Ingersoll-Rand 2000 Manuel utilisateur

NIRVANA CYCLING REFRIGERATED DRYER

MODELS 2000-2400

OPERATORS MANUAL

C.C.N. : 80442809

DATE : APRIL 2009

REV. : B

Ensure that the operator reads and understands the

decals and consults the manuals before maintenance

or operation.

Ensure that the Operation and Maintenance manual is

not removed permanently from the machine.

Ensure that maintenance personnel are adequately

trained, competent and have read the Maintenance

Manuals.

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CONTENTS PAGE

1.0 CONTENTS 1

2.0 INTRODUCTION 2

3.0 WARRANTY 2

4.0 REFRIGERATED DRYER

NOMENCLATURE 2

5.0 RECEIVING AND INSPECTION 3

5.1 INSPECTION

5.2 UNPACKING AND HANDLING

6.0 SAFETY AND OPERATION

PRECAUTIONS 3

7.0 PRINCIPLES OF OPERATION 5

7.1 INTRODUCTION

7.2 AIR SYSTEM

7.3 MOISTURE REMOVAL SYSTEM

7.4 REFRIGERATION SYSTEM

7.5 THERMAL MASS CIRCULATING

SYSTEM

7.6 CONTROLS

7.6.1 BASIC USER INTERFACE

7.6.2 DISPLAY PARAMETERS

7.6.3 DRYER SET POINTS

AND ALARMS

7.6.4 ADJUSTING SET POINTS

7.6.5 ALARMS AND

THEIR FUNCTIONS

7.6.6 START MODES

7.6.6.1 Manual Mode

7.6.6.2 Auto Restart Mode

7.6.6.3 Remote Automatic Mode

CONTENTS PAGE

8.0 INSTALLATION AND

INITIAL START-UP 9

8.1 LOCATION AND MOUNTING

8.2 PIPING AND VALVES

8.3 FILTRATION

8.4 ELECTRICAL CONNECTION

8.5 INITIAL START-UP

8.5.1 START- UP SEQUENCE

9.0 SCHEDULED MAINTENANCE 12

9.1 INTRODUCTION

9.2 REFRIGERANT CONDENSER

9.3 CONDENSATE DISCHARGE

SYSTEM

10.0 TECHNICIAN MODE 14

10.1 ENTERING TECHNICIAN

MODE

10.2 ALARM LIST

11.0 TROUBLESHOOTING 16

11.1 INTRODUCTION

11.2 PROBLEM / ACTION GUIDE

12.0 WIRING DIAGRAMS 18

13.0 GENERAL ARRANGEMENT 19

14.0 REPLACEMENT PARTS 20

15.0 ENGINEERING

SPECIFICATIONS 21

CONTENTS

The Ingersoll Rand Nirvana Cycling refrigerated air dryer removes

moisture, oil vapor, and other contaminants from compressed air. These

contaminants are detrimental to pneumatically operated appliances,

controls, instruments, machinery and tools. This is accomplished by

cooling the air with a refrigeration unit to a temperature at which

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moisture in the air is condensed and separated from the airstream. The

temperature the air is cooled to, normally between 36 and 40°F, is

known as dew point. This dryer can be easily installed into various

pneumatic systems in which dry air is required or desired. Please refer

to Principles of Operation for complete operating details.

The Company warrants that the equipment manufactured by it and

delivered hereunder will be free of defects in material and workmanship

for a period of twelve months from the date of placing the Equipment in

operation or eighteen months from the date of shipment from the factory,

whichever shall first occur. The Purchaser shall be obligated to promptly

report any failure to conform to this warranty, in writing to the Company

in said period, whereupon the Company shall, at its option, correct such

nonconformity, by suitable repair to such equipment or, furnish a

replacement part F.O.B. point of shipment, provided the Purchaser has

stored, installed, maintained and operated such Equipment in

accordance with good industry practices and has complied with specific

recommendations of the Company. Accessories or equipment furnished

by the Company, but manufactured by others, shall carry whatever

warranty the manufacturers have conveyed to the Company and which

can be passed on to the Purchaser. The Company shall not be liable for

any repairs, replacements, or adjustments to the Equipment or any costs

of labor performed by the Purchaser or others without Company's prior

written approval.

The effects of corrosion, erosion and normal wear and tear are

specifically excluded. Performance warranties are limited to those

specifically stated within the Company's proposal. Unless responsibility

for meeting such performance warranties are limited to specified tests,

the Company's obligation shall be to correct in the manner and for the

period of time provided above.

THE COMPANY MAKES NO OTHER WARRANTY OR

REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR

IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES

OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE, 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 constitute

fulfillment of all liabilities of the Company for such nonconformities

whether based on contract, warranty negligence, indemnity, strict liability

or otherwise with respect to or arising out of such Equipment.

The Purchaser shall not operate Equipment which is considered to be

defective, without first notifying the Company in writing of its intention to

do so. Any such use of Equipment will be at Purchaser's sole risk and

liability.

Note that this is Ingersoll Rand standard warranty. Any warranty in force

at the time of purchase of the equipment or negotiated as part of the

purchase order may take precedence over this warranty.

2.0 INTRODUCTION

3.0 WARRANTY

4.0 REFRIGERATED DRYER NOMENCLATURE

NOMINAL*

FLOW CONDENSER

PREFIX (SCFM) TYPE POWER RATING

NVC 2000-2400 A = AIR 4 = 460-3-60 0 = NEMA 1

W = WATER 5 = 230-3-60 H = NEMA 4

6 = 575-3-60

7 = 380-3-50

8 = 220-3-50

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

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5.1 INSPECTION

Upon receiving your Ingersoll Rand air dryer, please inspect the unit

closely. If rough handling has been detected, please note it on your

delivery receipt, especially if the dryer will not be immediately uncrated.

Obtaining the delivery person's signed agreement to any noted

damages will facilitate any insurance claims

5.2 UNPACKING AND HANDLING

WARNING

Under no circumstances should any person attempt to lift heavy

objects without proper lifting equipment (i.e., crane, hoist, slings or fork

truck). Lifting any unit without proper lifting equipment, can cause

serious injury.

