Ingersoll-Rand HEATER 420 User manual

1 - 8
COMPRESSED AIR HEATERS
Operators Manual

2 - 8

Cod. 710.0185.40.00 Rev1B –11.2018 © Copyright 2018 Ingersoll Rand - All rights reserved
- EN -
CONTENTS
1. GENERAL INFORMATION 2
1.1 Functional description 2
1.2 Safe use of the product 2
2. INSTALLATION 2
2.1 Acceptance, unpacking and handling 2
2.2 Storage and installation location 2
2.3 Unpacking 3
2.4 Installation 3
3. START-UP 3
4. MAINTENANCE 3
4.1 Weekly 3
4.2 Monthly 4
5. CONTROL PANEL 4
5.1 Icons description 4
5.2 Buttons function 5
5.3 Functions menu 5
5.4 Alarms 6
5.5 Set point display 6
5.6 Black out 6
6. DECOMMISSIONING 6
ATTACHMENTS TO THIS MANUAL
A) Electric circuit diagram 8
B) Technical data sheet 9
C) Product dimensions 9
D) Basic spare parts 9

Cod. 710.0185.40.00 Rev1B –11.2018 © Copyright 2018 Ingersoll Rand - All rights reserved 1 - 9
- EN -
Introduction
This manual is an integral part of the product you bought, and must remain with the product even if this will be resold.
It is highly recommended that the qualified*personnel for installation maintenance and/or control will fully comply with the contents of
this manual and the prevention and safety rules in force in the country where the system will be used. In this way, not only the usage of
the product will be rational, but also the service will result cost effective.
In case your product will present any kind of problem, please contact your local authorized Ingersoll Rand distributor.
Please note that, when necessary, the use of original spare parts will ensure efficiency and long duration to your product.
Due to the continuous technological evolution, Ingersoll Rand reserves the right to modify the specifications contained in this manual
without giving previous notice.
Symbols and labels used in the manual and on the product
Air entry point
Air outlet point
Read the Operators manual before attempt to start
up the product and to perform any service operation
on the heater.
Pay particular attention to components or systems
under pressure.
Installation, maintenance, and/or control operations
preceded by these symbols must be performed
exclusively by qualified personnel*.
Pay particular attention to the indications preceded
by these symbols.
Lifting point.
Don’t lift from this point.
Attention: Before performing any
maintenance operation on this product,
do not forget to disconnect the electric
supply, to completely discharge air
pressure, and to refer to the Operators
manual.
Condensate drain point.
Explosion risk.
Pay particular attention to the risk of electric shock.
Pay particular attention to hot surfaces.
* Qualified personnel must be trained and certified in accordance with local laws and regulations.
Warranty
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.

Cod. 710.0185.40.00 Rev1B –11.2018 © Copyright 2018 Ingersoll Rand - All rights reserved 2 - 9
1. GENERAL INFORMATION
1.1 Functional description
Ingersoll Rand compressed air heaters are used to warm compressed air.
Compressed air enters the vessel where it is warmed to the required temperature by ohmic elements. If any liquid or dust enters the
vessel, it can be collected at the bottom and eliminated through the manual drain valve. This product can be easily installed into various
pneumatic systems in which warm air is required or desired. Please refer to Principles of Operation for complete operating details.
The product comes provided with all the control, safety and adjustment devices, therefore no auxiliary devices are needed.
A system overload not exceeding the maximum operative limits can worsen the operational performance of the product
(lower outlet temperature), but it will not affect its safety.
The electric diagram (attachment A) shows the minimum protection degree IP 54.
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 or
lead on the product.
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 wire for the
electric current.
Ground must be established with a bare 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.
This product is designed to work only with compressed air. For a different use, please contact your
distributor Ingersoll Rand.
1.2 Use of the device in safe conditions
This system has been designed and manufactured in compliance with the European safety directive in force, therefore any installation,
use and maintenance operations must be performed respecting the instructions contained in this manual. Because an air product is a
pressurized vessel, the same precautions should be observed as with anypiece of equipment 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 equipment,
safety precautions as listed below must be observed.
1. Only qualified personnel shall be permitted to adjust, perform maintenance or repair this air heater.
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 the device 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 operate the product at pressures in excess of its rating.
7. Inspect unit daily to observe and correct any unsafe operating conditions.
2.0 INSTALLATION
2.1 Acceptance and handling
Upon receiving your Ingersoll Rand air product, please inspect the unit closely. If rough handling is detected, please note it on your
delivery receipt, especially if the product will not be uncrated immediately. Then obtain the freight carrier's signed agreement to any noted
damages: this is a precondition for any insurance claims by the customer.
For handling, use devices having sufficient capacity for the weight of the machine.
Remove the packaging after having positioned the product in the installation site. For unpacking, refer to section 3.3.
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, may cause serious injury. Use fork lift channels where provided.
2.2 Storage and installation location
If not in use, the product can be stored in its packaging in a dust free and protected site between 32°F (0°C) and 120 °F (50 °C), and a
specific humidity not exceeding 90 %. Should the stocking time exceed 12 months, please contact your local Ingersoll Rand authorized
distributor.

