Nirvana D4290NCHP User manual

80445455
Revision C
December 2013
Save These Instructions
Nirvana High Pressure Cycling Refrigerated Dryer
Models D4290NCHP, D5635NCHP AND D7055NCHP
Operator’s Manual
Manual Del Operador
ES
Manual do Operador
PT
Manuel De L’opérateur
FR
Operator’s Manual
EN
120.26A D4290NCHPW400F Installation Operation and Maintenance Manual

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1.0 CONTENTS
CONTENTS PAGE
1.0 CONTENTS 3
2.0 INTRODUCTION 3
3.0 WARRANTY 3
4.0 REFRIGERATED DRYER NOMENCLATURE 3
5.0 RECEIVING AND INSPECTION 4
5.1 INSPECTION 4
5.2 UNPACKING AND HANDLING 4
6.0 SAFETY AND OPERATION PRECAUTIONS 4
OSHA HEADING DESCRIPTIONS 4
7.0 PRINCIPLES OF OPERATION 6
7.1 INTRODUCTION 6
7.2 AIR SYSTEM 6
7.3 MOISTURE REMOVAL SYSTEM 6
7.4 REFRIGERATION SYSTEM 6
7.5 THERMAL MASS CIRCULATING SYSTEM 6
7.6 CONTROLS 9
7.6.1 BASIC USER INTERFACE 10
BUTTONS 10
7.6.2 DISPLAY PARAMETERS 10
7.6.3 DRYER SET POINTS AND ALARMS 11
7.6.4 ADJUSTING SET POINTS 11
7.6.5 ALARMS AND THEIR FUNCTIONS 11
7.6.6 START MODES 12
7.6.6.1 MANUAL MODE 12
7.6.6.2 AUTO RESTART MODE 12
7.6.6.3 REMOTE AUTOMATIC MODE 12
CONTENTS PAGE
8.0 INSTALLATION AND INITIAL STARTUP 13
8.1 LOCATION AND MOUNTING 13
8.2 PIPING AND VALVES 13
8.3 FILTRATION 13
8.4 ENVIRONMENTAL CONSIDERATIONS 13
8.5 ELECTRICAL CONNECTION 15
8.5.1 START SETTINGS 15
8.6 INITIAL STARTUP 16
8.6.1 START UP SEQUENCE 16
9.0 SCHEDULED MAINTENANCE 16
9.1 INTRODUCTION 16
9.2 REFRIGERANT CONDENSER 16
9.3 PREFILTERS AND POSTFILTERS 16
10.0 TECHNICIAN MODE 17
10.1 ENTERING TECHNICIAN MODE 17
10.2 ALARM LIST 18
11.0 TROUBLESHOOTING 19
11.1 INTRODUCTION 19
11.2 PROBLEM / ACTION GUIDE 19
12.0 WIRING DIAGRAM 21
13.0 GENERAL ARRANGEMENT 23
14.0 REPLACEMENT PARTS 25
15.0 ENGINEERING SPECIFICATIONS 26
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2.0 INTRODUCTION
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 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.
3.0 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 rst 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 specic 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 eects of corrosion, erosion and normal wear and tear
are specically excluded. Performance warranties are limited
to those specically stated within the Company’s proposal.
Unless responsibility for meeting such performance
warranties are limited to specied 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 fulllment 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 rst 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 prec-
edence over this warranty.
4.0 REFRIGERATED DRYER NOMENCLATURE
DRYER NOMINAL*
FLOW
(Nm/hr)
NIRVANA
CYCLING
HIGH
PRESSURE
CONDENSER
TYPE
POWER RATING
D 4290
5635
7055
NC HP A = AIR
W = WATER
4 = 460-3-60
6 = 575-3-60
7 = 380-3-50
0 = NEMA 1
H = NEMA 4
* Nominal Flows indicated are for 100°F inlet temperature, 100°F ambient temperature and 580 psig compressed air pressure
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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:
Only qualied personnel shall be permitted to adjust,
perform maintenance or repair this air dryer.
Read all instructions completely before operating
unit.