5.0 RECEIVING AND INSPECTION

All dryer packages have been mounted on a base which provides for

forklifting between the two base channels to facilitate handling during

shipment. Forks should extend all the way through forklift channels to

reduce unnecessary forces to the dryer during moving. Slings can be

used to lift the crates, but spreader bars must be used to prevent the

slings from exerting a force against the sides of the crates.

6.0 SAFETY AND OPERATION PRECAUTIONS

Because an air dryer is pressurized and contains rotating parts, the

same precautions should be observed as with any piece of machinery

of this type where carelessness in operation or maintenance could be

hazardous to personnel. In addition to obvious safety rules that should

be followed with this type of machinery, safety precautions as listed

below must be observed:

1. Only qualified personnel shall be permitted to adjust, perform

maintenance 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 perform

maintenance on the unit.

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

mode.

5. Do not attempt to remove any parts without first relieving the entire

air system of pressure.

6. Do not attempt to remove any part of the refrigeration system without

removing and containing refrigerant in accordance with the EPA and

local 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.

OSHA

Heading Descriptions

WARNING

“Warning” is used to indicate a hazardous situation which has some

probability of death or severe injury. Warning should not be considered

for property damage accidents unless personal injury risk is present.

CAUTION

“Caution” is used to indicate a hazardous situation which may result in

minor or moderate injury.

NOTICE

“Notice” is used to indicate a statement of company policy as the

message relates directly or indirectly to the safety of personnel or

protection of property. Notice should not be associated directly with a

hazard or hazardous situation and must not be used in place of

“Danger,” “Warning,” or “Caution.”

NOTICE

The user of any air dryer manufactured by Ingersoll Rand, is hereby

warned that failure to follow the above Safety and Operation

Precautions may result in personal injury or equipment damage.

However, Ingersoll Rand does not state as fact, nor does it mean to

imply, that the preceding list of Safety and Operating Precautions is all

inclusive, and further, that the observance of this list will prevent all

personal injury or equipment damage.

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6.0 SAFETY AND OPERATION PRECAUTIONS

Air Under Pressure Will Cause

Injury, 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

Air Under Pressure Will Cause

Injury, Death Or Property Damage.

• Relieve Press. Before Servicing.

• Condensate Drain Discharges

Under Pressure.

• Drain Requires Periodic

Cleaning (Service).

READ TECHNICAL MANUAL

Removing fuses will not disconnect

power from dryer. Always disconnect

power from ALL sources before

performing service.

READ TECHNICAL MANUAL

HIGH VOLTAGE

This unit is charged with

refrigerant under high pressure.

FAN MAY AUTOMATICALLY

START AT ANY TIME

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7.1 INTRODUCTION

Ingersoll Rand Nirvana™ Cycling dryers remove moisture from

compressed air by cooling the air temperature to between 36° and 40°F

(2 and 4°C). This causes vapors to condense into liquid droplets which

can then be easily removed from the air. The major systems of the dryer

which contribute to its operation are the Air System, the Moisture

Removal System, the Refrigeration System, the Thermal Mass

Circulating System and the Controls. The following paragraphs

describe each of the systems in greater detail.

7.2 AIR SYSTEM

The air system consists of the dryer components which are in contact

with the compressed air. Referring to Figure 1 and following the bold

7.0 PRINCIPLES OF OPERATION

“AIR FLOW,” hot saturated air from the compressor enters the

precooler/reheater where the air temperature is reduced prior to

entering the chiller by the cool air exiting the air/moisture separator. This

precooling allows for the use of a smaller refrigeration system. The air

then goes into the chiller section where it is further cooled to the desired

dew point by a thermal mass fluid. The temperature of the thermal mass

fluid is maintained by the refrigeration circuit and controls. The air

continues to the separator where moisture is removed, thereby, allowing

the cool, dry air to return back to the precooler/reheater to be heated by

the incoming moist hot air. The air exiting the “reheater” portion of the

dryer should be approximately 15°- 20°F lower than the inlet air

temperature based on standard conditions at full rated flow.

7.3 MOISTURE REMOVAL SYSTEM

Ingersoll Rand condensate drains discharge condensed moisture and

lubricants (condensate) from compressed air equipment. The

condensate drain operates as a zero-air-loss drain, returning air that is

displaced in the drain bowl back into the compressed air system.

Consistent discharging of condensate from compressed air equipment

is essential for proper equipment operation and performance.

The condensate drain uses a unique sensing method to determine the

level of condensate in the drain bowl. A transducer located in the drain

bowl continuously sends out a signal 50 times per second. Once the

transducer determines that the level of condensate has reached a

predetermined level within the drain bowl, a signal is sent to the no-loss

drain valve to open. This operation permits removal of condensate of up

to 80 gallons per hour.

The drain also features a test button that permits manual operation of

the no-loss drain valve. Depressing the test button illuminates the LED

and energizes the solenoid valve. The LED illuminates to indicate

"POWER ON" and goes off when the no-loss drain valve is operated by

the transducer or manual test button.

The condensate flows through the feed line into the drain unit and

accumulates in the container. A capacitive sensor continuously registers

the liquid level and passes a signal to the electronic control as soon as

the container is filled. The pilot valve is then activated and the

diaphragm opens the outlet line for discharging the condensate. When

the drain unit has been emptied, the outlet line is closed again quickly

and tightly without wasting compressed air.

7.4 REFRIGERATION SYSTEM

The Refrigeration System consists of all the components which handle

R-404A. This is a hermetically sealed closed-loop system. Referring to

Figure 1 and following the phantom “REFRIGERANT” line, refrigerant is

shown leaving the evaporator section where, in the process of removing

heat, it is changed from a low pressure liquid into a low pressure gas.

