) meters the refrigerant forintroduction into the evaporator. The refrigerant pressure is reducedupon entering the evaporator where as it evaporates, removes heat fromthe thermal mass fluid.



7.5 THERMAL MASS CIRCULATING SYSTEMThe thermal mass fluid in a Ingersoll Rand Nirvana Cycling™ dryer iscontinuously circulated in a closed pump loop system. Referring toFigure 1 and following the dashed “THERMAL FLUID” line, the heat isremoved from the fluid in the evaporator by the refrigeration system.The thermal mass reservoir is sized to minimize refrigeration cyclesduring reduced air load periods. The thermal mass fluid is pulled fromthe bottom of the reservoir and pumped through the chiller, removingheat from the air and then returned to the evaporator. The pump utilizedon the Ingersoll Rand Nirvana Cycling™ dryer is a maintenance-free,quiet cartridge circulator pump similar to those used in residential watersystems. While the refrigeration system cycles on and off based onloading conditions, the circulating pump runs continuously to maintainflow through the chiller at all times. Note that when the power switch isset to the off position, the circulating pump will not operate.

7.6 CONTROLSThe Ingersoll Rand NVC200-400 Series dryers incorporate automaticcontrols for proper operation. The thermal mass fluid temperature ismaintained by a microprocessor control that monitors the temperatureand cycles the refrigeration system in response to varying air flow andtemperature. Upon an increase in the temperature of the thermal massfluid, the refrigeration compressor is cycled on. When the fluid is cooledto two deg.F below its control set point, the refrigerant compressor iscycled off. The thermal mass fluid functions as a thermal storage massin the NVC Series dryer.

A low pressure cut out (LPCO) switch is provided for all NVC seriesdryers. This switch is factory set to open at 20 psig. If the refrigerantsuction pressure draws below 20 psig, the LPCO opens to shut off therefrigerant compressor. Once the switch has opened, it will prevent thecompressor from running until the suction pressure rises above 60 psigand the LPCO has been manually reset.

All water cooled units come with a high pressure cut out (HPCO) switch.This switch is set to open at 320 psig and close at 270 psig. Tocompensate for water temperature variation, it may be necessary toadjust the water regulating valve to maintain a 250 psig dischargepressure. Adjustment can be done by rotating the adjusting screwcounterclockwise for an increase in discharge pressure. For conditionswhere low water temperature and/or high water pressure are expectedit is advisable to install a water pressure regulator ahead of thecondenser.

7.6.1 BASIC USER INTERFACEThe Controller provides the user with information about thedryer’s operation and alarms.

The following illustration summarizes the keypad functions.

BUTTONS

• ON / OFF Toggles the dryer operation between "On Line" and “Off Line” status;Energizes glycol pump. Note that the refrigeration system will operate basedon temperature.

• EXCH SETWhen depressed, will display the current exchanger set point in the LCDwindow. While the exchanger set point is displayed, the up and down arrowsmay be used to increase or decrease the exchanger set point temperature.

• ALARM RESETPressing once clears the local alarm indication and de-energizes the remotealarm contact. Should the alarm condition persist, the alarm will return afterthe alarm inhibit time has expired.

• % SAVINGSDepressing once changes LED display to indicate ratio of refrigeration systemrunning time vs. total dryer ON time.

• °F / °CToggles the LED temperature display between Fahrenheit and Celsius units ofmeasure.

• ARROW KEYSAllows user to increase set point values. Set point values cycle through afixed range.

LIGHTS

• LCD DisplayDisplays exchanger temperature during normal operation. Also used todisplay exchanger temperature set point, alarm condition and timing functions.

• SYSTEM ENERGIZED Indicates when power is applied to unit.

• DRYER ONIlluminated when the On/Off switch has been pressed to place the unit inoperation. The refrigerant system may start at any time when the light is on.

• REFRIGERATION COMPRESSOR ONIndicates that the refrigeration system is operating.

• DEGREES F / DEGREES CIndicates the temperature units of measure.