Pull main electrical disconnect switch and disconnect
any separate control lines, if used, before attempting
to work or perform maintenance on the unit.
Do not attempt to service any part while machine is in
an operational mode.
Do not attempt to remove any parts without rst
relieving the entire air system of pressure.
Do not attempt to remove any part of the
refrigeration system without removing and
containing refrigerant in accordance with the EPA and
local regulations.
Do not operate the dryer at pressures in excess of its
rating.
Do not operate the dryer without guards, shields and
screen in place.
Inspect unit daily to observe and correct any unsafe
operating conditions.
1.
2.
3.
4.
5.
6.
7.
8.
9.
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.
6.0 SAFETY AND OPERATION PRECAUTIONS
5.0 RECEIVING AND INSPECTION
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.
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.
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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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7.0 PRINCIPLES OF OPERATION
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“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 uid. The
temperature of the thermal mass uid 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 ow.
7.3 MOISTURE REMOVAL SYSTEM
Ingersoll Rand condensate drains discharge condensed
moisture and lubricants (condensate) from compressed air
equipment. Consistent discharging of condensate from
compressed air equipment is essential for proper equipment
operation and performance. The drain valve is designed for
trouble-free and maintenance free draining of unwanted
accumulations of condensation and other foreign matter
from any collection point in a compressed air system without
the need for electricity.
The high pressure condensate drain installed on the dryer
requires the user to supply clean dry air (80 - 120 psig)
for proper operation. Refer to the instruction label on the
condensate drain for details. A small volume of air must be
displaced (vented to atmosphere) to allow for the collection
of condensate. Make certain the vent valve on the drain is
open to assure proper drain operation.
7.4 REFRIGERATION SYSTEM
The Refrigeration System consists of all the components
which handle. This is a hermetically sealed closed-loop
system. Referring to Figure 1 and following the phantom
“REFRIG FLOW,” 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 lter dryer that ensures the
refrigeration system is free of contaminants. A thermostatic
expansion valve meters the refrigerant for introduction into
the evaporator. The refrigerant pressure is reduced upon
entering the evaporator where as it evaporates, heat is
removed from the thermal mass uid.
7.5 THERMAL MASS CIRCULATING SYSTEM
The thermal mass uid 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 uid 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
uid 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 o
based on loading conditions, the circulating pump runs
continuously to maintain ow through the chiller at all times.
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PROCESS AND INSTRUMENTIONA DIAGRAM D4290NCHP WATERCOOLED 550130
FIGURE 1
7.0 PRINCIPLES OF OPERATION
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PROCESS AND INTRUMENTATION DIAGRAM D5635NCHP & D7055NCHP AIR AND WATERCOOLED 550116
FIGURE 1
7.0 PRINCIPLES OF OPERATION
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7.6 CONTROLS
Ingersoll Rand 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 O temperature. Once the Chiller Temperature
has fallen below the Chiller Temperature Set point, the
refrigeration compressor will de-energize. The Operating
Temperature Dierential 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 oer 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 o by the Microprocessor based on
the refrigerant discharge pressure. The primary fan
is cycled on at 275 psig and o 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 o.
Water cooled condensers utilize a water regulating
valve (Note Figure 2). The water regulating valve
comes pre-adjusted from the factory at 250 psig
discharge pressure. To compensate for water
temperature variation, it may be necessary to adjust
the water regulating valve to maintain a 250 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
WATER REGULATING VALVE
FIGURE 2
•
•
7.0 PRINCIPLES OF OPERATION
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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.
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 “O 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 xed range. Also allows
entering negative numbers in FACTORY MODE.
TEST
Button not used on high pressure dryers.
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.
7.6.2 DISPLAY PARAMETERS
The Microprocessor Control is capable of displaying a
number of system parameters. For NVC dryers, Module #1
is supplied with a Deluxe Microprocessor Controller. The
remaining modules feature a Microprocessor Controller. The
following summarizes the parameters that can be accessed
by the user from the Microprocessor Controller:
Chiller Temperature (CHLLR TEMP): For Nirvana
Cycling Dryers, the Chiller Temperature is the
temperature, in degrees Fahrenheit, of the thermal
mass uid.