This gas enters the suction side of the compressor where it is

compressed into a high pressure gas. The high pressure gas is cooled

in the air cooled or water cooled condenser section until it becomes a

high pressure liquid. It then goes through a permanent filter dryer that

ensures the refrigeration system is free of contaminants. A thermostatic

expansion valve meters the refrigerant for introduction into the

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FIGURE 1

FLOW DIAGRAM

PROCESS AND

INSTRUMENTATION DIAGRAM

NVC2000-2400

AIR AND WATERCOOLED

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7.0 PRINCIPLES OF OPERATION

evaporator. The refrigerant pressure is reduced upon entering the

evaporator where as it evaporates, heat is removed from the thermal

mass fluid.

7.5 THERMAL MASS CIRCULATING SYSTEM

The thermal mass fluid in a Ingersoll Rand Nirvana™ Cycling dryer is

continuously circulated in a closed pump loop system. Referring to

Figure 1 and following the dashed “

THERMAL MASS FLUID” line, the heat is

removed from the fluid in the evaporator by the refrigeration system.

The thermal mass reservoir is sized to minimize refrigeration cycles

during reduced air load periods. The thermal mass fluid is pulled from

the bottom of the reservoir and pumped through the chiller, removing

heat from the air and returned to the evaporator. The pump utilized on

Ingersoll Rand Nirvana™ Cycling dryer is a maintenance-free, quiet

cartridge circulator pump similar to those used in residential water

systems. While the refrigeration system cycles on and off based on

loading conditions, the circulating pump runs continuously to maintain

flow through the chiller at all times.

7.6 CONTROLS

Ingersoll Rand 2000-2400 Refrigerated Compressed Air Dryers are

equipped with the Microprocessor Control. This advanced

microprocessor-based controller has been engineered by Ingersoll

Rand exclusively for use with Ingersoll Rand Compressed Air Dryers.

The Microprocessor Control cycles the refrigeration system based on

the dryer's Chiller Temperature. A temperature sensor samples the

thermal mass temperature as it enters the chiller exchanger. The

Chiller Temperature Set point is a user adjustable set point that is used

to set the Refrigeration Compressor Off temperature. Once the Chiller

Temperature has fallen below the Chiller Temperature Set point, the

refrigeration compressor will de-energize. The Operating Temperature

Differential is factory set at 4°F above the Chiller Temperature Set point.

Therefore, if a user adjusts the Chiller Temperature at 36°F, the

Refrigeration Compressor On temperature will be 40°F.

In addition to the operation of the Nirvana™ Cycling dryers as described

above, the Microprocessor Control permits monitoring of dryer

parameters and enunciation of alarm conditions.

The list below summarize the features the Microprocessor Control:

• 2 X 16 Character Backlit LCD Display - Easy-to-read display provides

continuous indication of dryer default parameter. Standard backlight

permits viewing of critical information in low light environments.

• Remote Start / Stop: Microprocessor Control-equipped dryers offer a

unique remote start / stop feature. This feature allows the dryer to be

operated via a remote user-supplied switch.

• Remote Alarm Contact: Microprocessor Control-equipped dryers

include a remote alarm contact to provide indication of any of the

dryers alarms described later in this manual. Contact rated for 2A /

120V max.

The Microprocessor Control features three levels of access. The default

level CUSTOMER MODE permits adjustment of dryer parameters to

address seasonal variations for drain timing and pressure dew point

temperature. A protected TECHNICIAN MODE permits access to and

manipulation of additional parameters. A password protected

FACTORY MODE is also included for use with Ingersoll Rand Service

Personnel for troubleshooting the dryer.

The Microprocessor Control includes a digital readout for monitoring the

discharge pressure of the refrigerant gas exiting the compressor. This

reading will vary dependent upon condenser type as indicated below:

• For air-cooled applications, condensing fans are cycled on and off by

the Microprocessor Control based on the refrigerant discharge pressure.

Primary fan is cycled on at 275 psig and off at 195 psig. Should the

discharge pressure continue to climb above 335 psig, the secondary

condensing fan will cycle on. As discharge pressure is reduced below

235 psig, the secondary fan will cycle off.

• Water cooled condensers utilize a water regulating valve (Note Figure

2). The water regulating valve comes pre-adjusted from the factory at

260 psig discharge pressure. To compensate for water temperature

variation, it may be necessary to adjust the water regulating valve to

maintain a 260 psig discharge pressure. Adjustment can be done by

rotating the adjusting screw counterclockwise for an increase in

discharge pressure. For conditions where low water temperature and/or

high water pressure are expected it is advisable to install a water

pressure regulator ahead of the condenser.

ADJUSTMENT

SCREW

FIGURE 2

WATER REGULATING VALVE

7.6.1 BASIC USER INTERFACE

The Microprocessor Control display provides the user with the

operating parameters and their corresponding values. The

following illustration summarizes the keypad functions.

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7.0 PRINCIPLES OF OPERATION

7.6.2 DISPLAY PARAMETERS

The Microprocessor Control is capable of displaying a number

of system parameters. The following summarizes the

parameters that can be accessed by the user from the

Microprocessor Control:

• Chiller Temperature (CHLLR TEMP): For Nirvana Cycling

Dryers, the Chiller Temperature is the temperature, in

degrees Fahrenheit, of the thermal mass fluid.

• Compressor Status (CMPRSSR): Displays whether the

refrigeration compressor is “ON” or “OFF”.

• Discharge Pressure (P disch): Displays the discharge

pressure of the refrigeration system.

• Suction Temperature (T suction): Displays the suction

temperature, in deg. F, of the refrigeration system. This

value is useful in determining superheat of the refrigerant.

• Suction Pressure (P suction): Displays the suction pressure,

in psig, of the refrigeration system.

• Percent Savings (% SVGS): Displays the length of time the

compressor has been operating versus the length of time

the dryer has been on.

• Cumulative Dryer Hours (CUM DRYER HR): Displays the

length of time, in hours, that the dryer has been operational.

• Cumulative Compressor Operating Hours (CUM CMP HR):

Displays the length of time, in hours, that the refrigeration

compressor has been energized.