• HIGH TEMP ALARMIndicates that the exchanger temperature has risen to 10°F or 5°C above theexchanger temperature set point.

• LOW TEMP ALARMWhen activated, indicates that the exchanger temperature has dropped below29°F or -2°C. This condition stops the compressor. The compressor will notrestart until the temperature has risen two degrees above exchanger set point.

ADJUSTMENTSCREW

FIGURE 2WATER REGULATING VALVE

7.6.2 EXCHANGER TEMPERATURE SET POINT AND ALARMSThe Controller allows the user to configure the dryer’sExchanger Temperature Setpoint to operate according to siteconditions. The Controller is shipped from the factory with theexchanger temperature having a default value of 38 deg.

7.6.3 ADJUSTING SET POINTSAccessing and manipulating the Exchanger TemperatureSetpoint is accomplished as follows.



The alarm names and a brief description of each are described indetail below.

HIGH TEMPERATURE ALARMWhen the thermal mass (glycol) temperature reaches the alarm setpoint, the alarm will be activated. This alarm condition may notnecessarily damage the dryer when subjected to long-term exposure.It may, however, have a significant impact on downstream processesand thus should be investigated upon detection. Note that this alarmwill not shut down the dryer. This alarm will activate the remote alarmcontact and reset automatically once the alarm condition is rectified.

LOW TEMPERATURE SAFETY ALARMIf the dryer chiller temperature falls below the factory set point, thealarm routine will activate. This alarm condition may cause damage tothe dryer when subjected to continuous or long-term exposure. Notethat this alarm will shut down the dryer after a response time delay.This alarm will activate the remote alarm contact and resetautomatically once the alarm condition is rectified.

7.6.5 ALERT MESSAGESThe Controller features the following readouts to communicate thestatus of the dryer’s operation.

EXCH.SET

Pressing EXCHANGER SETPOINT button will change the display toshow the current setpoint.

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Pressing the UP or DOWN arrows increment the EXCHANGERSETPOINT in one degree increment.

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Pressing the UP or DOWN arrows increment the EXCHANGERSETPOINT in one degree increment.

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The Controller accepts the last setpoint. After 5 seconds, the readoutwill return to displaying the current Exchanger Temperature.

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a CAUTIONDo not set the Exchanger Temperature greater than 50 deg.F. Runningdryer at an Exchanger Temperature higher than 50 deg.F may damagerefrigeration system.

7.6.4 ALARMS AND THEIR FUNCTIONSThe Controller indicates critical alarms to alert the user of anout of tolerance condition. Once each alarm condition isdetected, the appropriate LED indicator will illuminate and theremote alarm contact will close.

Alarm Display Alarm Set Point

HIGH TEMPERATURE ALARM HI TEMP ALARM EXCH SETPOINT + 10 °F

LOW TEMPERATURE ALARM LOW TEMP ALARM 28 °F

Indicates a probe failure. This conditionis usually caused by a probe beingunplugged, damage to the probe lead ora defective probe.

P F

Indicates that the refrigerant compressorwill not start until the end of a threeminute safety delay. The display of “cd” isimmediately followed by the number ofminutes left in the delay. This is a normalfunction of the controller and not a faultindication.

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7.6.6 START MODESThe NCV200-400 dryers are capable of starting in one of thefollowing start modes:

7.6.6.1 Manual ModeAfter power is supplied to the dryer, the LED display willindicate the chiller temperature as well as the time remainingfor the safety delay. Once the delay has timed out,depressing the On/Off button will permit the refrigerationsystem to operate. Should the chiller temperature be greaterthan the set point, the refrigeration system will energize.Should the chiller temperature be below the set point, therefrigeration system will remain off until the chiller temperaturerises to the setpoint.

7.6.6.2 Remote Mode (Optional)This mode of operation allows the user to control the dryerremotely and requires the installation of a customer-suppliedcontact. With power applied to the dryer and once the safetydelay has timed out, the dryer will start once the remote switchis closed. In addition, this mode of operation still permitsmanual control of the dryer via the On/Off pushbutton on thelocal control panel. Note that if the dryer was turned "On"from the remote switch and then turned "Off" via the localcontrol panel, the remote switch must be turned "Off" and then"On" to reinstate the dryer.



