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Dokumen - Tips - D12in To D480in Refrigerated Dryer Service Manual PDF
Dokumen - Tips - D12in To D480in Refrigerated Dryer Service Manual PDF
Dokumen - Tips - D12in To D480in Refrigerated Dryer Service Manual PDF
Refrigerated Dryers
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 com-
petent 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 dam-
age. When handling, installing or operating this equipment, personnel must employ
safe engineering practices and observe all related regulation, health & safety proce-
dures, and legal requirements for safety. Ensure that the equipment is depressur-
ized and electrically isolated, prior to carrying out any of the scheduled maintenance
instructions specified within this user guide. Most accidents that occur during the op-
eration and maintenance of machinery are the result of failure to observe basic
safety rules and procedures.
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.
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 ther-
mal 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 per-
formance whatever the application if properly sized for the application. In D-IN/T
dryers, refrigerant constantly flows through the evaporator. The flow varies depend-
ent on the percentage of rated air capacity flowing through the dryer. See page 29
for correct adjustment procedures.
Air to Refrigerant
Heat Exchanger
D
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.
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 ma-
chine and returns diagnostic information in the presence of a malfunction.
The controller also monitors the evaporation temperature via a highly sensitive tem-
perature probe this allows the controller to govern the condenser fan motor speed.
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.
In models D240IN to D480IN, in order to greater adjust the dryer’s cooling capacity,
a hot gas by-pass valve cooperates with the variable speed system.
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 con-
troller, if it is a requirement for the dryer not to automatically re-start after power fail-
ure. The dryer must be connected to a suitable device with a manual reset that will
trip on power loss.
ON Compressor Is Energised
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 0.5ºC (32.9ºF)
When pushed for 10 seconds, it allows the user to change the C8 and C9 conden-
sate drain parameters programming menu (see relevant table).
When pushed after having set new configuration values, it stores the applied modifi-
cations.
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 cy-
cle 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.
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 LED’s, 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 dis-
play the firmware a key is pressed then the display will show F1 through to F5 de-
pendant 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 opera-
tion.
D-IN Dryers Service Manual Page 22
Ingersoll Rand Global Service Education Team
Draft Version, June, 2008. ©Ingersoll Rand Proprietary Information
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.
To gain access to all parameters press the UP and DOWN keys together for 5 sec-
onds. The LED display will the flash POn for 3 seconds once the parameter pro-
gramming mode has been activated.
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 re-
activated by following the procedure above.
18 _tAt Time the fan will run at minimum speed be- 0…999s
fore switching to logarithmic control,
22 _tEF The time the fan will be supplied with a volt- 0.0 … 2.0 s
age signal on startup
1. C1
Setpoint. The setpoint value of the temperature of the evaporator, adjustable
between -9.9ºC 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 be-
fore 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 compres-
sor 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 so-
lenoid will remain closed (de-energized) 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 Tem-
perature 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 refrig-
erant 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
Nº 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 control-
ler 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.
20. tdI
Time to wait for the temperature to stabilize below the Setpoint before decreas-
ing fan speed
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.
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.
2. 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.
3. Press the controller UP and DOWN keys together for 5 seconds. The LED dis-
play 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.
4. Press the SET key until parameter C12 is displayed adjust this parameter us-
ing 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.
6. If no further buttons are pressed the controller will save and exit from program-
ming mode. Note the main LED should now have changed and be displaying
the evaporator temperature in ºC for 50hz models (where 20 = 2.0ºC) or in ºF
for 60hz models.
7. Allow the dryer to operate for at least 5 minutes to allow the refrigerant tem-
peratures and pressures to stabilise.
8. 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 maxi-
mum of 5° angle and wait each time a minimum of 2 minutes before making
further adjustments.
9. After completion of setting. Using the PT charts (see page 39) verify the read-
ing 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.
7.0 WARNINGS
ESA
This occurs when the evaporator temperature drops below -1°C (30.2°F) 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 6°C (42.8°F), the outputs to the compres-
sor and fan motor should be re–energised and the dryer will resume normal opera-
tion.
ES2
This occurs should the evaporator temperature drop below -18°C (-0.4°F). This
alarm is immediate without any time delay. This warning will de-energise the refrig-
erant 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 6°C (42.8°F), the outputs to the compres-
sor and fan motor will be re–energised and the dryer will resume normal operation.
Probable Causes
8.0 ALARMS
HtA
This alarm occurs when the evaporator temperature reaches 14.5°C (58.1°F) for a
period of 6 minutes. 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 stan-
dard.
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 45°C (113°F). 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 ener-
gised at full speed for a period of 10 seconds, the condensate drain cycle will re-
main as standard.
Reset manually from the control panel by pressing ON / OFF button on the control-
ler.
Probable Causes
Condenser dirty
Check that the airflow through the condenser is not obstructed, clean if necessary.
Manual Reset
Pin 5
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
Probable Causes
Condenser dirty
Check that the airflow through the condenser is not obstructed, clean if necessary.
Coil
Pre-filter
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 activat-
ing the condensate drain test if no voltage is detected replace the controller.
An ASt alarm occurs when there are three HTA or HT2 alarms within a one hour pe-
riod. 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.
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 proce-
dure.
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 suc-
cessfully charge dryers with the correct quantity of refrigerant. These procedures
must only be carried out by qualified personnel holding the correct licenses in accor-
dance with local legislation.
Equipment Required
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.
4. 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.
5. 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.
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 sys-
tem, if not, the system was not properly charged or evacuated.
2. Calculate how much more will be needed too fully charge the system.
4. Open the suction-side valve and slowly weigh in the rest of the charge.
5. Once the unit is fully charged, close the valves on the gauges and on the
charging bottle.
Compressor Oil:
For normal working conditions there is no need to remove or add oil to a compres-
sor. 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.
Note:
Pressures in bar are
Actual Not Gauge
D12IN to D480IN
Inlet Temperature
Inlet Air Temperature (°F / °C) 86 / 30 95 / 35 104 / 40 113 / 45 122 / 50 131 / 55
Correction Factor 1.2 1 0.85 0.71 0.56 0.42
Ambient Temperature
45 /
Ambient Air Temperature (°C / °F) 25 / 77 30 / 86 35 / 95 40 / 104 42 / 108 113
Correction Factor 1 0.96 0.92 0.88 0.85 0.76
Inlet Pressure
Inlet Pres-
3/ 4/ 5/ 6/ 14 /
sure (barg / 7 / 102 8 / 116 9 / 131 10 / 145 12 / 174
44 58 78 87 203
psig)
Correction
0.7 0.78 0.85 0.93 1 1.06 1.11 1.15 1.2 1.24
Factor
Example: D300IN has nominal capacity of 300 m3/hr. At an inlet temperature of 40°C, ambi-
ent temperature of 35°C 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 appro-
priate factors.
Note: Correction factors are to be used for general sizing guidance. Dryer perform-
ance is guaranteed at nominal rating only.
R134a