Depressing the SELECT DISPLAY button repeatedly scrolls

through the above non-adjustable displays. The Customer

Set Points appear at the end of the list and may be adjusted

by the end user to match seasonal refrigeration and drain

operation. These settings are as follows:

• Chiller Temperature (CHLLR TEMP)

CHLLR TEMP: 37

BUTTONS

• ON

Places the dryer "On Line"; Energizes glycol pump on Nirvana™ Cycling

dryers. For Nirvana™ Cycling models, the compressor will operate based on

temperature;

• OFF

Places the dryer "Off Line"; Stops all automatic functions, including circulating

pump operation on Nirvana™ Cycling dryers.

• SELECT DISPLAY

Allows the user to cycle through the available displays. The last display

selected will remain displayed as the default display.

• + / -

Allows user to modify set point values. Set point values cycle through a fixed

range. Also allows entering negative numbers in FACTORY MODE.

• TEST

Allows user to manually activate the drain no-loss drain valve.

• RESET

Pressing once clears the local alarm indication and de-energizes the remote

alarm contact. Should the alarm condition persist, the alarm will return after

the alarm inhibit time has expired.

• SET

Permits the adjustment of parameters in TECHNICIAN and FACTORY

MODES. In CUSTOMER MODE, allows user to back through displays,

• ENTER

Used to accept changed parameters and set point values.

• i

Restricted Level access for factory use only. Not used for basic dryer

functions. Not to be used by customer or service technician.

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7.0 PRINCIPLES OF OPERATION

7.6.3 DRYER SET POINTS AND ALARMS

The Microprocessor Control has several user adjustable set

points that are displayed at the end of the display parameter

list. These set points allow the user to configure the dryer to

operate according to site conditions. The controller is shipped

from the factory with each parameter having its own default

value. The following chart summarizes the parameters that

may be adjusted by the user:

Display Parameter Factory Setpoint

Description Range Nirvana

SETPOINT Cycling

Chiller Off Temperature CHLLR TEMP 32°F - 50°F; 1 °F increments 34°F

7.6.4 ADJUSTING SET POINTS

Accessing and manipulating each of the set points in the

CUSTOMER MODE is accomplished as follows. The

parameter is selected using the SELECT DISPLAY button.

After scrolling through the displays, the “Cust Set Points”

screen is displayed. The parameters after this screen may be

adjusted by the user. Once the desired parameter is

displayed, depressing the “+/-” button changes the set point.

Once the new set point is displayed, depressing ENTER

saves the set point. Exiting the Customer Set Point routine is

accomplished by depressing the SELECT DISPLAY button

until the END CUST SET PTS screen is displayed. The

following example illustrate the keystrokes required to change

the Chiller Temperature Set Point from 36 F to 38 F.

SELECT

DISPLAY

Pressing SELECT DISPLAY will increment the display through the

available display parameters.

Depress “ + / -“ as required to change the CHLLR TEMP to 38

degrees.

Pressing “ENTER” saves the set point.

ENTER

CHLLR TEMP:38

SELECT

DISPLAY

Press SELECT DISPLAY as necessary to display the End

Customer Set points Screen.

End Cust Set Pts

CHLLR TEMP:38

+

-

CHLLR TEMP: 36

SELECT

DISPLAY

Continue pressing SELECT DISPLAY until the Customer Set point

screen is displayed. The parameters that follow are the User

Adjustable Parameters for the controller.

Cust Set Points

SELECT

DISPLAY

Press SELECT DISPLAY until “CHLLR TEMP” is displayed.

CHLLR TEMP:36

SELECT

DISPLAY

Press SELECT DISPLAY as necessary to return the

Microprocessor Control to the desired display parameter.

CHLLR TEMP: 36

7.6.5 ALARMS AND THEIR FUNCTIONS

There are several alarms detected by the Microprocessor

Control to alert the user of an out of tolerance condition. Once

each alarm is detected, a description of the alarm will appear

in the screen and the remote alarm contact will close. Note

that during the alarm condition, the SELECT DISPLAY button

may be depressed to scroll through the available parameters.

After approximately 30 seconds, the alarm screen will

reappear, provided the alarm condition persists.

The alarm names and a brief description of each are described in detail

below.

HIGH TEMPERATURE ALARM (HITEMP ALARM)

When the thermal mass (glycol) temperature in a Nirvana™ Cycling

dryer reaches the factory alarm set point, after an alarm delay, the

alarm will be activated. This alarm condition may not necessarily

damage the dryer when subjected to long-term exposure. It may,

however, have a significant impact on downstream processes and thus

should be investigated upon detection. Note that this alarm will not

shut down the dryer. This alarm will activate the remote alarm contact

and reset automatically once the alarm condition is rectified.

LOW TEMPERATURE SAFETY ALARM (LOWTEMP ALARM)

If the dryer chiller temperature falls to or below the factory set point and

remains at or below this set point for the factory delay time, the alarm

routine will activate. This alarm condition may cause damage to the

dryer when subjected to continuous or long-term exposure. Note that

this alarm will shut down the dryer after a response time delay. This

alarm will activate the remote alarm contact and reset automatically

once the alarm condition is rectified.

HIGH PRESSURE CUTOUT ALARM (HPCO ALARM)

If the discharge pressure of the refrigerant is determined to be above

the set point, the alarm routine will activate. This alarm condition may

cause damage to the dryer when subjected to continuous or long-term

exposure. Note that this alarm will shut down the dryer after a

response time delay. The operator must depress the RESET button in

order to clear the alarm and restart the refrigeration system.