7.6.6.3 Auto RestartShould the dryer lose power while in the "On" mode, the dryerwill revert to the "On" mode once power is restored. Similarly,should power be removed from the dryer while the dryer is inthe "Off" mode, the dryer will remain in the "Off" mode oncepower is restored until the On/Off switch is depressed or theremote switch is closed.

8.0 INSTALLATION AND INITIAL START-UP

8.1 LOCATION AND MOUNTINGThe dryer should not be located in an area where ambient temperatureis likely to exceed 113°F (45°C) or be less than 50°F (10°C). The dryermust be located in an area that provides sufficient clearance from wallsand other adjoining equipment to allow easy access for servicing andmaintenance requirements. A minimum of 18 inches is required to allowfree flow of air to the condenser inlet.

On installations with a relatively steady flow rate, the dryer is normallyconnected after the air receiver. If loads fluctuate widely, the dryershould be positioned ahead of the receiver and sufficient storagecapacity downstream is necessary to prevent excessive air flow throughthe dryer.

When installed after any compressor that causes significant vibration orair pulsation, such as reciprocating compressors, proper vibrationisolation and pulsation dampening devices should be added to protectthe dryer.

a NOTICEFailure to comply to the above instructions may result in equipmentmalfunction and will void warranty.

a NOTICEAlways use a backup wrench when making any threaded connectionto the dryer. Failure to use a backup wrench may result in damagedtubing and components internal to the cabinet.

8.2 PIPING AND VALVESInstall piping, fittings and accessories as required for specific siteconditions and requirements. Figure 3 indicates a typical pipingarrangement for a refrigerated dryer, including dryer and filter bypasses.This figure can be used as a guide for valve and accessory placementin the system.

Ingersoll Rand NVC200-400 models come factory installed with a drainisolation valve (D). The isolation valve permits maintenance of theautomatic drain without isolating air flow to the dryer. To operate dryer,all valves shown in Figure 3 are to be closed except valves (B), (C) and(D). Valve (A) is used for bypass purposes and valve (E) is for test andmanual drain purposes.

8.3 FILTRATIONTo protect the air dryer from gross contamination associated withcompressor oil and debris and ensure maximum dryer performance, apre-filter is recommended. Pre-filters and post-filters sized to your dryingapplication can be provided by Ingersoll Rand and are available factoryinstalled. Call your local distributor to select the filter that best suits yourfiltration requirements. In addition to air filtration, condensate dischargeoil/water separators are also available to address stringent EPAregulations.



FIGURE 3

TYPICAL PIPING ARRANGEMENT

8.4 ELECTRICAL CONNECTIONEquipment is available in various electrical configurations. All customerconnections can be made at the terminal connections located in thecustomer electrical connection box on the rear of the dryer. (Refer toGeneral Arrangement and appropriate Wiring Diagrams.)

A suitable fused disconnect switch or circuit breaker, in accordance withnational and local code requirements, is recommended for all IngersollRand equipment. Refer to Section 13 for voltage requirements andload.

a CAUTIONNever wire directly or connect any additional wires to the compressorjunction box. This will cause severe system malfunction.

8.4.1 Ingersoll Rand dryers can be configured for three variations ofstart modes: Manual Mode, Automatic Mode and RemoteMode. The instructions below describe the methods toconfigure the dryer for a particular Start Mode.

A) Manual Mode (Factory Default) - No modification requiredto operate dryer in Manual Mode. Once power is applied,dryer can be started or stopped by depressing the localON / OFF pushbuttons located on the front panel.

B) Auto Restart Mode - Auto Restart Mode permits the dryerto start after a brief delay once power is applied to thedryer. Note that the dryer’s touch pad will still affect dryeroperation. Depressing the OFF button will de-energize therefrigeration compressor and all other electricalcomponents. After the OFF button has been depressed,the user must depress the ON button to permit the dryer tooperate.