Cod. 710.0185.40.00 Rev1B –11.2018 © Copyright 2018 Ingersoll Rand - All rights reserved 3 - 9
If the product is not used, it will be placed in a site with the following conditions:
The device must be protected from atmospheric agents and not directly exposed to sun light.
A seating base flat and capable to hold the weight of the device.
Ambient temperature complying with the nominal data of the product.
The product should be located in a clean area.
Make sure to leave sufficient clearance (20 inches, 0.5 m) around the product in order to allow an adequate
maintenance and/or control operations.
The incoming air must be free from smoke or flammable vapours which could lead to explosion or fire risks.
2.3 Unpacking
The packaging is made of carton or of cellophane. We recommend that you keep the original packaging for the device in case it has to
be transported to another location or sent to a service center. Dispose the various packaging materials in compliance with the relevant
rules locally in force.
unpack the device, removing the strapping from the carton. Always wear safety gloves when using scissors or other tools to cut the
straps or the cellophane;
remove the carton or the cellophane;
in case it’s necessary another handling of the device, refer to section 3.1;
remove the pallet (if present);
remove the operating manual, accessories and key from the device.
2.4 Installation
Before attempting any installation operation, make sure that
No parts of the air system are under pressure.
No parts of the system are electrically powered.
Tubing to be connected to the product are free of impurities.
The pipes to be connected to the product does not weigh on the device.
All interconnecting piping has been tightened.
After having verified the points listed above, you can proceed to the installation of the device.
1. Connect the product to the compressed air lines. If not already existing, we suggest to install a by-pass allowing
to isolate the device from the plant, thus to facilitate eventual maintenance operations.
2. It is highly recommended to insulate the outlet piping, to guarantee the required outlet temperature
3. Perform the electrical connection in accordance with any local laws and regulations after reviewing the product
electrical specifications and wiring diagram.
4. Power the product after having checked that the nominal voltage and line frequency are constant and matching
the nominal values of the device. The user must provide the installation with an adequate line protection
and a ground terminal complying with the electrical rules locally in force.
In order to optimise the use of the product, we suggest to place it in such a way that all the control instruments of the device
will result easily visible.
A suitably sized prefilter must be installed before the product. Failure to install and maintain a proper prefilter will
void the product warranty. The rating for this filter must be at least 10 micron.
It is necessary for the user to install a protective device (a safety accessory) to protect the equipment under
pressure from the risk of exceeding the maximum allowable pressure (PS);
3.0 START-UP
Make sure that intake and outtake valves are closed, switch on the device (1S1).
Now open the outlet air valve and then open gradually the intake air valve. In this way, the plant is gradually pressurized.
If the plant is overloaded over the max. use limits (see technical data), the product's performance will be remarkably lower but safety will not be in
danger.
4.0 MAINTENANCE
Attention! Perform pressure test with inert gases only (helium, nitrogen).
4.1 Weekly
Check manually if there is condensate on the bottom of the vessel.

Cod. 710.0185.40.00 Rev1B –11.2018 © Copyright 2018 Ingersoll Rand - All rights reserved 4 - 9
4.2 Monthly
Clean prefilter to remove any possible dirt on the inner filtering element.
Perform the following after stopping the compressed air flow by closing the intake and outtake valves.
In case of replacement of one or more components of the device, disposed it along the eventual packaging of the
replacement part, as reported in section 6.0.
5.0 CONTROL PANEL
This kit is equipped with a temperature controller for the adjustment of the heating parameters. It is provided with an output relay to drive
the solid state relay for the heater and with a NTC probe for temperature control. The regulation is performed according to the temperature
measured by the probe. If the temperature decreases and reaches “set point minus differential” value, the regulation output is activated.
Then it turns off when the temperature reaches the “set point”value again. Adjustments can be made using the digital panel, located on
the electrical box front panel.
The SET & other control parameters have been optimized and factory set. Although the set point value can be
displayed, the ability to alter these factory settings via the digital interface on the front panel has been removed
to eliminate the possibility of unit damage caused by improper settings.
fig.1 - Control panel
Normal conditions read - out
At normal operating conditions, if no alarms are present, the display shows the temperature of
the outlet air:
On: Heater ON
Off: Heater OFF
5.1 Icons description
ICON
STATUS
DESCRIPTION
ON
Heater ON
BLINKING
Anti-short cycle delay enabled
ON
Generic Alarm
ON
Not used
ON
Measurement unit
BLINKING
Programming phase