Alarm

Display

Alarm Set Point

HIGH PRESSURE CUTOUT HI PRESS CO See Table 1

LOW PRESSURE CUTOUT LO PRESS CO See Table 1

HIGH TEMPERATURE ALARM HITEMP ALRM 55 °F

LOW TEMPERATURE ALARM LOTEMP ALRM 30 °F

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LOW PRESSURE CUTOUT ALARM (LO PRESS CO)

If the suction pressure of the refrigerant is determined to be below the set

point of the LPCO alarm, the Microprocessor Control alarm routine will

activate. This alarm condition may cause damage to the dryer when

subjected to continuous or long-term exposure. Note that once cleared,

the compressor will restart automatically. However, if two successive low-

pressure conditions are determined, this alarm will shut down the dryer

after a response time delay and will display the alarm condition. The

operator must depress the RESET button in order to reinstate the

compressor.

TABLE - 1

7.6.6 START MODES

Ingersoll Rand dryers are capable of starting in one of three

start modes. Note that to protect the refrigeration compressor

from repeated rapid starts, the Microprocessor Control is

equipped with an an anti-short cycle (ASC) delay. The ASC

delay will countdown from the factory set point. Only after the

ASC delay has timed out will the refrigeration system operate.

Below are brief descriptions of these various start modes.

7.0 PRINCIPLES OF OPERATION

7.6.6.1 Manual Mode

Ingersoll Rand dryers are shipped from the factory in the

Manual Mode. After power is supplied to the dryer, the user

will be presented with the ASC delay, followed by the “PRESS

ON BUTTON” display. After the ASC delay has timed out, the

dryer will only start once the ON button is depressed. In this

configuration, to restart the dryer, the user must manually

depress the ON button on the dryer’s control panel.

7.6.6.2 Auto Restart Mode

After power is applied to the dryer, and once an anti-short

cycle delay has timed out, the dryer will start automatically. In

addition, this mode of operation allows manual control of the

dryer via the ON & OFF pushbuttons. This is useful for

applications where automatic restarting of the dryer is desired

after a power failure has occurred.

7.6.6.3 Remote Automatic Mode

This mode of operation allows the user to control the dryer

remotely and requires the installation of a customer-supplied

contact and grounded 24V power supply. With power applied

to the dryer and once the anti-short cycle delay has timed out,

the dryer will start automatically once the switch is closed. In

addition, this mode of operation allows manual control of the

dryer via the ON & OFF pushbuttons.

8.0 INSTALLATION AND INITIAL START-UP

8.1 LOCATION AND MOUNTING

The dryer should not be located in an area where ambient temperature

is likely to exceed 113°F (45°C) or be less than 50°F (10°C). The dryer

must be located in an area that provides sufficient clearance from walls

and other adjoining equipment to allow easy access for servicing and

maintenance requirements. A minimum of 18 inches is required to allow

free flow of air to the condenser inlet.

If loads fluctuate widely, the dryer should be positioned ahead of the

receiver and sufficient storage capacity downstream is necessary to

prevent excessive air flow through the dryer.

When installed after any compressor that causes significant vibration or

air pulsation, such as reciprocating compressors, proper vibration

isolation and pulsation dampening devices should be added to protect

the dryer.

NOTICE

Failure to comply to the above instructions may result in equipment

malfunction and will void warranty.

NOTICE

Always use a backup wrench when making any threaded connection

to the dryer. Failure to use a backup wrench may result in damaged

tubing and components internal to the cabinet.

8.2 PIPING AND VALVES

Install piping, fittings and accessories as required for specific site

conditions and requirements. Figure 3 indicates a typical piping

arrangement for a refrigerated dryer, including dryer and filter bypasses.

This figure can be used as a guide for valve and accessory placement

in the system.

Ingersoll Rand 2000 through 2400 models come factory installed with a

drain isolation valve (D). The isolation valve permits maintenance of the

automatic 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 and

manual drain purposes.

8.3 FILTRATION

To protect the air dryer from gross contamination associated with

compressor oil and debris and ensure maximum dryer performance, a

pre-filter is recommended. Pre-filters and post-filters sized to your drying

application can be provided by Ingersoll Rand and are available factory

installed. Call your local distributor to select the filter that best suits your

filtration requirements. In addition to air filtration, condensate discharge

oil/water separators are also available to address stringent EPA

regulations.

Parameter R-404A

FAN 1 ON 275 psig

FAN 1 OFF 195 psig

FAN 2 ON 335 psig

FAN 2 OFF 235 psig

HPCO (Air Cooled) 450 psig

HPCO (Water Cooled) 320 psig

LPCO 20 psig

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10

8.0 INSTALLATION AND INITIAL START-UP

FIGURE 3

TYPICAL PIPING ARRANGEMENT

8.4 ELECTRICAL CONNECTION

Equipment is available in various electrical configurations. All customer

connections can be made at the terminal connections located in the

customer electrical connection box on the rear of the dryer. (Refer to

General Arrangement and appropriate Wiring Diagrams.)

A suitable fused disconnect switch or circuit breaker, in accordance with

national and local code requirements, is recommended for all Ingersoll

Rand equipment. Refer to the Engineering Specifications Section for

voltage requirements and load.

CAUTION

Never wire directly or connect any additional wires to the compressor

junction box. This will cause severe system malfunction.

8.4.1 Ingersoll Rand dryers can be configured for three variations of

start modes: Manual Mode, Automatic Mode and Remote

Mode. Refer to Section 10 for instructions on how to change

the dryer’s start settings. The instructions below describe the

methods to configure the dryer for a particular Start Mode.

A) Manual Mode (Factory Default) - No modification required

to operate dryer in Manual Mode. Once power is applied,

dryer can be started or stopped by depressing the local

ON / OFF pushbuttons located on the front panel.

B) Auto Restart Mode - Auto Restart Mode permits the dryer

to start after a brief delay once power is applied to the

dryer. Note that the dryer’s touch pad will still affect dryer

operation. Depressing the OFF button will de-energize the

refrigeration compressor and all other electrical

components. After the OFF button has been depressed,

the user must depress the ON button to permit the dryer to

operate.

C) Remote Mode - Remote Mode allows the dryer to be

turned ON or OFF via a remote switch supplied by the

customer. This mode will work regardless of the setting for

Auto Restart. The dryer must be powered on for this

feature to take effect. To enable this feature:

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

appropriate wiring diagram.