C) Remote Mode - Remote Mode allows the dryer to beturned ON or OFF via a remote switch supplied by thecustomer. This mode will work regardless of the setting forAuto Restart. The dryer must be powered on for thisfeature to take effect. To enable this feature:

• Install N.O. remote switch as indicated on the appropriatewiring diagram.

• Customer-supplied contact should be rated at 1A at 24V.To operate dryer, close switch or contact and allow dryerto start after an initial delay. The local On / OFFpushbuttons may also be used at any time after contactclosure.

8.5 INITIAL START-UP

a NOTICEFor water cooled models, the water valve must be manually opened toensure that the condenser is full of water prior to start-up.

8.5.1 START- UP SEQUENCE• Apply power to dryer. LCD Panel will illuminate. The Anti-

Short Cycle delay will commence counting down.

a NOTICEAfter installation or a prolonged shutdown, start the dryer with no airload (no air flow). This enables the dryer to reach its proper operatingtemperature in the shortest time possible (typically within 30 minutesfor Nirvana Cycling™ dryers).

AIRDRYER

OILSEPARATOR

DRAINVALVE

CHECKVALVE

CHECKVALVE

CHECKVALVE

DRAINVALVE

CHECKVALVE

PREFILTER

B

A

CAIR OUTAIR IN

UNIT AS DELIVERED

OPTIONAL ACCESSORY ITEMS

NOTE: DRAIN TUBE MUST NOT RISE OR BE CONNECTED TOEXCESSIVELY LONG PIPE WHICH MAY CREATE BACK PRESSUREA CONNECTION TO OPEN FLOOR DRAIN IS REQUIRED

DE

PRE-FILTER


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• Start Dryer, using one of the following methods, dependingon Start Mode setting:

Manual Mode - Press the ON pushbutton.

Auto Restart Mode - No additional action required

Remote Automatic Mode - Close the remote contact.

9.0 SCHEDULED MAINTENANCE

9.1 INTRODUCTIONIngersoll Rand Nirvana Cycling™ refrigerated air dryers require littlemaintenance. These dryers utilize hermetically sealed compressorswhich do not require any lubrication. Fan motors require lubrication atboth oil ports every six months. Ingersoll Rand recommends componentinspection and service at regular intervals to obtain maximumperformance from your dryer.

9.2 REFRIGERANT CONDENSERFor standard dryers, regular inspection and cleaning of the condenser isrecommended. Ingersoll Rand dryers may be equipped with an optionalambient air filter designed to protect the condenser from dirt and debristhat can accumulate on the condenser. For proper operation with thisoption, it is imperative that this filter be inspected and cleaned on aregular basis. Annual replacement of the filter is recommended. Forapplications where excessive dirt, dust or debris is encountered, morefrequent inspection and cleaning may be required.

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9.3 CONDENSATE DISCHARGE SYSTEM

Before maintenance work always ensure that the device is:

• pressureless and• de-energized.

Maintenance recommendations

Replace service unit (5) annually.

Remove control unit (1) by pressing latching hook (2).

Detach Bekomat from outlet (3).

Remove design shell (4) (where applicable) using a screw driver (10).

Remove service unit (5) from pipe at inlet by undoing union nut

or by undoing screws (6) at elbow connector (7)

orby undoing screws (8) at intermediate adapter (9) which is then detached from the service unit by downward movement.

• Check if new service unit (5) matches control unit (1)- type designation and colour of latching hook (2)

• Fit new service unit (5) in reverse order

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9.4 PANEL FILTER ELEMENTAnnual replacement of the panel filter element is recommended. Toreplace the panel filter element, remove the panel filter by pulling up andout of its slots, then fit the new element in.

9.5 PREFILTERS AND AFTERFILTERS

a WARNINGDepressurize the system before disassembling filters. Failure to do somay result in injury or death.

Filter elements should be changed as indicated on the pressuredifferential gauge. Change carbon elements when hydrocarbons arefirst detected downstream or every six months, whichever comes first.