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)
•
•
•
•
•
•
•
•
•
•
•
•
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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 congure 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:
SETPOINT Display
Description
Parameter
Range
Factory
Setpoint
Nirvana
Cycling
Chiller O
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 CHLLR TEMP: 36
Pressing SELECT DISPLAY will increment the display through
the available display parameters.
SELECT
DISPLAY Cust Set Points
Continue pressing SELECT DISPLAY until the Customer Set
point screen is displayed. The parameters that follow are the
User Adjustable Parameters for the controller.
SELECT
DISPLAY CHLLR TEMP: 36
Press SELECT DISPLAY until “CHLLR TEMP” is displayed.
CHLLR TEMP:38
+
-
Depress “ + / -“ as required to change the CHLLR TEMP to 38
degrees.
ENTER CHLLR TEMP:38
Pressing “ENTER” saves the set point.
SELECT
DISPLAY End Cust Set Pts
Press SELECT DISPLAY as necessary to display the End
Customer Set points Screen.
SELECT
DISPLAY CHLLR TEMP: 36
Press SELECT DISPLAY as necessary to return the
Microprocessor Control to the desired display parameter.
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.
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
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 signicant
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 rectied.
7.0 PRINCIPLES OF OPERATION
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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 rectied.
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.
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
lowpressure 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.
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
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.
7.6.6.1 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
conguration, 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.
7.0 PRINCIPLES OF OPERATION
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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 sucient 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 ow of air to the condenser inlet.
If loads uctuate widely, the dryer should be positioned
ahead of the receiver and sucient storage capacity
downstream is necessary to prevent excessive air ow
through the dryer.
When installed after any compressor that causes signicant
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, ttings and accessories as required for specic
site conditions and requirements. Figure 3 indicates a typical
piping arrangement for a refrigerated dryer, including dryer
and lter bypasses. This gure can be used as a guide for
valve and accessory placement in the system.
A high-pressure condensate drain is preinstalled at the
factory. These drains require the user to provide clean, dry
air (80 psig - 120 psig) for proper operation. Connect clean,
dry air source to 1/8” NPT port as indicated on condensate
drain instruction label. Assure needle vent valve is open to
allow for displacement of air with condensate in reservoir.
8.3 FILTRATION
To protect the air dryer from gross contamination associated
with compressor oil and debris and ensure maximum dryer
performance, a pre-lter is recommended. Pre-lters and
post-lters sized to your drying application can be provided
by Ingersoll Rand and are available factory installed. Call
your local distributor to select the lter that best suits
your ltration requirements. In addition to air ltration,
condensate discharge oil/water separators are also available
to address stringent EPA regulations.
8.4 ENVIRONMENTAL CONSIDERATIONS
In many applications, high pressure dryers are a component
of air systems that use high-pressure, oil-free compressors.
These compressors can generate condensate that is
acidic. Such acidic condensate by itself is not considered
problematic for the dryer. However, in environments where
the air compressor is ingesting certain airborne chemicals,
such as the o-gassing from a thermal processing or blow
molding operation, the acidic condensate, when mixed with
the resulting contaminants, can result in a strong organic
acid that can be detrimental to the dryer’s internal surfaces.
This condition is characterized by acidic condensate
(ph below 5.0), condensate with an acrid odor and / or
condensate with a distinct yellow color. Should any of these
conditions be observed, it is recommended that the air
source for the air compressor(s) be relocated such that intake
air for the air compressors is derived from outside the facility.
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8.0 INSTALLATION AND INITIAL STARTUP
DRAIN CONDENSATE INLET
(PIPING VARIES BY MODEL)
OPERATING AIR PRESSURE, CONNECT HERE AT AIR FILTER,
CUSTOMER SUPPLIED CLEAN DRY AIR AT 80 - 120 PSIG
CHECK VALVE
VENT NEEDLE VALVE
VALVE MUST BE ADJUSTED OPEN TO ALLOW
FOR FREE FLOW OF CONDENSATE INTO DRAIN.