• Customer-supplied contact should be rated at 1A at 24V.

To operate dryer, close switch or contact and allow dryer

to start after an initial delay. The local On / OFF

pushbuttons may also be used at any time after contact

closure.

8.5 INITIAL START-UP

NOTICE

For water cooled models, the water valve must be manually opened to

ensure that the condenser is full of water prior to start-up.

CAUTION

Allow 8 hours of warm-up time for the crankcase heater prior to start

up. Crankcase heater is connected directly to the incoming power and

is energized at all times.

8.5.1 START- UP SEQUENCE

• Apply power to dryer. LCD Panel will illuminate. The Anti-

Short Cycle delay will commence counting down.

Remaining time on the Crankcase heater will also

countdown.

AIR

DRYER

OIL

SEPARATOR

DRAIN

VALVE

CHECK

VALVE

CHECK

VALVE

CHECK

VALVE

DRAIN

VALVE

CHECK

VALVE

PREFILTER

B

A

C

AIR OUT

AIR IN

UNIT AS DELIVERED

OPTIONAL ACCESSORY ITEMS

NOTE:

DRAIN TUBE MUST NOT RISE OR BE CONNECTED TO

EXCESSIVELY LONG PIPE WHICH MAY CREATE BACK PRESSURE

A CONNECTION TO OPEN FLOOR DRAIN IS REQUIRED

DE

PRE-FILTER

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8.0 INSTALLATION AND INITIAL START-UP

NOTICE

After installation or a prolonged shutdown, start the dryer with no air

load (no air flow). This enables the dryer to reach its proper operating

temperature in the shortest time possible (typically within 30 minutes

for Nirvana™ Cycling dryers).

• Start Dryer, using one of the following methods, depending

on Start Mode setting:

Manual Mode - Press the ON pushbutton.

Auto Restart Mode - No additional action required

Remote Automatic Mode - Close the remote contact.

• For Nirvana™ Cycling dryers, the circulating pump will be

energized and will run continuously. Provided the CHILLER

TEMPERATURE is greater than the Compressor Off Set point plus 4° F

and the anti-short cycle delay and crankcase heater delay have timed

out, the refrigeration system will energize. As the system operates and

thermal mass temperature drops, the suction pressure will be lowered to

between 50 and 70 psig.

After the alarm delay, provided the Chiller Temperature is

greater than the HIGH TEMPERATURE ALARM set point, the

dryer will go into HIGH TEMPERATURE ALARM. The LCD

panel will indicate the alarm and the refrigeration system will

continue to operate. Pressing the SELECT DISPLAY button

will permit viewing of the available dryer parameters during

this alarm condition. Note that the alarm condition screen will

reappear after approximately 30 seconds until the alarm

condition is cleared.

The CHILLER TEMPERATURE will gradually drop as

indicated on the display. Once the temperature falls below the

HIGH TEMPERATURE ALARM set point, the alarm will reset

and the LCD panel will return to its default display. After the

refrigeration system shuts off, air flow may be slowly

introduced to the dryer.

NOTICE

If power is removed from the dryer for less than two hours, the

crackcase heater delay will be automatically bypassed. If, however,

the power is removed from the dryer for more than two hours, the full

crankcase heater delay must be observed.

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9.0 SCHEDULED MAINTENANCE

9.1 INTRODUCTION

Ingersoll Rand Nirvana™ Cycling refrigerated air dryers require little

maintenance. These dryers utilize hermetically sealed compressors

which do not require any lubrication. Fan motors require lubrication at

both oil ports every six months. The condensate drain requires annual

replacement of the service unit. Ingersoll Rand recommends

component inspection and service at regular intervals to obtain

maximum performance from your dryer.

9.2 REFRIGERANT CONDENSER

For standard dryers, regular inspection and cleaning of the condenser

is recommended. Ingersoll Rand dryers may be equipped with an

optional ambient air filter designed to protect the condenser from dirt

and debris that can accumulate on the condenser. For proper operation

with this option, it is imperative that this filter be inspected and cleaned

on a regular basis. Annual replacement of the filter is recommended.

For applications where excessive dirt, dust or debris is encountered,

more frequent inspection and cleaning may be required.

9.3 CONDENSATE DISCHARGE SYSTEM

8

9

5

6

7

1

6

2

4

1

3

10

89

5

7

1

3

2

4

Before drain maintenance work always close the drain isolation

ball valve and 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 Drain 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)

or

by 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

• Open drain isolation ball valve. Press drain test button to verify proper

drain operation.

2

1

3

4

5

6

7

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2

5

4

3

2

1

6

4

3

1

Assembly Control unit onto service unit:

Check if service unit (3) matches control unit (1) (type designation and

colour 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

• Open drain isolation ball valve. Press drain test button to verify proper

drain operation.

2

1

3

4

9.0 SCHEDULED MAINTENANCE

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10.0 TECHNICIAN MODE

The Microprocessor Control provides a protected TECHNICIAN MODE

to manipulate several parameters not accessible by the typical operator.

This mode also permits viewing of the factory settings to aid in

troubleshooting of the dryer. Below is a list of parameters that can be

accessed and manipulated by the technician in the TECHNICIAN

MODE:

In TECHNICIAN MODE, the following parameters can be viewed but

not changed:

Parameter Display Set Point

CONFIGURATION (# of

sensors)

CONFIG #: 1 or 2 or 4 or 8

OPERATING MODE OP MODE: HS or NC

REFRIGERANT REFRIG: 404

CONDENSER TYPE COND: AC OR WC

OPERATING

TEMPERATURE

DIFFERENTIAL

T OP DIFF: 4

SHORT CYCLE DELAY SHT CYC DLY: 3

HIGH PRESSURE CUTOUT HPCO: See Table-1

HIGH PRESSURE CUTOUT

DELAY

HPCO DLY: 10

LOW PRESSURE CUTOUT LPCO: See Table-1

LOW PRESSURE CUTOUT

DELAY

LPCO DLY: 00:10

HIGH TEMPERATURE

ALARM

HITEMP ALRM: 55

LOW TEMPERATURE

ALARM

LOWTEMP

ALRM:

30

LOW TEMPERATURE

ALARM DELAY

LOTEMP DLY: 2:00

DISCHARGE PRESSURE

TRANSDUCER

Pd TRANS Y (N)

SUCTION PRESSURE

TRANSDUCER

Ps TRANS Y (N)

SUCTION TEMPERATURE

PROBE

Ts Probe Y (N)

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 ALARM

LIST

N/A

Parameter Display Set Point

NO-LOSS DRAIN VALVE

ENABLE

DRAIN ENABLE ON (or OFF)

CRANKCASE HEATER

DELAY

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

AUTO RESTART ENABLE AUTO RESTART N (or Y)

10.1 ENTERING TECHNICIAN MODE

WARNING

TECHNICIAN MODE should only be entered by qualified service

personnel. Altering the set points in TECHNICIAN MODE will have a

significant effect on the operation of the dryer. Incorrect set points may

damage dryer and cause potential serious injury.

To enter the TECHNICIAN MODE, perform the following keystrokes:

Pressing the “2” and “3” buttons simultaneously enters the

TECHNICIAN MODE.

TECH SET MODE

SELECT

DISPLAY

Depressing SELECT DISPLAY scrolls through the available

parameters. The first three parameters viewed are adjustable in

TECHNICIAN MODE.

DRAIN ENABLE: OFF

2

3

The DRAIN ENABLE parameter determines whether the

Microprocessor Control shall control an electronic no-loss drain valve. A

value of “ON” will permit the Microprocessor Control to control the drain

valve. A value of “OFF” will disable this feature. Ingersoll Rand dryers

are equipped with a no air loss drain as standard equipment. As such,

DRAIN ENABLE must remain “OFF”:

Depressing the SELECT DISPLAY button advances to the

next adjustable parameter for the Crankcase Heater Delay.

This parameter must not be altered unless instructed by

Ingersoll Rand Service personnel.

CCH DELAY: 8

SELECT

DISPLAY

NOTICE

The Crankcase Heater Delay set point must not be altered unless

directed by Ingersoll Rand Service Personnel. Improperly altering the

set point may result in damage to the dryer. Contact Ingersoll Rand

Compressed Air Solutions before altering the default set point.

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10.0 TECHNICIAN MODE

The AUTO RESTART feature permits the dryer to operate once power

is applied to the dryer without requiring operator intervention. This would

be desirable should the user wish to have the dryer restart automatically

after a power outage. To change the AUTO RESTART set point from “N”

(NO) to “Y” (YES), perform the following. Otherwise, depress the

SELECT DISPLAY button to advance to the next display:

Depressing ENTER saves the selected set point.

AUTO RESTART: Y

SET

Depressing the SET button changes the AUTO RESTART

parameter from “N” to “Y”.

AUTO RESTART: Y

ENTER

Depressing the SELECT DISPLAY button advances to the

next adjustable parameter for the Auto Restart feature.

AUTO RESTART: N

SELECT

DISPLAY

WARNING

Changing the AUTO RESTART feature to “Y” will permit the dryer to

operate automatically once power is applied and after a brief delay.

Proper warning signs should be affixed to the dryer to alert users and

service personnel that dryer may start without warning. Failure to do so

may result in serious injury.

Depressing the SELECT DISPLAY button displays the END

TECH SET PTS display.

END TECH SET PTS

SELECT

DISPLAY

The remaining non-adjustable parameters may be viewed by

depressing the SELECT DISPLAY button as required to arrive at the

desired display.

NOTICE

To exit the TECHNICIAN MODE at any time, depress the  button

located above the SET button to return to the CUSTOMER MODE.

10.2 ALARM LIST

At the end of the list of non-adjustable parameters, the Microprocessor

Control displays a list of the most recent 20 alarm conditions. This list

can facilitate troubleshooting the dryer.

At the end of the list of parameters, depressing the SELECT

DISPLAY button displays the beginning of the ALARM LIST.

BEGIN ALARM LIST

SELECT

DISPLAY

Depressing the SELECT DISPLAY button displays the alarms

that the dryer has experienced, with the most recent alarm

displayed first. The actual display will depend on the most

recent alarm detected by the Microprocessor Control.

HPCO

SELECT

DISPLAY

The list of alarms can be scrolled by depressing the SELECT

DISPLAY button as needed. At the end of the alarm list, the

END ALARM LIST screen is displayed.

END ALARM LIST

SELECT

DISPLAY

Depressing the SELECT DISPLAY list displays the ALARM

LIST screen at the top of the ALARM LIST.

BEGIN ALARM LIST

SELECT

DISPLAY

The Alarm List will repeat as many times as the SELECT DISPLAY

button is depressed. To EXIT the ALARM LIST, perform the following:

Depressing the BLANK button (located above the SET

button) returns the controller to the top of the TECHNICIAN

MODE.

TECH SET MODE

Depressing the BLANK button again returns the controller to

the default display of the CUSTOMER MODE.

CHLLR TEMP: 37

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11.0 TROUBLESHOOTING

11.1 INTRODUCTION

Ingersoll Rand Nirvana™ Cycling dryers are designed for reliable, trouble-free operation. In the event of any dryer malfunction, the guide below has

been developed to facilitate problem identification and corrective actions.

WARNING

An air dryer always operates under pressure. Any maintenance

procedure that involves disassembly of pipe fittings, valves or any

other components requires the dryer be isolated from the compressed

air stream and fully depressurized.

WARNING

Prior to working on the unit, make sure that all circuit breakers or

disconnected switches are tagged “Out of Service.”

11.2 PROBLEM / ACTION GUIDE

PROBLEM

Moisture down stream

SYMPTOM(S)

Dryer is properly cooling air

stream (Check Chiller. Temp

on controller)

Inlet and outlet temperatures

are the same.

Inlet and outlet temperatures

are the same.