Certain filters contain multiple elements. When replacing filter elements,all elements should be replaced simultaneously. Mixing new and oldelements can result in reduced air quality.

9.5.1 THREADED FILTERS:

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1 Assembly Control unit onto service unit:

Check if service unit (3) matches control unit (1) (type designation andcolour of latching hook)

Check if sensor tube plate (5) with contact springs (4) is clean, dry and free from foreign matter.

Insert sensor (2) into sensor tube plate (5).

Fit latching hook (6) of control unit (1) into sensor tube plate (5).

Press control unit (1) against service unit (3) and snap into place

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67

1

23

34

21

3a 3b

1

21

2

5

2

1

3

4

16mm(5/8”)

1

✔

✘

4

✔

✘

6 7

8 9

1

13

1

2 2

2


13

10.0 TECHNICIAN MODE

The Microprocessor Control provides a protected TECHNICIAN MODEto manipulate several parameters not accessible by the typical operator.This mode also permits viewing of the factory settings to aid introubleshooting of the dryer. Below is a list of parameters that can beaccessed and manipulated by the technician in the TECHNICIANMODE:

In TECHNICIAN MODE, the following parameters can be viewed butnot changed:

Parameter Display Set Point

CONFIGURATION (# ofsensors) CONFIG #: 1, 2, 4, 8

OPERATING MODE OP MODE: HS or NC

REFRIGERANT REFRIG: 22 or 404 or 407

CONDENSER TYPE COND: AC OR WC

OPERATINGTEMPERATUREDIFFERENTIAL

T OP DIFF: 4

SHORT CYCLE DELAY SHT CYC DLY: 3

HIGH PRESSURE CUTOUT HPCO: See Table-1

HIGH PRESSURE CUTOUTDELAY HPCO DLY: 10

LOW PRESSURE CUTOUT LPCO: See Table-1

LOW PRESSURE CUTOUTDELAY LPCO DLY: 00:10

HIGH TEMPERATUREALARM HITEMP ALRM: 55

LOW TEMPERATUREALARM

LOWTEMPALRM: 30

LOW TEMPERATUREALARM DELAY LOTEMP DLY: 2:00

FAN 1 ON PRESSURE FAN1 ON: See Table-1

FAN 1 OFF PRESSURE FAN1 OFF: See Table-1

FAN 2 ON PRESSURE FAN2 ON: See Table-1

FAN 2 OFF PRESSURE FAN2 OFF: See Table-1

ALARM LIST BEGIN ALARMLIST N/A

Parameter Display Set PointNO-LOSS DRAIN VALVEENABLE DRAIN ENABLE ON (or OFF)

CRANKCASE HEATERDELAY CCH DLY 0 (or 2,4,8,12 hours)

AUTO RESTART ENABLE AUTO RESTART N (or Y)

10.1 ENTERING TECHNICIAN MODE

a WARNINGTECHNICIAN MODE should only be entered by qualified servicepersonnel. Altering the set points in TECHNICIAN MODE will have asignificant effect on the operation of the dryer. Incorrect set points maydamage dryer and cause potential serious injury.

To enter the TECHNICIAN MODE, perform the following keystrokes:

Pressing the “2” and “3” buttons simultaneously enters theTECHNICIAN MODE.

TECH SET MODE

SELECTDISPLAY

Depressing SELECT DISPLAY scrolls through the availableparameters. The first three parameters viewed are adjustable inTECHNICIAN MODE.

DRAIN ENABLE: ON

2 3

The DRAIN ENABLE parameter determines whether theMicroprocessor Control shall control an electronic no-loss drain valve. Avalue of “ON” will permit the Microprocessor Control to control the drainvalve. A value of “OFF” will disable this feature. This would be suitablefor servicing the drain valve or if an independent no air loss drain is tobe used with the dryer. To change the DRAIN ENABLE set point fromthe displayed set point, perform the following. Otherwise, depress theSELECT DISPLAY button to advance to the next adjustable parameter:

Depressing ENTER saves the selected set point.

Depressing the SELECT DISPLAY button advances to thenext adjustable parameter for the Crankcase Heater Delay.This parameter must not be altered unless instructed byIngersoll Rand Service personnel.