DRAIN WILL NOT FUNCTION IF VALVE IS CLOSED.
VENT VALVE EXHAUST MUFFLER
REMOVE MECHANISM PROTECTIVE SHIPPING MATERIAL
AND INSTALL PIPE PLUG BEFORE PRESSURIZING DRYER
TEST BUTTON
DRAIN CONDENSATE INLET
DRAIN DISCHARGE VALVE
DRAIN VALVE ACTUATOR
DRAIN INSTRUCTION
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FIGURE 3  TYPICAL PIPING ARRANGEMENT
8.5 ELECTRICAL CONNECTION
Equipment is available in various electrical congurations.
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 Specications 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.
8.5.1 START SETTINGS
Ingersoll Rand dryers can be congured 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 congure the dryer for a particular Start Mode.
A) Manual Mode (Factory Default) - No modication
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
aect 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 eect. 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.
•
•
8.0 INSTALLATION AND INITIAL STARTUP
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8.6 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.
8.6.1 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.
NOTICE
After installation or a prolonged shutdown, start
the dryer with no air load (no air ow). 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 O 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 40 and 65 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 o, air ow 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.
•
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. 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 lter 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 lter be inspected and
cleaned on a regular basis. Annual replacement of the lter is
recommended.
For applications where excessive dirt, dust or debris is
encountered, more frequent inspection and cleaning may be
required.
9.3 PRE-FILTERS AND POST-FILTERS
WARNING
Depressurize the system before disassembling
lters. Failure to do so may result in injury or death.
Filter elements should be changed every 6 months to 1
year. Change carbon elements when hydrocarbons are rst
detected downstream or every six months, whichever comes
rst.
Certain lters contain multiple elements. When replacing
lter elements, all elements should be replaced
simultaneously. Mixing new and old elements can result in
reduced air quality.
8.0 INSTALLATION AND INITIAL STARTUP
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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:
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)
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: 22 or 404 or 407
CONDENSER TYPE COND: AC OR WC
OPERATING
TEMPERATURE
DIFFERENTIAL
T OP DIFF: 3
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
FAN 1 ON PRESSURE FAN1 ON: See Table-1
DISCHARGE PRESSURE
TRANSDUCER Pd TRANS Y (N)
SUCTION PRESSURE
TRANSDUCER Ps TRANS Y (N)
SUCTION
TEMPERATURE
PROBE
Ts Probe Y (N)
Parameter Display Set Point
FAN 1 ON PRESSURE FAN1 OFF: 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
10.1 ENTERING TECHNICIAN MODE
WARNING
TECHNICIAN MODE should only be entered by
qualied service personnel. Altering the set points
in TECHNICIAN MODE will have a signicant eect
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:
TECH SET MODE
23
Pressing the “2” and “3”buttons simultaneously enters
the TECHNICIAN MODE.
SELECT
DISPLAY DRAIN ENABLE:OFF
Depressing SELECT DISPLAY scrolls through the
available parameters. The rst three parameters
viewed are adjustable in TECHNICIAN MODE.
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”:
CCH DELAY:8
SELECT
DISPLAY
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.
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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.
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:
AUTO RESTART:N
SELECT
DISPLAY
Depressing the SELECT DISPLAY button advances to
the next adjustable parameter for the Auto Restart
feature.
SET AUTO RESTART:Y
Depressing the SET button changes the AUTO
RESTART parameter from “N” to “Y”.
AUTO RESTART:Y
ENTER
Depressing ENTER saves the selected set point.
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 axed to the dryer to alert users and service
personnel that dryer may start without warning.
Failure to do so may result in serious injury.
END TECH SET PTS
SELECT
DISPLAY
Depressing the SELECT DISPLAY button displays the
END TECH SET PTS 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 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.
BEGIN ALARM LIST
SELECT
DISPLAY
At the end of the list of parameters, depressing the
SELECT DISPLAY button displays the beginning of the
ALARM LIST.
HPCO
SELECT
DISPLAY
Depressing the SELECT DISPLAY button displays the
alarms that the dryer has experienced, with the most
recent alarm displayed rst. The actual display will
depend on the most recent alarm detected by the
Microprocessor Control.