Cod. 710.0185.40.00 Rev1B –11.2018 © Copyright 2018 Ingersoll Rand - All rights reserved 5 - 9
5.2 Buttons function
Single buttons function
SYMBOL
DESCRIPTION
Not used
Not used
Pressed during normal operation displays the max air outlet stored temperature; when pressed during
programming mode, it scrolls the parameters list or increases the displayed value.
Pressed during normal operation displays the min air outlet stored temperature; when pressed during
programming mode, it scrolls the parameters list or decreases the displayed value.
Pushed and released shows on display the SET POINT value. In programming mode selects a parameter
or confirms a value.
Not used
Buttons combinations
To lock & unlock the keyboard.
Enters the parameter programming menu.
Exits the parameter programming menu.
5.3 Functions menu
How to see the min temperature
1. Press and release the key.
2. The “Lo” message will be displayed followed by the minimum temperature recorded.
3. By pressing the key again or by waiting 5s the normal display will be restored.
How to see the max temperature
1. Press and release the key.
2. The “Hi” message will be displayed followed by the maximum temperature recorded.
3. By pressing the key again or by waiting 5s the normal display will be restored.
How to reset the man and min temperature recorded
1. Hold press the SET key for more than 3s, while the max. or min temperature is displayed. (rSt message will be displayed)
2. To confirm the operation the “rSt” message starts blinking and the normal temperature will be displayed.
How to lock the keyboard
1. Keep pressed for more than 3 s the + keys.
2. The “POF” message will be displayed and the keyboard will be locked. At this point it will be possible only to see the set point or the
MAX o Min temperature stored
3. If a key is pressed more than 3s the “POF” message will be displayed.
How to unlock the keyboard
Keep pressed together for more than 3s the and keys, till the “Pon” message will be displayed.

Cod. 710.0185.40.00 Rev1B –11.2018 © Copyright 2018 Ingersoll Rand - All rights reserved 6 - 9
5.4 Alarms
The controller is able to recognize particular types of faults. When this occurs, the display shows the required information necessary to
find out the cause.
The controller is programmed to recognize and display alarms.
Alarm table
Label
Meaning
Cause / Origin
Controller status
Reset
P1
Air output probe alarm
Missing, faulty probe or
resistance exceeding
value
General alarm icon lighted
Alarm code on display
Automatic
if the probe value recovers
If the alarm persists call your local distributor
HA
Air output high
temperature alarm (P1
probe)
Air output temperature
higher than the presetted
value
General alarm icon lighted
Alarm code on display
Automatic If the temperature returns into range of good
working.
Warning for user:
It’s forbidden to modify setting parameters of the electronic controller without the authorization of the manufacturer.
5.5 Set Point Display
Push and release SET button: display will show the set point value. Push and release SET button or wait for 5 seconds to display the air
outlet temperature value again.
NOTE: Any change to the machine’s configuration parameters could be harmful to its efficiency and therefore it must be done
only in collaboration with the Manufacturer.
5.6 Black Out
After a power black-out:
1. The controller restarts from the previous status.
2. All the working time delay will be reloaded.
6.0 DECOMMISSIONING
All work on the product may only be carried out by specialist personnel!
Follow this procedure if you need to shut down the product:
Stop the device and permanently isolate it from the electricity mains;
Disconnect the power cable;
Take pressure off the air circuit;
If the device has to be dispatched, use the original or similar packaging and keep the device in an up-right position.
Before carrying out any work on the electrical parts, make sure that the main switch interrupts the electricity supply to the
product and then affix appropriate warning signs to avoid the machine being reconnected to the electricity mains!
Please consult the contents and the safety instructions in the relevant sections of these instructions for details of the correct
handling and storage of the product.
Send the product to an approved waste disposal company in accordance with current environmental protection legislation. The
other materials/waste constituents must be treated in line with the provisions of the valid legislation.