DRAIN ENABLE: OFF

CCHDELAY: 4

SET

For parameters with “ON / “OFF” or “Y” / “N” choices, the setpoint is changed using the SET button. Pressing the SETbutton changes the Drain Enable from ON to OFF.

DRAIN ENABLE: OFF

ENTER

SELECTDISPLAY

a NOTICEThe Crankcase Heater Delay set point must not be altered unlessdirected by Ingersoll Rand Service Personnel. Improperly altering theset point may result in damage to the dryer. Contact Ingersoll RandCompressed Air Solutions before altering the default set point.


10.0 TECHNICIAN MODE

The AUTO RESTART feature permits the dryer to operate once poweris applied to the dryer without requiring operator intervention. This wouldbe desirable should the user wish to have the dryer restart automaticallyafter a power outage. Note that the dryer will energize once the ASCtimes out. To change the AUTO RESTART set point from “N” (NO) to “Y”(YES), perform the following. Otherwise, depress the SELECT DISPLAYbutton to advance to the next display:

Depressing ENTER saves the selected set point.

AUTO RESTART: Y

SET

Depressing the SET button changes the AUTO RESTARTparameter from “N” to “Y”.

AUTO RESTART: Y

ENTER

Depressing the SELECT DISPLAY button advances to thenext adjustable parameter for the Auto Restart feature.

AUTO RESTART: N SELECTDISPLAY

a WARNINGChanging the AUTO RESTART feature to “Y” will permit the dryer tooperate automatically once power is applied and after a brief delay.Proper warning signs should be affixed to the dryer to alert users andservice personnel that dryer may start without warning. Failure to do somay result in serious injury.

Depressing the SELECT DISPLAY button displays the ENDTECH SET PTS display.

END TECH SET PTS SELECTDISPLAY

The remaining non-adjustable parameters may be viewed bydepressing the SELECT DISPLAY button as required to arrive at thedesired display.

a NOTICETo exit the TECHNICIAN MODE at any time, depress the “BLANK”button located above the SET button to return to the CUSTOMERMODE.

10.2 ALARM LISTAt the end of the list of non-adjustable parameters, the MicroprocessorContro displays a list of the most recent 20 alarm conditions. This listcan facilitate troubleshooting the dryer.

At the end of the list of parameters, depressing the SELECTDISPLAY button displays the beginning of the ALARM LIST.

BEGIN ALARM LIST SELECTDISPLAY

Depressing the SELECT DISPLAY button displays the alarmsthat the dryer has experienced, with the most recent alarmdisplayed first. The actual display will depend on the mostrecent alarm detected by the Microprocessor Control.

HPCO SELECTDISPLAY

The list of alarms can be scrolled by depressing the SELECTDISPLAY button as needed. At the end of the alarm list, theEND ALARM LIST screen is displayed.

END ALARM LIST SELECTDISPLAY

Depressing the SELECT DISPLAY list displays the ALARMLIST screen at the top of the ALARM LIST.

BEGIN ALARM LIST SELECTDISPLAY

The Alarm List will repeat as many times as the SELECT DISPLAYbutton is depressed. To EXIT the ALARM LIST, perform the following:

Depressing the BLANK button (located above the SETbutton) returns the controller to the top of the TECHNICIANMODE.

TECH SET MODE

Depressing the BLANK button again returns the controller tothe default display of the CUSTOMER MODE.

CHLLR TEMP: 37


PROBLEM

Moisture down stream

Moisture down stream

SYMPTOM(S)

Dryer is properly cooling airstream (Check Chiller. Tempon controller)

Inlet and outlet temperaturesare the same.

Inlet and outlet temperaturesare the same.

Compressor and fan arerunning, exchanger temphigh, pump not running.

POSSIBLE CAUSE

Condensate drain failurecaused by defective serviceunit.

Excessive flow

Dryer by-pass valve notclosed

No power to the dryer

High suction pressure

Refrigerant leak

Compressor not running andfan is running

Compressor and fan notrunning.