END ALARM LIST
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.
BEGIN ALARM LIST
SELECT
DISPLAY
Depressing the SELECT DISPLAY list displays the
ALARM LIST screen at the top of the ALARM LIST.
The Alarm List will repeat as many times as the SELECT
DISPLAY button is depressed. To EXIT the ALARM LIST,
perform the following:
TECH SET MODE
�
Depressing the back arrow button (located above the
SET button) returns the controller to the top of the
TECHNICIAN MODE.
CHLLR TEMP: 37
�
Depressing the back arrow button again returns the
controller to the default display of the CUSTOMER
MODE.
10.0 TECHNICIAN MODE
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11.2 PROBLEM / ACTION GUIDE
PROBLEM SYMPTOM(S) POSSIBLE CAUSE CORRECTIVE ACTION
Moisture down stream Dryer is properly cooling air
stream (Check Chiller. Temp
on controller)
Condensate drain failure Service drain
Excessive ow Check inlet and outlet pressure
and system design capacity.
Correct cause of excessive ow.
Dryer by-pass valve not
closed
Close by-pass valve
Inlet and outlet
temperatures are the same.
No power to the dryer Check power supply and fuses/
circuit breakers
High suction pressure Check and clean condenser.
Refrigerant leak Check suction pressure gauge if
reading is 0 psig, turn dryer o
and contact your distributor
Compressor not running and
fan is running
Check and clean condenser.
Check ambient temperature and
reduce below 113°F
Moisture down stream Inlet and outlet
temperatures are the same.
Compressor and fan not
running.
Check Chiller Temperature
Compressor and fan not
running. Controller indicates
compressor is ON.
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.
Compressor and fan are
running, exchanger temp
high, pump not running.
Defective Pump Contact your local distributor for
further assistance.
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 identication and corrective actions.
WARNING
An air dryer always operates under pressure. Any
maintenance procedure that involves disassembly of
pipe ttings, 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.”
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PROBLEM SYMPTOM(S) POSSIBLE CAUSE CORRECTIVE ACTION
Apparent controller
display malfunction
Display Blank Blown Fuse Check Fuses
Board Failure Contact your local distributor for
further assistance.
Unrealistic temperature
displayed
Probe loose,o connection
or defective probe
Inspect probe cable and terminal
connection Replace probe
Erratic or inaccurate
temperature readings
Probe not completely in
thermal well
Inspect probe and check readings
against independent source (eg.
temperature analyzer/pyrometer/
ice bath) both in temperature well
and to ambient
Defective probe Replace probe
Unrealistic pressure
displayed
Transducer loose, o
connection or defective
transducer
Inspect transducer cable and
terminal connection
Replace transducer
High pressure drop
across dryer
Outlet pressure substantially
lower than inlet pressure
System operating tempera-
ture is above 32°F
Inlet and outlet valves not
completely open
Open valves
Inlet and outlet lters
blocked up
Change lter elements
Outlet pressure substantially
lower than inlet pressure
System operating tempera-
ture is below 32°F
Compressor relay / contactor
stuck.
Replace relay / contactor.
Microprocessor Control relay
bad
Replace relay
Probe not completely in
thermal well
Inspect probe and check readings
against independent source (eg.
temperature analyzer/pyrometer/
ice bath) both in exchanger well
and to ambient
Problem persists Turn dryer o and consult your
local distributor for further
assistance
Condensate drain does
not re
Inlet / outlet pipe internal
diameter too small causing
air-lock or back pressure.
Replace with larger diameter
piping.
Excessive use of bends /
elbows in inlet / outlet pipe
work causing air-lock/ back
pressure.
Reduce the amount of bends and
elbows.
Outlet pipe too long / too
high causing back pressure.
Recongure condensate piping.
More than one condensate
source connected providing
alternative path for
condensate.
Reroute condensate to eliminate
secondary path. Install check
valves as required.
11.0 TROUBLESHOOTING
120.26A D4290NCHPW400F Installation Operation and Maintenance Manual