Cod. 710.0185.40.00 Rev1B –11.2018 © Copyright 2018 Ingersoll Rand - All rights reserved 7 - 9
EN
ATTACHMENTS TO THE MANUAL
Legend
1A1
1B1
1B2
EN
Electronic Controller
Drain solenoid valve coil
Liquid solenoid valve coil
1B3
1M1
1M2
1M3
EN
By-pass solenoid valve coil
Refrigerant compressor
Fan Motor
Glycol circulator
1P1
1P2
1Q1
EN
High pressure Switch
Fan pressure Switch
Compressor circuit breaker
1Q2
1Q3
1R1
EN
Fan circuit breaker
Transformer circuit breaker
Compressor crankcase heater
1R2
1R3
1S1
1S2
EN
Electrical panel heater
Condensate drain heater
Main power switch
Plug
1S3
1T1-1T2-1T3
1V1
1V2
EN
ZERO DRAIN Terminal blocks
Transformer
Solenoid drain Valve
Liquid solenoid valve
1V3
ACC
CB
CBL
CNA
CND
EN
By-pass solenoid valve
Tank
Compressor box
Cables
Sacrificial anode
Condenser
CNV
CPL
EB
ED
EN
Fan capacitor
Capillary tube
Electrical box
10 micron filter element
EH
EP
EQ
EVA
F1-F2
EN
0.01 micron filter element
1 micron filter element
5 micron filter element
Evaporator
Fuses
FD
FF
FH
FP
EN
Air filter 10 micron
Filter dryer
Air filter 0.01 micron
Air filter 1 micron
FQ
FR
FT
FV
G
EN
Air filter 5 micron
Drain screen
Noise filter
Fan motor fuse
Grid
GFCI
IM
K1
EN
Ground fault circuit breaker
Moisture indicator
Contactor switch
K2
KRC1
MHP
MLP
EN
Fan contactor switch
Protection module
High pressure manometer
Low pressure manometer
PCP
PR
PSC
R
EN
Thermal protection
Air-air heat exchanger
Air-air heat exchanger (D-IT)
Compressor relay
RB1
RBF
RBS
RD1
REF
EN
Freon Tap
Tap with strainer
Changeover tap
Reed sensor
Fan speed regulator
RF
RL
RR
RS
PB / RT
EN
Phase control relais
Liquid receiver
Rotalock tap
RS485 Interface
Temperature probes
SC
SCO
SH
SLI
EN
Heat exchanger base
Condensate separator
Sensor hose
Liquid separator
SP
SSC
STC
TEMP
TH1
EN
Schrader
Condensate drain
Control panel cover
Time setter
Thermostat
THR
TLT
VA
VB
EN
Electrical box thermostat
Remote cont. Thermostat
Glycol valve
By-pass hot gas valve
VBA
VE
VNR
VP
EN
Air by-pass valve
Expansion valve
One way valves with strainer
Pressostatic valve
VS
VSR
VT
X1-X2-X3-X4
EN
Tap
Freon safety valve
Fan blade
Terminal blocks

Cod. 710.0185.40.00 Rev1B –11.2018 © Copyright 2018 Ingersoll Rand - All rights reserved 8 - 9
(A)
EN
WIRING DIAGRAM
Cod. 714.0275.02.00 –Rev. 01
Model 420 (230V/1Ph/50-60Hz)
Power and control circuit diagram
Components layout

Cod. 710.0185.40.00 Rev1B –11.2018 © Copyright 2018 Ingersoll Rand - All rights reserved 9 - 9
(B)
EN
DATA SHEET
MODEL
HEATER 420
AR
Air flow rate
Nl/min
Nm³/h
7000
420
CONN
Air connections
BSP
1”-1/2
W
Weight
Kg
24
AIR T
Air inlet temp.
°C
Min 0 / Max 50
AMB T
Ambient temp.
°C
Min -10 / Max 45
PRESS W
Working pressure
bar
7 (Max 14)
POW SUPPLY
Power supply
V/Ph/Hz
230/1/50-60
kW
Nom. consumption
KW
1,6
RLA
Nom. Current
A
7
(C)
EN
DIMENSIONS
(D)
EN
BASIC SPARE PARTS
Model
SSP
Heater 420
Pos
Element
1A1
Electronic Controller
A
47644985
RT1
Temperature probe
A
18301697
K1
Relay
B
47644984
F1
Fuse
B
47644983
TH
Thermic switch
C
24165847

710.0185.40.00-01B