Compressor and fan notrunning. Controller indicatescompressor is ON.

Defective Pump

CORRECTIVE ACTION

Replace service unit.

Check inlet and outlet pressure and systemdesign capacity. Correct cause of excessive flow.

Close by-pass valve

Check power supply and fuses/circuitbreakers

Check and clean condenser.

Check suction pressure gauge if reading is 0 psig, turn dryer off and contact yourdistributor

Check and clean condenser.

Check ambient temperature and reducebelow 113°F

Check Chiller Temperature

Check MAIN CONTROL fuse.

Compressor relay may be bad, replace relay

Check for loose wire connections atcontactor or loss of power at control board

Defective control board - replace asnecessary

Contact your local distributor for furtherassistance.


a WARNINGAn air dryer always operates under pressure. Any maintenanceprocedure that involves disassembly of pipe fittings, valves or anyother components requires the dryer be isolated from the compressedair stream and fully depressurized.

a WARNINGPrior to working on the unit, make sure that all circuit breakers ordisconnected switches are tagged “Out of Service.”

11.2 PROBLEM / ACTION GUIDE

11.0 TROUBLESHOOTING

11.1 INTRODUCTIONIngersoll Rand Nirvana Cycling™ dryers are designed for reliable, trouble-free operation. In the event of any dryer malfunction, the guide belowhas been developed to facilitate problem identification and corrective actions.


11.0 TROUBLESHOOTING

PROBLEM

Apparent controller displaymalfunction

High pressure drop acrossdryer

Condensate drain does not fire

Condensate drain LED is off

Air bleed from condensatedrain outlet port

Condensate drain bowl doesnot seem to fill withcondensate, drain does notseem to work due to airlocking

SYMPTOM(S)

Display Blank

Unrealistic temperaturedisplayed

Erratic or inaccuratetemperature readings

Unrealistic pressuredisplayed

Outlet pressure substantiallylower than inlet pressureSystem operatingtemperature is above 32°F

Outlet pressure substantiallylower than inlet pressureSystem operatingtemperature is below 32°F

POSSIBLE CAUSE

Blown Fuse

Board Failure

Probe loose,off connection ordefective probe

Probe not completely inthermal well

Defective probe

Transducer loose, offconnection or defectivetransducer

Inlet and outlet valves notcompletely open

Inlet and outlet filters blockedup

Compressor relay / contactorstuck.

Microprocessor Control relaybad

Probe not completely inthermal well

Problem persists

Inlet / outlet pipe internaldiameter too small causingair-lock or back pressure.

Excessive use of bends /elbows in inlet / outlet pipework causing air-lock/ backpressure.

Outlet pipe too long / toohigh causing back pressure.

More than one condensatesource connected providingalternative path forcondensate.

Debris trapped under seal.Damage to seal.

CORRECTIVE ACTION

Check Fuses


Inspect probe cable and terminal connectionReplace probe

Inspect probe and check readings againstindependent source (eg. temperatureanalyzer/pyrometer/ice bath) both intemperature well and to ambient

Replace probe

Inspect transducer cable and terminalconnection

Replace transducer

Open valves

Change filter elements

Replace relay / contactor.

Replace relay

Inspect probe and check readings againstindependent source (eg. temperatureanalyzer/pyrometer/ice bath) both inexchanger well and to ambient

Turn dryer off and consult your localdistributor for further assistance

Check installation is in accordance with thismanual. Revise installation accordingly.

Replace with larger diameter piping.

Reduce the amount of bends and elbows.

Reconfigure condensate piping.

Reroute condensate to eliminate secondarypath. Install check valves as required.

Check power supply. Press test button forminimum 2 seconds and observe. Locateand eliminate supply fault.

Press and hold the test button to clear (drainvalve will open). Replace seal with ServiceKit.

If bottom inlet is used, top port must be usedas air bleed. Make sure Connect the topinlet to a higher point in system, which willfunction as an air bleed for the drain.