Compressor and fan are

running, exchanger temp

high, pump not running.

POSSIBLE CAUSE

Condensate drain failure

caused by defective service

unit.

Excessive flow

Dryer by-pass valve not

closed

No power to the dryer

High suction pressure

Refrigerant leak

Compressor not running and

fan is running

Compressor and fan not

running.

Compressor and fan not

running. Controller indicates

compressor is ON.

Defective Pump

CORRECTIVE ACTION

Replace service unit.

Check inlet and outlet pressure and system

design capacity. Correct cause of excessive flow.

Close by-pass valve

Check power supply and fuses/circuit

breakers

Check and clean condenser.

Check suction pressure gauge if reading is

0 psig, turn dryer off and contact your

distributor

Check and clean condenser.

Check ambient temperature and reduce

below 113°F

Check Chiller Temperature

Check MAIN CONTROL fuse.

Compressor relay may be bad, replace relay

Check for loose wire connections at

contactor or loss of power at control board

Defective control board - replace as

necessary

Contact your local distributor for further

assistance.

Contact your local distributor for further

assistance.

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11.0 TROUBLESHOOTING

PROBLEM

Apparent controller display

malfunction

High pressure drop across

dryer

Condensate drain does not fire

Condensate drain LED is off

Air bleed from condensate

drain outlet port

Condensate drain bowl does

not seem to fill with

condensate, drain does not

seem to work due to air

locking

SYMPTOM(S)

Display Blank

Unrealistic temperature

displayed

Erratic or inaccurate

temperature readings

Unrealistic pressure

displayed

Outlet pressure substantially

lower than inlet pressure

System operating

temperature is above 32°F

Outlet pressure substantially

lower than inlet pressure

System operating

temperature is below 32°F

POSSIBLE CAUSE

Blown Fuse

Board Failure

Probe loose,off connection or

defective probe

Probe not completely in

thermal well

Defective probe

Transducer loose, off

connection or defective

transducer

Inlet and outlet valves not

completely open

Inlet and outlet filters blocked

up

Compressor relay / contactor

stuck.

Microprocessor Control relay

bad

Probe not completely in

thermal well

Problem persists

Inlet / outlet pipe internal

diameter too small causing

air-lock or back pressure.

Excessive use of bends /

elbows in inlet / outlet pipe

work causing air-lock/ back

pressure.

Outlet pipe too long / too

high causing back pressure.

More than one condensate

source connected providing

alternative path for

condensate.

Debris trapped under seal.

Damage to seal.

CORRECTIVE ACTION

Check Fuses

Contact your local distributor for further

assistance.

Inspect probe cable and terminal connection

Replace probe

Inspect probe and check readings against

independent source (eg. temperature

analyzer/pyrometer/ice bath) both in

temperature well and to ambient

Replace probe

Inspect transducer cable and terminal

connection

Replace transducer

Open valves

Change filter elements

Replace relay / contactor.

Replace relay

Inspect probe and check readings against

independent source (eg. temperature

analyzer/pyrometer/ice bath) both in

exchanger well and to ambient

Turn dryer off and consult your local

distributor for further assistance

Check installation is in accordance with this

manual. Revise installation accordingly.

Replace with larger diameter piping.

Reduce the amount of bends and elbows.

Reconfigure condensate piping.

Reroute condensate to eliminate secondary

path. Install check valves as required.

Check power supply. Press test button for

minimum 2 seconds and observe. Locate

and eliminate supply fault.

Press and hold the test button to clear (drain

valve will open). Replace seal with Service

Kit.

If bottom inlet is used, top port must be used

as air bleed. Make sure Connect the top

inlet to a higher point in system, which will

function as an air bleed for the drain.

12.0 WIRING DIAGRAMS

WIRING DIAGRAM FOR

NVC2000-2400 AIR AND WATERCOOLED

230-575V/3/60, 200-440V/3/50

550019D

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13.0 GENERAL ARRANGEMENT

FRONT VIEW AIRCOOLED

AIR AND WATERCOOLED RIGHT SIDE VIEW

REAR VIEW

TOP VIEW

1.00

TYP

3.09

TYP

6.3173.50

6.75

16.50

34.00

79.94

.56 MTG HOLES

4 PLCS

CUSTOMER MAIN POWER

ELECTRICAL CONNECTION BOX

6"-150# R.F.S.O. FLANGE

AIR INLET CONNECTION

6"-150# R.F.S.O. FLANGE

AIR OUTLET CONNECTION

STANDARD DRAIN

3/8" I.D. NYLON TUBE

72.00

75.12

FRONT VIEW WATERCOOLED

76.00

2.00

TYP

32.00

90.69

3.00

10.50

4.75

5.00 86.00

COVER FOR

WATERCOOLED

HEADERS

90.00

24.0031.00

3.00

FORK POCKETS

6.00 X 2.50

CONDENSER FOR

WATERCOOLED UNITS

(REF)

A

DETAIL A (TYP)

AIR TREATMENT

CONTROL SYSTEM

LCD DISPLAY

1) CHILLER TEMP

2) COMPRESSOR ON/OFF

3) DRAIN INTERVAL

4) DRAIN ON

5) PERCENT SAVINGS

6) CUMULATIVE DRYER HOURS

7) CUMULATIVE COMPRESSOR HOURS

8) CUSTOMER SET POINTS

A) CHILLER TEMP

B) DRAIN INTERVAL

C) DRAIN ON

PUSHBUTTONS

1) ON

2) OFF

3) RESET

4) TEST

5) SET

6) SELECT DISPLAY

7) ENTER

8) +/-

1.38

1-1/2" MPT WATER

OUTLET CUSTOMER

CONN.

1-1/2" MPT WATER

INLET CUSTOMER

CONN.

CONDENSER FOR

AIRCOOLED UNITS

(REF)

SHOWN FOR

REFERENCE

550000

GENERAL ARRANGEMENT

NVC2000-2400

AIR AND WATERCOOLED, NEMA-1

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