12.0 WIRING DIAGRAMS


12.0 WIRING DIAGRAMS


13.0 GENERAL ARRANGEMENT


20

14.0 PARTS IDENTIFICATION

NVC200A200 NVC200A400 NVC300A400 NVC400A400

COMPRESSOR 38446746 #N/A 38052270 38052288

CONDENSER 38053104 38053104 38052700 38052700

CONTACTOR 38052858 38052718 38052718 38052718

DRAIN 38052684 38052684 38052684 38052684

DRAIN, CONDENSATE 38052684 38052684 38052684 38052684

FAN MOTOR 38053229 38446498 38446498 38446498

FILTER, DRYER 38052916 38052916 38052916 38052916

FILTER, AMBIENT 38446753 38446753 38446753 38446753

FUSE, 0.5A 600V - 38054268 38054268 38054268

FUSE, 2A 250V - 38052361 38052361 38052361

FUSE, 0.125A 250V 38053195 - - -

MICRO-PROCESSOR 38052197 38052197 38052197 38052197

MICRO-PROCESSOR OVERLAY 38052676 38052676 38052676 38052676

PROBE, TEMPERATURE 38052908 38052908 38052908 38052908

PUMP, GLYCOL 38052262 38052262 38052262 38052262

STRAINER, BALL 1/2" 38052569 38052569 38052569 38052569

SWITCH, LOW PRESSURE CUTOUT 38052171 38052171 38052171 38052171

TRANSFORMER - 38053252 38053252 38053252

VALVE, SHUTOFF 3/4" 38052320 38052320 38052320 38052320


MAXIMUM ALLOWABLE WORKING PRESSURE: 232 psig

a NOTICESpecification information above accurate at time of publication. Refer to equipment serial labelfor actual refrigerant charges and specifications for units.

15.0 ENGINEERING SPECIFICATIONS

AIR COOLED CONDENSERSWEIGHT R-404A MAX. FUSE

SIZEMIN. CIRCUIT

AMPACITYCOMPRESSOR RATINGS FAN RATINGS

MODEL NO. VOLTS/PH/HZ LBS. KG. LB-OZ KG. HP RLA LRA QTY HP RLA LRANVC200 230/1/60 540 245 2-4 1.02 20 13.7 1 9.7 40 1 1/6 1 3NVC200 460/3/60 540 245 2-4 1.02 6 3.9 1 2.4 13 1 1/6 0.5 1.2NVC200 230/3/60 540 245 2-4 1.02 12 7.7 1 4.8 25 1 1/6 1 3NVC200 575/3/60 540 245 2-4 1.02 5 3.0 1 2.4 13 1 1/6 0.5 1.2NVC250 460/3/60 570 259 3-8 1.588 8 5.3 11/2 3.6 16 1 1/6 0.5 1.2NVC250 230/3/60 570 259 3-8 1.588 15 9.6 11/2 6.4 38 1 1/6 1 3NVC250 575/3/60 570 259 3-8 1.588 7 4.3 11/2 3.6 16 1 1/6 0.5 1.2NVC300 460/3/60 630 286 4-0 1.814 10 6.2 2 4.3 16 1 1/6 0.5 1.2NVC300 230/3/60 630 286 4-0 1.814 18 11.5 2 7.9 38 1 1/6 1 3NVC300 575/3/60 630 286 4-0 1.814 8 4.9 2 4.3 16 1 1/6 0.5 1.2NVC400 460/3/60 670 304 4-0 1.814 12 7.6 2 1/2 5.4 23 1 1/6 0.5 1.2NVC400 230/3/60 670 304 4-0 1.814 25 15.9 2 1/2 11.4 57 1 1/6 1 3NVC400 575/3/60 670 304 4-0 1.814 10 6.0 2 1/2 5.4 23 1 1/6 0.5 1.2

Documents

NIRVANA CYCLING REFRIGERATED DRYER …manualarchive.ingersollrandproducts.com/manuals/manuals/dryers...NIRVANA CYCLING REFRIGERATED DRYER MODELS 200-400 OPERATORS MANUAL ... 7.2 AIR